AAON SA-070 User Manual

SA SERIES

Vertical Self Contained Units and

Indoor Air Handling Units

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

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.

WARNING

Installation, Operation

& Maintenance

Table of Contents

Safety .............................................................................................................................................. 6

General Information ...................................................................................................................... 16

Codes and Ordinances ............................................................................................................... 16

Receiving Unit ........................................................................................................................... 16

Storage ....................................................................................................................................... 17

Direct Expansion (DX) Systems ............................................................................................... 17

Wiring Diagrams ....................................................................................................................... 18

Condensate Drain Pans .............................................................................................................. 18

Unit Size .................................................................................................................................... 18

Installation..................................................................................................................................... 18

Locating the Unit ....................................................................................................................... 18

Lifting and Handling the Unit ................................................................................................... 19

Split Unit Assembly .................................................................................................................. 26

Refrigerant-to-Water Heat Exchanger ...................................................................................... 29

Open Loop Applications ........................................................................................................ 29

Freezing Water in the Heat Exchanger .................................................................................. 29

Water Piping .......................................................................................................................... 30

Brazed Plate Heat Exchanger Cleaning ................................................................................. 33

Electrical .................................................................................................................................... 33

Cutting Electrical Openings ................................................................................................... 34

Thermostat Control Wiring .................................................................................................... 35

Duct Connection ........................................................................................................................ 36

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

Waterside Economizer .............................................................................................................. 37

Hot Water Coil .......................................................................................................................... 41

Chilled Water Coil .................................................................................................................... 41

Startup ........................................................................................................................................... 41

Supply Fans ............................................................................................................................... 41

Supply Fan Spring Isolator Adjustment ................................................................................ 41

Supply Fan Removal .............................................................................................................. 43

Fan Airflow Adjustment ........................................................................................................ 43

Filters ......................................................................................................................................... 45

Adjusting Refrigerant Charge ................................................................................................... 45

Operation....................................................................................................................................... 47

Steam or Hot Water Preheating Operation ................................................................................ 47

Chilled Water or Non-Compressorized DX Cooling Operation ............................................... 47

Packaged DX Cooling Operation and Control .......................................................................... 48

Maintenance .................................................................................................................................. 48

DX Cooling ............................................................................................................................... 48

Condensate Drain Pans .............................................................................................................. 48

E-Coated Coil Cleaning ............................................................................................................ 48

Recommended Coil Cleaner .................................................................................................. 49

Recommended Chloride Remover ......................................................................................... 49

Supply Fans ............................................................................................................................... 50

Phase and Brownout Protection ................................................................................................ 50

Filter Replacement .................................................................................................................... 51

Replacement Parts ..................................................................................................................... 52

AAON Warranty, Service, and Parts Department ..................................................................... 52

Appendix A - Heat Exchanger Corrosion Resistance ................................................................... 53

SA Series Startup Form ................................................................................................................ 55

Maintenance Log .......................................................................................................................... 59

Literature Change History............................................................................................................. 60

R74130 · Rev. E · 131107

Index of Tables and Figures

Tables:

Table 1 - SA Series Models .......................................................................................................... 18

Table 2 - Glycol Freezing Points .................................................................................................. 30

Table 3 - Condenser Water Connections ...................................................................................... 31

Table 4 - Condenser Pressure Drops (Each Heat Exchanger) ...................................................... 32

Table 5 - Control Wiring............................................................................................................... 35

Table 6 - Duct Connection Sizes .................................................................................................. 36

Table 7 - Drain Trap Dimensions ................................................................................................. 37

Table 8 - Acceptable Refrigerant Circuit Values .......................................................................... 46

Table 9 - R-410A Refrigerant Temperature-Pressure Chart ......................................................... 47

Table 10 - 23-35 tons, Pre Filters.................................................................................................. 52

Table 11 - 45-70 tons, Pre Filters.................................................................................................. 52

Table 12 - 23-35 tons, Unit Filters ................................................................................................ 52

Table 13 - 45-70 tons, Unit Filters ................................................................................................ 52

Figures:

Figure 1 - SA Series Unit with Right Intake ................................................................................. 19

Figure 2 - One Piece Single Unit Lifting Details .......................................................................... 20

Figure 3 - Two Piece Single Unit Coil Section Lifting Details .................................................... 21

Figure 4 - Two Piece Single Unit Fan Section Lifting Details ..................................................... 22

Figure 5 - One Piece Dual Unit Lifting Details ............................................................................ 23

Figure 6 - Two Piece Dual Unit Coil Section Lifting Details....................................................... 24

Figure 7 - Two Piece Dual Unit Fan Section Lifting Details ....................................................... 25

Figure 8 - Dual unit without splices and before being bolted together. ........................................ 27

Figure 9 - Dual Unit Assembly Details......................................................................................... 27

Figure 10 - Dual unit with splices after being bolted together. .................................................... 28

Figure 11 - Drain Trap .................................................................................................................. 36

Figure 12 - SA Series Unit with Waterside Economizer Piping ................................................... 38

Figure 13 - Air Conditioner Waterside Economizer Piping Kit ................................................... 39

Figure 14 - Air Conditioner Waterside Economizer Back View .................................................. 39

Figure 15 - Water-Source Heat Pump Waterside Economizer Piping Kit .................................... 40

Figure 16 - Water-Source Heat Pump Waterside Economizer Back View .................................. 40

Figure 17 - Spring Isolation .......................................................................................................... 42

Figure 18 - Back View with Supply Fan Access Panel Removed ................................................ 43

Figure 19 - Front View with Supply Fan Access Door Open ....................................................... 43

Figure 20 - Blower Wheel with Band ........................................................................................... 44

Figure 21 - Band Tabs................................................................................................................... 44

Figure 22 - Blower Wheel............................................................................................................. 44

Figure 23 - Securing the Band ...................................................................................................... 45

Figure 24 - Voltage Monitor ......................................................................................................... 50

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

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

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

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

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. 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

A4 B1

1D 2 3 4 5A

5C 6A

6C 7 8 9

13 14A

14B 15

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

BASE MODEL

SERIES AND GENERATION

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

VOLTAGE

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

INTAKE CONFIGURATION/INTERIOR PROTECTION

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

SA Series Feature String Nomenclature

GEN SIZE VLT CONFIG A1

A4 B1

1D 2 3 4 5A

5C 6A

6C 7 8 9

13 14A

14B 15

SA - 035 - 3 - A - E R 0 9 -

0 0 0 : A C 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

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

SA Series Feature String Nomenclature

GEN SIZE VLT CONFIG A1

A4 B1

1D 2 3 4 5A

5C 6A

6C 7 8 9

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 - H A -

0 0 0 0 0 0 0

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

6B: UNIT FILTER TYPE

0 = 2” Pleated - 30% Eff. - MERV 8 A = 4” Pleated - 30% Eff. - MERV 8 B = 4” Pleated - 65% Eff. - MERV 11 C = 4” Pleated - 85% Eff. - MERV 13 D = 4” Pleated - 95% Eff. - MERV 14

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 = 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

SA Series Feature String Nomenclature

GEN SIZE VLT CONFIG A1

A4 B1

1D 2 3 4 5A

5C 6A

6C 7 8 9

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 - H

A - 0

0 0 0 0 0 0 0

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

SA Series Feature String Nomenclature

GEN SIZE VLT CONFIG A1

A4 B1

1D 2 3 4 5A

5C 6A

6C 7 8 9

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 -

A - 0

0 0 0 0 0 0 0

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

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

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

Model

Cabinet Type

Intake

Cabinet 1

Cabinet 2

SA-023

Single

Left or Right

Side

SA-023

SA-028

SA-030

SA-035

SA-045

Dual

Left and Right

Sides

SA-023

SA-050

SA-023

SA-028

SA-055

SA-028

SA-058

SA-028

SA-030

SA-060

SA-030

SA-065

SA-030

SA-035

SA-070

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.

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.

Figure 2 - One Piece Single Unit Lifting Details

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