If the information in this manual is not
followed exactly, a fire or explosion
may result causing property damage,
personal injury or loss of life.
FOR YOUR SAFETY
Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of this or any other appliance.
WARNING
WARNING
QUALIFIED INSTALLER
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.
Figure 23 - Securing the Band ...................................................................................................... 45
Figure 24 - Voltage Monitor ......................................................................................................... 50
5
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.
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 unit. 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
Electric shock hazard. Before
servicing, disconnect all electrical
power to the unit, including remote
disconnects, to avoid shock hazard
or injury from rotating parts. Follow
proper Lockout-Tagout procedures.
WARNING
FIRE, EXPLOSION OR CARBON
MONOXIDE POISONING HAZARD
Failure to replace proper controls
could result in fire, explosion or
carbon monoxide poisoning. Failure
to follow safety warnings exactly
could result in serious injury, death or
property damage. Do not store or use
gasoline or other flammable vapors
and liquids in the vicinity of this
appliance.
WARNING
Safety
6
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
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
During installation, testing, servicing
and troubleshooting of the equipment
it may be necessary to work with live
electrical components. Only a
qualified licensed electrician or
individual properly trained in handling
live electrical components shall
perform these tasks.
Standard NFPA-70E, an OSHA
regulation requiring an Arc Flash
Boundary to be field established and
marked for identification of where
appropriate Personal Protective
Equipment (PPE) be worn, should be
followed.
WARNING
UNIT 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
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
Electric motor over-current protection
and overload protection may be a
function of the Variable Frequency
Drive to which the motors are wired.
Never defeat the VFD motor overload
feature. The overload ampere setting
must not exceed 115% of the electric
motors FLA rating as shown on the
motor nameplate.
CAUTION
Failure to properly drain and vent
coils when not in use during freezing
temperature may result in coil and
equipment damage.
CAUTION
7
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.
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
system water piping.
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
WARNING
CAUTION
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
Do not work in a closed area where
refrigerant or nitrogen gases may be
leaking. A sufficient quantity of
vapors may be present and cause
injury or death.
WARNING
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
8
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
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 the
condenser water loop with harsh
chemicals, such as hydrochloric acid
(muriatic acid) or chlorine, can
damage the water-cooled condenser.
Care should be taken to avoid
allowing chemicals to enter the
water-cooled condenser. 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
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.
WARNING
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
9
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.
10
2. The unit is for indoor use only. See
General Information section for more
unit information.
3. 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.
4. READ THE ENTIRE INSTALLATION,
OPERATION AND MAINTENANCE
MANUAL. OTHER IMPORTANT
SAFETY PRECAUTIONS ARE
PROVIDED THROUGHOUT THIS
MANUAL.
5. Keep this manual and all literature
safeguarded near or on the unit.
SA Series Feature String Nomenclature
GEN SIZE VLT CONFIG A1
A2
A3
A4 B1
B2
B3
1A
1B
1C
1D 2 3 4 5A
5B
5C 6A
6B
6C 7 8 9
10
11
12
13 14A
14B 15
SA
-
035
- 3 - A - E R 0 9
-
0 0 0 : A C 0 0 - 0 0 0 - E B F - A B
0 - 0 0 0 0 0 0 0 - H A -
0
0 0 0 0 0 0 0
B
16
17
18
19
20
21
22
23
BASE MODEL
SERIES AND GENERATION
SA
UNIT SIZE
023 = 23 ton Capacity
028 = 28 ton Capacity
030 = 30 ton Capacity
035 = 35 ton Capacity
045 = 45 ton Capacity
050 = 50 ton Capacity
055 = 55 ton Capacity
058 = 58 ton Capacity
060 = 60 ton Capacity
065 = 65 ton Capacity
070 = 70 ton Capacity
A = Left Intake
B = Right Intake
C = Combination, Left and Right Intake
D = Option A + Interior Corrosion Protection
E = Option B + Interior Corrosion Protection
F = Option C + Interior Corrosion Protection
Model Option A: COOLING/HEAT
PUMP
A1: REFRIGERANT STYLE
0 = Air Handling Unit
B = R-410A Non-Compressorized DX AHU
E = R-410A Variable Capacity Scroll Compressor
A2: UNIT CONFIGURATION
0 = No Cooling
A = Remote Condenser + Std Evap. Coil
B = Remote Condenser + 6 Row Evap. Coil
J = Shell and Tube Water-Cooled Cond. + Std Evap.
Coil
K = Shell and Tube Water-Cooled Cond. + 6 Row
Evap. Coil
R = Brazed Plate Water-Cooled Cond. + Std Evap.
Coil
T = Brazed Plate Water-Cooled Cond. + 6 Row
Evap. Coil
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
7 = Water-Source/Geothermal Heat Pump - Shell
and Tube Heat Exchanger
8 = Water-Source/Geothermal Heat Pump - Brazed
Plate Heat Exchanger
A3: COIL COATING
0 = Standard
1 = Polymer E-Coated Cooling Coil
D = Stainless Steel Cooling Coil Casing
A4: COOLING/HEAT PUMP STAGING
0 = No Cooling
2 = 2 Stage
4 = 4 Stage
9 = Modulating - Lead Variable Capacity
Compressors
A = Modulating - All Variable Capacity Compressors
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
11
SA Series Feature String Nomenclature
GEN SIZE VLT CONFIG A1
A2
A3
A4 B1
B2
B3
1A
1B
1C
1D 2 3 4 5A
5B
5C 6A
6B
6C 7 8 9
10
11
12
13 14A
14B 15
SA - 035 - 3 - A - E R 0 9 -
0 0 0 : A C 0 0 - 0 0
0
- E B F - A B
0 - 0 0 0 0 0 0 0 - H A -
0
0 0 0 0 0 0 0
B
16
17
18
19
20
21
22
23
Model Option B: HEATING
B1: HEATING TYPE
0 = No Heating
C = Steam Distributing Standard Coil
D = Steam Distributing Polymer E-Coated Coil
E = Hot Water Standard Coil
F = Hot Water Polymer E-Coated Coil
B2: HEATING DESIGNATION
0 = No Heating
H = 1 Row Coil
J = 2 Row Coil
B3: HEATING STAGING
0 = No Heating
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 &
DISCHARGE AIR
1A: RETURN/OUTSIDE AIR SECTION
0 = Standard
A = Waterside Economizer - 4 Row Coil
B = Waterside Economizer - 6 Row Coil
1B: PLENUM HEIGHT
0 = 33” Plenum Height
A = 37” Plenum Height
B = 41” Plenum Height
C = 45” Plenum Height
D = 49” Plenum Height
E = 53” Plenum Height
F = 57” Plenum Height
G = 37” Plenum Height + Sound Attenuation
H = 41” Plenum Height + Sound Attenuation
J = 45” Plenum Height + Sound Attenuation
K = 49” Plenum Height + Sound Attenuation
L = 53” Plenum Height + Sound Attenuation
M = 57” Plenum Height + Sound Attenuation
1C: DISCHARGE CONFIGURATION
0 = Right - Horizontal Discharge
A = Left - Horizontal Discharge
B = Back - Horizontal Discharge
C = Top - Vertical Discharge
D = Options 0 + A
E = Options 0 + B
F = Options 0 + C
G = Options A + B
H = Options A + C
J = Options B + C
K = Options 0 + A + B
L = Options 0 + A + C
M = Options 0 + B + C
N = Options A + B + C
P = Options 0 + A + B + C
1D: WATERSIDE ECONOMIZER CIRCUITRY
0 = No Waterside Economizer
E = Single Serpentine 12 fpi
Feature 2: BLANK
0 = Standard
Feature 3: BLANK
0 = Standard
Feature 4: MAINTENANCE OPTIONS
0 = Standard
A = Blower Aux. Contact - Low Voltage Terminal
Block
B = Remote Start/Stop Terminals - Low Voltage
Terminal Block
C = Options A + B
12
SA Series Feature String Nomenclature
GEN SIZE VLT CONFIG A1
A2
A3
A4 B1
B2
B3
1A
1B
1C
1D 2 3 4 5A
5B
5C 6A
6B
6C 7 8 9
10
11
12
13 14A
14B 15
SA - 035 - 3 - A - E R 0 9 - 0 0
0 : A C 0 0 - 0 0 0 -
E B F - A B 0 - 0
0
0 0 0 0 0 - H A -
0
0 0 0 0 0 0 0
B
16
17
18
19
20
21
22
23
Feature 5: SUPPLY AIR OPTIONS
5A: SUPPLY AIR BLOWER CONFIGURATION
0 = 2 Blowers + Standard Efficiency Motors
A = 4 Blowers + Standard Efficiency Motors
B = 2 Blowers + Premium Efficiency Motors
C = 4 Blowers + Premium Efficiency Motors
E = 2 Blowers + Premium Efficiency Motors + 2
VFDs
G = 4 Blowers + Premium Efficiency Motors + 4
VFDs
H = 1 Blower + Standard Efficiency Motor
J = 1 Blower + Premium Efficiency Motor
K = 1 Blower + Premium Efficiency Motor + 1 VFD
5B: SUPPLY AIR BLOWER
A = 18.5” Spring Isolated Direct Drive Backward
Curved Plenum
B = 22” Spring Isolated Direct Drive 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
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
Feature 6: FILTERS
6A: PRE FILTER TYPE
0 = No Pre Filter
A = 2” Pleated - 30% Eff. - MERV 8
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 = Freeze Stats - Each Circuit
D = Options A + B
E = Options A + C
F = Options B + C
G = Options A + B + C
Feature 8: REFRIGERATION OPTIONS
0 = Standard
D = Modulating Hot Gas Reheat
13
SA Series Feature String Nomenclature
GEN SIZE VLT CONFIG A1
A2
A3
A4 B1
B2
B3
1A
1B
1C
1D 2 3 4 5A
5B
5C 6A
6B
6C 7 8 9
10
11
12
13 14A
14B 15
SA - 035 - 3 - A - E R 0
9 - 0 0 0 : A C 0 0 - 0 0 0 - E B F - A B
0 - 0
0
0 0 0 0 0 - H
A - 0
0 0 0 0 0 0 0
B
16
17
18
19
20
21
22
23
Feature 9: REFRIGERATION
ACCESSORIES
0 = Standard
A = Sight Glass
B = Compressor Isolation Valves
C = Options A + B
Feature 10: POWER OPTIONS
0 = Standard Power Block
Feature 11: SAFETY OPTIONS
0 = Standard
A = Supply Air Smoke Detector
H = Remote Smoke Detector Terminals
Feature 12: CONTROLS
0 = Standard
A = Low Limit Controls
B = Phase and Brown Out Protection
C = Options A + B
Feature 13: SPECIAL CONTROLS
0 = Terminal Block for Thermostat Control
A = VAV Unit Controller - VAV Cool + CV Heat
B = Constant Volume Unit Controller - CV Cool +
CV Heat
C = Make Up Air Unit Controller - CV Cool + CV
Heat
L = Terminal Block for Thermostat Control with
Isolation Relays
Y = VAV Single Zone Heat Pump Unit Controller -
VAV Cool + VAV Heat
Z = Constant Volume Heat Pump Unit Controller -
CV Cool + CV Heat
1 = Make Up 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 by Others with
Isolation Relays
6 = Factory Installed DDC Controls Furnished by
Others with Isolation Relay
Feature 14: WATER-COOLED
CONDENSER AND WATERSIDE
ECONOMIZER
14A: 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
S = Option A + SMO 254 Corrosion Resistant
Brazed Plate Condenser
T = Option B + SMO 254 Corrosion Resistant
Brazed Plate
U = Option C + SMO 254 Corrosion Resistant
Brazed Plate
V = Option D + SMO 254 Corrosion Resistant
Brazed Plate
W = Option A + B + SMO 254 Corrosion Resistant
Brazed Plate
Y = Option A + C + SMO 254 Corrosion Resistant
Brazed Plate
Z = Option A + D + SMO 254 Corrosion Resistant
Brazed Plate
1 = Option B + C + SMO 254 Corrosion Resistant
Brazed Plate
2 = Option B + D + SMO 254 Corrosion Resistant
Brazed Plate
3 = Option C + D + SMO 254 Corrosion Resistant
Brazed Plate
4 = Option A + B + C + SMO 254 Corrosion
Resistant Brazed Plate
5 = Option A + B + D + SMO 254 Corrosion
Resistant Brazed Plate
14
SA Series Feature String Nomenclature
GEN SIZE VLT CONFIG A1
A2
A3
A4 B1
B2
B3
1A
1B
1C
1D 2 3 4 5A
5B
5C 6A
6B
6C 7 8 9
10
11
12
13 14A
14B 15
SA - 035 - 3 - A - E R 0 9 - 0 0
0 : A C 0 0 - 0 0 0 - E B F - A B 0 - 0 0 0 0 0 0 0 -
H
A - 0
0 0 0 0 0 0 0
B
16
17
18
19
20
21
22
23
14B: WATERSIDE ECONOMIZER PIPING
0 = Standard - None
A = Variable Water Flow Application Field Piped
Waterside Economizer
B = Constant Water Flow Application Field Piped
Waterside Economizer
C = Variable Water Flow Application Factory Piped
Waterside Economizer
D = Constant Water Flow Application Factory Piped
Waterside Economizer
Feature 15: GLYCOL PERCENTAGE
0 = Standard
A = Minimum 20% Propylene Glycol
B = Minimum 40% Propylene Glycol
Feature 16: INTERIOR CABINET
OPTIONS
0 = Standard
A = Overflow Switch
B = UV Lights
C = Options A + B
Feature 17: BLANK
0 = Standard
Feature 18: CUSTOMER CODE
0 = Standard
Feature 19: CODE OPTIONS
0 = Standard - ETL U.S.A. Listing
D = Chicago - Cool Only
G = Chicago - No Cool + No Heat
Feature 20: CRATING
0 = Standard
A = Export Crating
B = Forkliftable Base
C = Shipping Shrink Wrap
D = Export Crating + Forkliftable Base
E = Export Crating + Shipping Shrink Wrap
F = Forkliftable Base + Shipping Shrink Wrap C
G = Export Crating + Forkliftable Base + Shipping
Shrink Wrap
Feature 21: SHIPPING SPLITS
0 = Standard - One Piece Unit
A = Two Piece Single Unit - 1 Blower Plenum + 1
Air Tunnel
B = Two Piece Double Unit - 1 Blower Plenum + 1
Air Tunnel
C = Three Piece Double Unit - 1 Blower Plenum + 2
Air Tunnels
D = Four Piece Double Unit - 2 Blower Plenums + 2
Air Tunnels
Feature 22: CONTROL VENDORS
0 = Standard - None
A = WattMaster Orion Controls System
B = JENEsys Control System with WebUI
C = WattMaster Orion Controls System with
Specials
D = JENEsys Control System with WebUI and
Specials
E = Remote Mounted AAON Mini Controller
Feature 23: TYPE
B = Standard Paint
U = Special Pricing Authorization + Special Paint
X = Special Pricing Authorization + AAON Gray
Paint
15
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
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
General Information
SA Series self contained units and indoor air
handling units have been designed for
indoor installation only. SA Series units can
contain spring isolated direct drive
backward curved plenum fans, shell and
tube or brazed plate water-cooled
condensers, R-410A scroll compressors,
evaporator coils, chilled water cooling coils,
steam or hot water heating coils, waterside
economizers, and a single point power
connection. Units are assembled, wired,
charged and run-tested at the factory. SA
Series units are not intended for residential
use.
Codes and Ordinances
SA Series units have been tested and
certified, by ETL, in accordance with UL
Safety Standard 1995/CSA C22.2 No. 236.
System should be sized in accordance with
the American Society of Heating,
Refrigeration and Air Conditioning
Engineers Handbook.
Installation of units must conform to the
ICC standards of the International
Mechanical Code, the International Building
Code, Installation of Air Conditioning and
Ventilating Systems Standard, NFPA 90A,
and local building, plumbing and waste
water codes. All appliances must be
16
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.
CRANKCASE HEATER
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
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.
Direct Expansion (DX) Systems
All water-cooled condenser DX systems are
factory assembled, leak tested, charged with
R-410A refrigerant, and run tested.
All DX systems include evaporator coils,
liquid line filter dryers, thermostatic
expansion valves (TXV), and scroll
compressors. Compressors are equipped
with a positive pressure forced lubrication
system.
Never turn off the main power supply to the
unit, except for servicing, emergency, or
complete shutdown of the unit. When power
is cut off from the unit crankcase heaters
cannot prevent refrigerant migration into the
compressors. This means the compressor
may cool down and liquid refrigerant may
accumulate in the compressor. The
compressor is designed to pump refrigerant
gas and damage may occur when power is
restored.
If 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 emergency or complete
shutdown of the unit.
During the cooling season, if the airflow is
reduced due to dirty air filters or any other
reason, the cooling coils can get too cold
which will cause excessive liquid to return
to the compressor. As the liquid
17
Model
Cabinet Type
Intake
Cabinet 1
Cabinet 2
SA-023
Single
Left or Right
Side
SA-023
SA-028
SA-028
SA-030
SA-030
SA-035
SA-035
SA-045
Dual
Left and Right
Sides
SA-023
SA-023
SA-050
SA-023
SA-028
SA-055
SA-028
SA-028
SA-058
SA-028
SA-030
SA-060
SA-030
SA-030
SA-065
SA-030
SA-035
SA-070
SA-035
SA-035
Unit should not be operated without a
p-trap. Failure to install a p-trap may
result in overflow of condensate
water.
CAUTION
concentration builds up, oil is washed out of
the compressor, leaving it starved for
lubrication.
The compressor life will be seriously
shortened by reduced lubrication and the
pumping of excessive amounts of liquid oil
and refrigerant.
Wiring Diagrams
Unit specific wiring diagrams are laminated
and affixed inside the controls compartment
door.
Condensate Drain Pans
Units require drain p-traps and lines to be
connected to the condensate drain pans of
the unit. The lines 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.
Table 1 - SA Series Models
Waterside economizer coil units include a
separate condensate drain pan which drains
into the evaporator coil drain pan. No
additional drain line is needed for the
waterside economizer drain pan.
Unit Size
Units are modular and composed of
combination of the four standard unit sizes,
SA-023, SA-028, SA-030, and SA-035.
Installation
Locating the Unit
Placement of the unit relative to ductwork,
electrical and plumbing must be carefully
considered. Return air plenum or duct can be
mounted directly to the return air flanges.
Use flexible gasket material to seal the duct
to the unit.
18
Verify floor or foundation can support the
total unit weight, including accessory
weights. Unit must be level in both
horizontal axes to support the unit and
reduce noise and vibration from the unit.
Allow adequate service clearances as shown
on the unit nameplate and unit drawing.
UNIT HANDLING
Incorrect lifting can cause damage to
the unit, injury or death. Lifting
equipment capacity should 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.
WARNING
Consult your local building codes for
additional service clearance requirements.
Allow adequate space for piping access and
panel removal. Condenser water piping and
condensate drain connections are near the
bottom on the back of the unit.
Figure 1 - SA Series Unit with Right Intake
Lifting and Handling the Unit
Before lifting unit, be sure that all shipping
material has been removed from unit.
If cables or chains are used to hoist the unit
care should be taken to prevent damage to
the cabinet.
Secure hooks and cables at the all lift points
provided near the fan section at the top of
the unit.
19
20
Figure 2 - One Piece Single Unit Lifting Details
Figure 3 - Two Piece Single Unit Coil Section Lifting Details
21
22
Figure 4 - Two Piece Single Unit Fan Section Lifting Details
Figure 5 - One Piece Dual Unit Lifting Details
23
24
Figure 6 - Two Piece Dual Unit Coil Section Lifting Details
Figure 7 - Two Piece Dual Unit Fan Section Lifting Details
25
Split Unit Assembly
Units may be split into modules for
shipping. Fan and coil modules must be
bolted together and factory provided splices
must be installed before operation of the
unit.
Split units will also require electrical
connection between the modules and
individual units after assembly. See
Electrical Installation section and unit
specific wiring diagrams, within the unit
control compartment, for details.
Assembly
1. Remove all shipping covers prior to
assembly of modules.
2. Move the coil section to the required
location. See Figure 8.
3. For dual units (45-70 tons), move the
second coil section close to the first coil
section and align the bolt holes of the
coil sections. Compressor and control
service access doors of each section
should be on the same side of the
complete unit. A crow-bar or similar tool
can be used to line up the sections.
Factory provided bolts can then be used
to secure the coil sections together. See
Figure 9.
4. Align and set each fan section on top of
the coil section(s).
5. For dual units, align the bolt holes of the
fan sections, if they are shipped
separated. Fan service access doors of
each section should be on the same side
of the complete unit. A crow-bar or
similar tool can be used to line up the
sections. Factory provided bolts can then
be used to secure the fan sections
together. See Figure 9.
6. For dual units, install horizontal, vertical
and top splices, overlapping the fan and
coil sections. Fasten splices with selftapping #10 hex head screws. See Figure
9 and Figure 10. Single units (23-35
tons) do not require these splices. Only
corner slices are required for single
units.
7. Install corner splices, overlapping the
fan and coil sections. Fasten splices with
self-tapping #10 hex head screws. See
Figure 9 and Figure 10.
26
Figure 8 - Dual unit without splices and before being bolted together.
Figure 9 - Dual Unit Assembly Details
27
Figure 10 - Dual unit with splices after being bolted together.
28
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
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
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
Refrigerant-to-Water Heat Exchanger
Condenser water pump, condenser water
piping, cooling tower, pressure gauges,
strainers, piping insulation and all
components of the waterside piping must be
field installed.
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 make-up water containing
salt water.
3. Disinfection 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 the fluid in the
condenser is excluded from coverage under
AAON warranties and the heat exchanger
manufacturer warranties.
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
29
% Glycol
Ethylene
Glycol
Propylene
Glycol
20
18°F
19°F
30
7°F
9°F
40
-7°F
-6°F
50
-28°F
-27°F
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 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.
WARNING
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 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
30
and also results in a decrease in unit
performance. A minimum concentration of
20% glycol solution is recommended.
Table 2 - 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
unit can operate without damaging unit
components.
Model (SA-)
Supply and Return
Connection Size
023, 045
1 1/2” MPT
028, 030, 035, 050,
055, 058, 060, 065,
070
2” MPT
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
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
Table 3 - Condenser 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 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 make-up 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
used as concentrated chemicals can cause
corrosion. Never use hydrochloric acid
(muriatic acid) or chlorine as it will corrode
stainless steel.
31
SA-023
SA-028
SA-030
SA-035
GPM
PSI
GPM
PSI
GPM
PSI
GPM
PSI
45
4.2
45
4.2
45
4.2
45
1.7
39
3.3
39
3.3
39
3.3
39 35
2.8
35
2.8
35
2.8
35
SA-045
SA-050
SA-055
SA-058
GPM
PSI
GPM
PSI
GPM
PSI
GPM
PSI
45
4.2
45
4.2
45
4.2
45
4.2
39
3.3
39
3.3
39
3.3
39
3.3
35
2.8
35
2.8
35
2.8
35
2.8
SA-060
SA-065
SA-070
Heat Exchanger 1
Heat Exchanger 2
GPM
PSI
GPM
PSI
GPM
PSI
GPM
PSI
45
4.2
45
4.2
45
1.7
45
1.7
39
3.3
39
3.3
39 39 35
2.8
35
2.8
35 35
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
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.
32
Do not exceed recommended
condenser fluid flow rates shown in
above table. Serious damage to or
erosion of the heat exchanger tubes
could occur.
CAUTION
Disconnect all electrical power
sources before servicing the unit.
More than one power source may be
provided. Failure to do so may result
in injury or death from electrical
shock or entanglement in moving
parts.
WARNING
The foam insulation releases
dangerous fumes when it is burnt. Do
not cut a foam part with a cutting
torch or plasma cutter. Do not weld to
a foam filled part.
WARNING
Piping systems should not exceed 10 ft/sec
fluid velocity to ensure tube wall integrity
and reduce noise.
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 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.
Electrical
Verify the unit name plate agrees with
power supply. SA Series units are provided
with single point power wiring connections.
Connection terminations are made to the
main terminal block. A complete set of unit
specific wiring diagrams, showing factory
and field wiring are laminated in plastic and
located inside the controls compartment
door.
All units require field supplied electrical
overcurrent and short circuit protection.
Device must not be sized larger than the
Maximum Overcurrent Protection (MOP)
shown on the unit nameplate.
Codes may require a disconnect switch be
within sight of the unit.
It is recommended that the field installed
overcurrent protection or disconnect switch
not be installed on the unit.
Electrical supply can enter through the
bottom or side of the controls compartment.
Entry must be field cut into panels of the
unit.
A single point connection to a terminal
block is provided. Split units may require
connection between the units. High voltage
conductors should enter the control panel in
a separate opening and separate conduit than
24V low voltage conductors.
33
Three phase voltage imbalance will
cause motor overheating and
premature failure.
CAUTION
Note: Locations for field cut electrical
entries are marked on the unit. Field cut
openings must be a minimum of 6 inches
away from all components and wiring to
prevent damage due to drilling or cutting.
To pass wires through the wall or roof of the
unit, a hole should be cut and conduit passed
through it. Use the following procedure to
cut a round hole in a foam panel.
Cutting Electrical Openings
1. Locate the placement of the hole. Be sure
that the conduit will not interfere with the
operation of any component or prevent
access of any door or removable panel.
2. Drill a pilot hole all the way through the
foam panel.
3. Using a hole saw cut the hole through the
metal on both sides of the foam part.
4. With a knife cut the foam out of the hole.
5. After the conduit is installed in the hole
caulk the entire perimeter of the hole on
both sides with an industrial grade silicone
sealant or a duct seal compound.
If a larger cut-out is needed for additional
duct connections not provided by the
factory, or for any other reason, it is very
important that the foam be completely
sealed. Insulation covers should be
fabricated from sheet metal to cover the
foam at the cut. The edges and corners that
are not covered should then be sealed using
silicone caulking or a duct seal compound.
If a reciprocating saw is used to make the
cut-out take care that the metal skins of the
foam part do not separate from the foam,
this would result in reduced structural
integrity of the part.
Size supply conductors based on the unit
Minimum Current Ampacity (MCA) rating.
Supply conductors must be rated a minimum
of 75°C.
34
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
208/230V, 460V, or 575V. If unit is to be
connected to a 208V supply, the transformer
must be rewired to 208V service. For 208V
service interchange the yellow and red
conductor on the low voltage control
transformer.
Red-Black for 208V
Yellow-Black for 230V
Wire power leads to the unit’s terminal
block or main disconnect. All wiring beyond
this point has been completed by AAON 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.
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 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
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 (VFD) and must not be bypassed.
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.
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 or 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 5 - Control Wiring
Total Wire Distance Allowable =
(Quantity of Control Wires) x
(Control Wire Distance)
Take the total wire distance allowable and
divide by the number 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.
35
Location
Model (SA-)
023-025
045-070
Top
30” x 64”
(2) 30” x 64”
Back
19” x 30”
(2) 19” x 30”
Side
(Right or Left)
19” x 64”
(2) 19” x 64”
Unit should not be operated without
p-traps. Failure to install a p-traps
may result in overflow of condensate
water.
CAUTION
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 5, 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.
Duct Connection
Return air enters the either the left, right or
both the left and right sides of the unit,
where the air filters are located. Ductwork
should be sized in accordance with the
ASHRAE Handbook. Ductwork should be
installed in accordance with NFPA Standard
90A.
When attaching duct to the unit, use a
flexible/compressible material rated for duct
connections. A three inch flexible connector
for both return and supply duct connections
is recommended.
Supply air duct connection can be on the
left, right, back, or top sides of the supply
fan plenum. See unit drawing for more
information.
Table 6 - Duct Connection Sizes
and pitch downward toward drain. An air
break should be used with long runs of
condensate lines.
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.
Note: The drain pan connection is a 1” MPT
fitting.
Condensate Drain Piping
Unit may be equipped with more than one
condensate drain pan connection. A p-trap
and drain line must be installed on every
drain connection, with the p-trap not to
exceed 6” from the drain connection. The
lines should be the same pipe size or larger
than the drain connection, include a p-trap,
36
Figure 11 - Drain Trap
The X dimension on the draw-through trap
should be at least equal to the absolute value
of the negative static pressure in the drain
pan plus one inch. To calculate the static
pressure at the drain pan add the pressure
drops of all components upstream of the
drain pan, including the cooling coil, and
add the return duct static pressure. Include
Draw-Through
Drain Pan Pressure
Trap Dimensions
Negative Static
X
X/2
(inches of water)
(inch)
(inch)
-0.50
1.50
0.75
-1.00
2.00
1.00
-1.50
2.50
1.25
-2.00
3.00
1.50
-2.50
3.50
1.75
-3.00
4.00
2.00
-3.50
4.50
2.25
-4.00
5.00
2.50
the dirt allowance pressure drop for the
filters to account for the worst-case scenario.
The height from top of the bottom bend of
the trap to the bottom of the leaving pipe
must be at least equal to one half of the X
dimension. This ensures that enough water
is stored in the trap to prevent losing the
drain seal during unit startup
Note: The absolute value of the fan inlet
pressure will always be greater than or equal
to the absolute value of the static pressure in
the drain pan on draw-through units, so the
fan inlet pressure is a safe value to use for
the drain pan static pressure.
Table 7 - Drain Trap Dimensions
Waterside Economizer
Cooling and pre-cooling waterside
economizer coil is factory installed upstream
of the evaporator coil. Factory tested and
field installed water piping kit includes fully
modulating waterside economizer valve and
fully modulating waterside economizer
bypass valve.
The waterside economizer circuit can
operate in three modes: waterside
economizer only, waterside economizer with
mechanical cooling, and mechanical cooling
only.
During waterside economizer only mode of
operation condenser water flows through the
waterside economizer coil with modulating
valves maintaining supply air temperature
setpoint. The condenser water then passes
through water-cooled condenser.
During waterside economizer with
mechanical cooling mode of operation
condenser water flows through the waterside
economizer coil with the waterside
economizer modulating valve fully open.
The condenser water then passes through
water-cooled condenser.
During mechanical cooling only mode of
operation condenser water flows around the
waterside economizer coil with the
waterside economizer bypass valve fully
open. The condenser water then passes
through water-cooled condenser.
Waterside economizer coil condensate drain
outlet drains into evaporator coil drain pan.
See the previous section on evaporator coil
condensate drain piping.
Mineral content of the condenser water must
be controlled. All make-up 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
used as concentrated chemicals can cause
corrosion. Never use hydrochloric acid
(muriatic acid) or chlorine as it will corrode
stainless steel.
37
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
Waterside Economizer Piping Kit
Figure 12 - SA Series Unit with Waterside
Economizer Piping
For single cabinet units connect the three
factory provided piping assemblies. For dual
cabinet units connect both sets of factory
provided piping assemblies.
Connect the piping assembly to the unit.
Connect the actuators to the water valves.
Actuators are factory wired and included
inside the unit.
38
Right Intake Piping Kit
Left Intake Piping Kit
Assembly 6
Assembly 1
Assembly 2
Assembly 3
Assembly 4
Assembly 5
Waterside Economizer Valve
Waterside Economizer
Bypass Valve
Head Pressure Control Valve
Supply
Connection
Supply
Connection
Return
Connection
Balancing Valve
Balancing Valve
Balancing Valve
Balancing Valve
Figure 13 - Air Conditioner Waterside Economizer Piping Kit
Figure 14 - Air Conditioner Waterside Economizer Back View
Figure 16 - Water-Source Heat Pump Waterside Economizer Back View
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
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
Failure to adjust the blower isolation
springs may cause premature failure
of the blower bulkhead and/or blower
assembly. These damages will not be
covered by warranty. Blower isolation
springs must be adjusted by installing
contractor prior to unit start up.
Springs must be adjusted such that
the blower assembly is “free floating”
and “level”.
CAUTION
Hot Water Coil
Factory installed one or two row hot water
heating coils can be factory mounted. These
coils are supplied from a hot water source
through separate piping from the condenser
water source. All controls for heating
operation are field supplied and field
installed.
Always connect the supply to the top of the
coil and the return to the bottom. 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.
Chilled Water Coil
Factory installed four or six row chilled
water cooling coils can be factory mounted.
These coils are supplied from a chilled water
source through separate piping from the
condenser water source. All controls for the
cooling coil are field supplied and field
installed.
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 of the air flow,
the air filters, condenser water flow and
refrigerant charge.
Supply Fans
SA Series units are equipped with direct
drive backward curved plenum supply fan
assemblies that deliver the air volume
specified according to unit size and job
requirements.
Supply Fan Spring Isolator Adjustment
41
Fan assemblies are equipped with spring
isolators in the fan section for vibration
attenuation.
Prior to shipment the isolators are set in the
lock down position to protect the unit during
transit.
Once the unit is set into place it is important
that all of the isolators are adjusted out of
the shipping position and the shipping
material is discarded before the unit is put
into operation.
Remove all six screws from each shipping
bracket and discard brackets.
On all four isolators, secure the adjustment
bolt and rotate the locking nut counter
clockwise approximately four full rotations.
This will allow the locking nut to spin when
the adjustment bolt is turned (See Figure
17).
Turn adjustment bolt counter-clockwise to
adjust all four isolators until 3/4 inch
clearance is obtained between all spring
brackets and spring supports.
Check all isolators to ensure that the spring,
spring cap and spring baseplate are aligned.
The position of the spring cap should be
adjusted such that the spring is straight up
and down. Adjustments can be made by
applying horizontal pressure to the locking
nut.
Individually tighten all four locking nuts
while the adjustment bolts are held in
position.
42
Figure 17 - Spring Isolation
Disconnect all electrical power
sources before servicing the unit.
More than one power source may be
provided. Failure to do so may result
in injury or death from electrical
shock or entanglement in moving
parts.
WARNING
Hold Down
Bracket Screws
Hold Down
Bracket Screws
Supply Fan Removal
1. Disconnect all electrical power sources
to the unit.
2. Disconnect the supply fans using the
quick connect electrical harness located
in the control compartment.
3. Remove the three screws on the hold
down bracket on the front side of the fan
assembly frame.
4. Remove the back fan access panel and
then remove the three screws on the rear
side of the fan assembly frame.
5. Slide the complete fan assembly forward
through the front supply fan access door.
Figure 18 - Back View with Supply Fan
Access Panel Removed
Figure 19 - Front View with Supply Fan
Access Door Open
Fan Airflow Adjustment
A specific air volume is delivered by the
fans with air volume bands in the blower
wheels or with VFDs. Field airflow
adjustment may be required at startup.
Air volume bands for the wheels are sized
according to the unit’s air delivery
specifications and can also be ordered from
the factory for field installation. Wheels
come standard with a 10% air volume band,
as a safety factor, in case additional air
volume is required from the unit.
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
43
required, the band can be removed from the
wheel.
Use fan program in AAONEcat32 to
determine the new band size for the required
cfm and static pressure.
The following photos of a wheel are
provided for practical guidelines only in
order to identify the air band location in the
wheel. Actual field installation of the air
band into the wheel will require access into
and through the blower wheel venture,
which may require removal of the 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.
alteration to the wheel or blades occurs
during the installation.
Figure 21 - Band Tabs
Figure 20 - Blower Wheel with 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
44
Figure 22 - Blower Wheel
Before completing startup and
leaving the unit a complete operating
cycle should be observed to verify
that all components are functioning
properly.
CAUTION
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
Figure 23 - Securing the Band
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.
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 tables below when
determining the proper sub-cooling.
Checking Liquid Sub-Cooling
Measure the temperature of the liquid line as
it leaves the condenser.
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
45
Air-Cooled Condenser/
Air-Source Heat Pump
Sub-Cooling
12-18°F
Sub-Cooling with
Hot Gas Reheat
15-22°F
Superheat
8-15°F
Water-Cooled Condenser/
Water-Source Heat Pump
Sub-Cooling
4-8°F
Sub-Cooling with
Hot Gas Reheat
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
will vary from discharge pressure due to
condenser 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.
46
Table 8 - Acceptable Refrigerant 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.
Unit operations should be controlled with
thermostat or unit controller, never at the
main power supply, except for emergency or
complete shutdown of the unit.
Steam or Hot Water Preheating
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.
Chilled Water or Non-Compressorized
DX Cooling Operation
Controls for chilled water cooling coil and
non-compressorized DX coil are by others.
47
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
Electric shock hazard. Shut off all
electrical power to the unit to avoid
shock hazard or injury from rotating
parts.
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
Packaged DX Cooling Operation and
Control
When a call for cooling (G and Y1, Y2, etc.)
is made the supply fan motors and
compressors will energize.
Maintenance
(See back of the manual for maintenance
log.)
At least once each year, a qualified service
technician should check out the unit. Supply
fans, evaporator coils and air filters should
be inspected monthly.
Periodically during operation, it is necessary
to perform routine service checks on the
performance of the unit. This includes
48
checking of the air flow, the air filters,
condenser water flow and refrigerant charge.
See Startup section for information on air
flow adjustment and refrigerant charge
adjustment.
DX Cooling
Set unit controls to cooling mode of
operation with supply fans on. Check the
fans for correct operating direction,
amperage and voltage. Check compressor
operation, rotation, amperage and voltage to
the unit nameplate (check the amperage on
the load side of the compressor contactor).
Condensate Drain Pans
Drain pans will have moisture present and
require periodic cleaning to prevent
microbial growth. Cleaning of the drain pans
will also prevent any possible plugging of
the drain lines and overflow of the pan itself.
Cleaning of the drain pans and inside of the
unit should be done only by qualified
personnel.
E-Coated Coil Cleaning
Documented routine cleaning of e-coated
coils is required to maintain coating
warranty coverage.
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
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
CAUTION
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
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.
49
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
Electric shock hazard. Shut off all
electrical power to the unit to avoid
shock hazard or injury from rotating
parts.
WARNING
Phase
Loss/Rev.
LED
On/Off
LED
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.
Supply Fans
Lubrication
All original blower motors and bearings are
furnished with factory lubrication. Some
applications will require that bearings be re-
50
lubricated 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 R
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 24 - 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
Electric shock hazard. Shut off all
electrical power to the unit to avoid
shock hazard or injury from rotating
parts.
WARNING
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
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
Filter Replacement
Monthly 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. Open access
panel and pull filters straight out to inspect
51
Feature 6A
Quantity/Size
Type
0
No Pre Filters
A
9/20” x 20” x 2”
Pleated, 30% Eff, MERV 8
Feature 6A
Quantity/Size
Type
0
No Pre Filters
A
18/20” x 20” x 2”
Pleated, 30% Eff, MERV 8
Feature 6B
Quantity/Size
Type
0
9/20” x 20” x 2”
Pleated, 30% Eff, MERV 8
A
9/20” x 20” x 4”
Pleated, 30% Eff, MERV 8
B
9/20” x 20” x 4”
Pleated, 65% Eff, MERV 11
C
9/20” x 20” x 4”
Pleated, 85% Eff, MERV 13
D
9/20” x 20” x 4”
Pleated, 95% Eff, MERV 14
Feature 6B
Quantity/Size
Type
0
18/20” x 20” x 2”
Pleated, 30% Eff, MERV 8
A
18/20” x 20” x 4”
Pleated, 30% Eff, MERV 8
B
18/20” x 20” x 4”
Pleated, 65% Eff, MERV 11
C
18/20” x 20” x 4”
Pleated, 85% Eff, MERV 13
D
18/20” x 20” x 4”
Pleated, 95% Eff, MERV 14
all of the filters. Replace filters with the size
indicated on each filter or as shown in the
tables below. Arrow on the replacement
filters must point towards the blower.
Table 10 - 23-35 tons, Pre Filters
Table 11 - 45-70 tons, Pre Filters
Table 12 - 23-35 tons, Unit Filters
Table 13 - 45-70 tons, Unit Filters
Replacement Parts
Parts for AAON equipment may be obtained
from AAON at www.aaonparts.com. When
ordering parts, reference the unit serial
number and part number.
AAON Warranty, Service, and Parts
Department
2424 S. Yukon Ave.
Tulsa, OK 74107
Ph: 918-583-2266
Fax: 918-382-6364
www.aaon.com
Note: Before calling, technician should have
model and serial number of the unit
available for the service department to help
answer questions regarding the unit.
52
Water
Containing
Concentration
(mg/l or ppm)
Time Limits -
Analyze Before
AISI
316
SMO
254
Copper
Alloy
Nickel
Alloy
Alkalinity
(HCO
3
-
)
< 70
Within 24 Hours
+ + 0 + 70-300
+ + + + > 300
+ + 0/+
+
Sulfate (SO
4
2-
)
< 70
No Limit
+ + + + 70-300
+ + 0/- + > 300
0 0 -
+
HCO
3
-
/ SO
4
2-
> 1.0
No Limit
+ + + + < 1.0
+ + 0/-
+
Electrical
Conductivity
< 10µS/cm
No Limit
+ + 0 + 10-500 µS/cm
+ + + + > 500 µS/cm
+ + 0
+
pH
< 6.0
Within 24 Hours
0 0 0 + 6.0-7.5
0/+ + 0 + 7.5-9.0
+ + + + > 9.0
+ + 0
+
Ammonium
(NH
4
+
)
< 2
Within 24 Hours
+ + + + 2-20
+ + 0 + > 20
+ + -
+
Chlorides (Cl-)*
< 300
No Limit
+ + + + > 300
0 + 0/+
+
Free Chlorine
(Cl2)
< 1
Within 5 Hours
+ + + + 1-5
+ + 0
+
> 5
0/+ + 0/-
+
Hydrogen
Sulfide (H2S)
< 0.05
No Limit
+ + + + > 0.05
+ + 0/-
+
Free (aggressive)
Carbon Dioxide
(CO
2)
< 5
No Limit
+ + + + 5-20
+ + 0 + > 20
+ + -
+
Appendix A - Heat Exchanger Corrosion Resistance
Corrosion Resistance of Copper and Stainless Steel in Brazed Plate Heat Exchangers
- Points to Measure and Check in a Water Analysis
The resistance guide below provides the corrosion resistance of stainless steel type AISI 316 and
pure Copper (99.9%) in water, to a number of important chemical factors. The actual corrosion is
a very complex process influenced by many different factors in combination.
Explanations: + Good resistance under normal conditions
0 Corrosion problems may occur especially when more factors are valued 0
Installing contractor should verify the following items.
1. Is there any visible shipping damage?
Yes No
2. Is the unit level?
Yes No
3. Are the unit clearances adequate for service and operation?
Yes No
4. Do all access doors open freely and are the handles operational?
Yes No
5. Have all shipping braces been removed?
Yes No
6. Have all electrical connections been tested for tightness?
Yes No
7. Does the electrical service correspond to the unit nameplate?
Yes No
8. On 208/230V units, has transformer tap been checked?
Yes No
9. Has overcurrent protection been installed to match the unit nameplate
requirement?
Yes No
10. Have all set screws on the fans been tightened?
Yes No
11. Do all fans rotate freely?
Yes No
12. Does the field water piping to the unit appear to be correct per design
parameters?
Yes No
13. Is all copper tubing isolated so that it does not rub?
Yes No
14. Are air filters installed with proper orientation?
Yes No
15. Have condensate drain and p-trap been connected?
Yes No
Ambient Dry Bulb Temperature ________°F
Ambient Wet Bulb Temperature ________°F
SA Series Startup Form
Pre Startup Checklist
Ambient Temperature
55
Alignment
Check Rotation
Nameplate Amps________
Number
hp
L1
L2
L3
1
2
3
4
Band Size_____________________
VAV Controls_________________
VFD Frequency________________
Springs Operating Correctly
Check Rotation
Number
L1
L2
L3
Head
Pressure
PSIG
Suction
Pressure
PSIG 1 2 3 4
Pressure
Saturated
Temperature
Line
Temperature
Sub-cooling
Superheat
Discharge
N/A
N/A
Suction
N/A
Liquid
N/A
Pressure
Saturated
Temperature
Line
Temperature
Sub-cooling
Superheat
Discharge
N/A
N/A
Suction
N/A
Liquid
N/A
Pressure
Saturated
Temperature
Line
Temperature
Sub-cooling
Superheat
Discharge
N/A
N/A
Suction
N/A
Liquid
N/A
Supply Fan Assembly
Compressors/DX Cooling
Refrigeration System 1 - Cooling Mode
Refrigeration System 2 - Cooling Mode
Refrigeration System 3 - Cooling Mode
56
Pressure
Saturated
Temperature
Line
Temperature
Sub-cooling
Superheat
Discharge
N/A
N/A
Suction
N/A
Liquid
N/A
Pressure
Saturated
Temperature
Line
Temperature
Sub-cooling
Superheat
Discharge
N/A
N/A
Suction
N/A
Liquid
N/A
Pressure
Saturated
Temperature
Line
Temperature
Sub-cooling
Superheat
Discharge
N/A
N/A
Suction
N/A
Liquid
N/A
Pressure
Saturated
Temperature
Line
Temperature
Sub-cooling
Superheat
Discharge
N/A
N/A
Suction
N/A
Liquid
N/A
Pressure
Saturated
Temperature
Line
Temperature
Sub-cooling
Superheat
Discharge
N/A
N/A
Suction
N/A
Liquid
N/A
Refrigeration System 4 - Cooling Mode
Refrigeration System 1 - Heating Mode (Heat Pump Only)
Refrigeration System 2 - Heating Mode (Heat Pump Only)
Refrigeration System 3 - Heating Mode (Heat Pump Only)
Refrigeration System 4 - Heating Mode (Heat Pump Only)
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Water-Cooled Condenser
Air-Cooled Condenser
No Water Leaks
Condenser Safety Check
Water Flow ________ gpm
Water Inlet Temperature ________°F
Water Outlet Temperature ________°F
1. Has the entire system been flushed and pressure checked?
Yes No
2. Has the entire system been filled with fluid?
Yes No
3. Has air been bled from the heat exchangers and piping?
Yes No
4. Is the glycol the proper type and concentration (N/A if water)?
Yes No
5. Is there a minimum load of 50% of the design load?
Yes No
6. Has the water piping been insulated?
Yes No
7. What is the freeze point of the glycol (N/A if water)? ______________________________
Alignment
Check Rotation
Nameplate Amps________
Number
hp
L1
L2
L3
1
2
3
4
5
6
Unit Configuration
Water/Glycol System
Air-Cooled Condenser Fans
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Entry Date
Action Taken
Name/Tel.
Maintenance Log
This log must be kept with the unit. It is the responsibility of the owner and/or
maintenance/service contractor to document any service, repair or adjustments. AAON Service
and Warranty Departments are available to advise and provide phone help for proper operation
and replacement parts. The responsibility for proper startup, maintenance, and servicing of the
equipment falls to the owner and qualified licensed technician.
59
Literature Change History
June 2010
Revision of the IOM adding PVC and CPVC piping Caution.
February 2011
Revision of the IOM correcting the information about head pressure control, adding information
about adjusting a heat pump unit’s refrigerant charge and adding information about assembling
split units.
April 2012
Update of IOM changing the 2” pleated 30% efficient filter from MERV 7 to MERV 8,
correcting the condensate drain connection to 1” MPT, adding the supply fan removal
instructions, adding the index of tables and figures, and updating the table of contents.
June 2012
Update of the IOM adding the brazed plate heat exchanger cleaning instructions.
November 2012
Update of the IOM adding information about compressor cycling.
July 2013
Updated qualified installed warning and removed warranty card verbiage.
November 2013
Updated water pipe connections.
60
AAON
2425 South Yukon Ave.
Tulsa, OK 74107-2728
Phone: 918-583-2266
Fax: 918-583-6094
www.aaon.com
SA Series
Installation, Operation &
Maintenance
R74130 · Rev. E · 131107
It is the intent of AAON to provide accurate and current product information. However, in the
interest of product improvement, AAON reserves the right to change pricing, specifications,
and/or design of its product without notice, obligation, or liability.