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
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
& 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
3
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
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 manufacturers 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
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
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
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
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.
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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.
Table 4 - Condenser Pressure Drops (Each Heat Exchanger)
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.
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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.
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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.
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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
39
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
40
Figure 15 - Water-Source Heat Pump Waterside Economizer Piping Kit
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.
°F
PSIG
°F
PSIG
°F
PSIG
°F
PSIG
°F
PSIG
20
78.3
47
134.7
74
213.7
101
321.0
128
463.2
21
80.0
48
137.2
75
217.1
102
325.6
129
469.3
22
81.8
49
139.7
76
220.6
103
330.2
130
475.4
23
83.6
50
142.2
77
224.1
104
334.9
131
481.6
24
85.4
51
144.8
78
227.7
105
339.6
132
487.8
25
87.2
52
147.4
79
231.3
106
344.4
133
494.1
26
89.1
53
150.1
80
234.9
107
349.3
134
500.5
27
91.0
54
152.8
81
238.6
108
354.2
135
506.9
28
92.9
55
155.5
82
242.3
109
359.1
136
513.4
29
94.9
56
158.2
83
246.0
110
364.1
137
520.0
30
96.8
57
161.0
84
249.8
111
369.1
138
526.6
31
98.8
58
163.8
85
253.7
112
374.2
139
533.3
32
100.9
59
166.7
86
257.5
113
379.4
140
540.1
33
102.9
60
169.6
87
261.4
114
384.6
141
547.0
34
105.0
61
172.5
88
265.4
115
389.9
142
553.9
35
107.1
62
175.4
89
269.4
116
395.2
143
560.9
36
109.2
63
178.4
90
273.5
117
400.5
144
567.9
37
111.4
64
181.5
91
277.6
118
405.9
145
575.1
38
113.6
65
184.5
92
281.7
119
411.4
146
582.3
39
115.8
66
187.6
93
285.9
120
416.9
147
589.6
40
118.1
67
190.7
94
290.1
121
422.5
148
596.9
41
120.3
68
193.9
95
294.4
122
428.2
149
604.4
42
122.7
69
197.1
96
298.7
123
433.9
150
611.9
43
125.0
70
200.4
97
303.0
124
439.6
44
127.4
71
203.6
98
307.5
125
445.4
45
129.8
72
207.0
99
311.9
126
451.3
46
132.2
73
210.3
100
316.4
127
457.3
Table 9 - R-410A Refrigerant Temperature-Pressure Chart

Operation

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
- Use is not recommended
*See Also Chloride Content Table
53
Water
Containing
Concentration
(mg/l or ppm)
Time Limits -
Analyze Before
AISI
316
SMO
254
Copper
Alloy
Nickel
Alloy
Total Hardness
(°dH)
4.0-8.5
No Limit
+ + +
+
Nitrate (NO3)
< 100
No Limit
+ + + + > 100
+ + 0
+
Iron (Fe)
< 0.2
No Limit
+ + + + > 0.2
+ + 0
+
Aluminum (Al)
< 0.2
No Limit
+ + + + > 0.2
+ + 0
+
Manganese (Mn)
< 0.1
No Limit
+ + + + > 0.1
+ + 0
+
Chloride Content
Maximum Temperature
60°C (140°F)
80°C (176°F)
120°C (248°F)
130°C (266°F)
= 10 ppm
SS 304
SS 304
SS 304
SS 316
= 25 ppm
SS 304
SS 304
SS 316
SS 316
= 50 ppm
SS 304
SS 316
SS 316
Ti / SMO 254
= 80 ppm
SS 316
SS 316
SS 316
Ti / SMO 254
= 150 ppm
SS 316
SS 316
Ti / SMO 254
Ti / SMO 254
= 300 ppm
SS 316
Ti / SMO 254
Ti / SMO 254
Ti / SMO 254
> 300 ppm
Ti / SMO 254
Ti / SMO 254
Ti / SMO 254
Ti / SMO 254
Chloride Content
54
Job Name:_______________________________________________
Date:______________
Address:______________________________________________________________________
______________________________________________________________________________
Model Number:_________________________________________________________________
Serial Number:_____________________________________________
Tag:_______________
Startup Contractor:______________________________________________________________
Address:______________________________________________________________________
_______________________________________________________
Phone:______________
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
58
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.
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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.
Copyright © AAON, all rights reserved throughout the world.
AAON® and AAONAIRE® are registered trademarks of AAON, Inc., Tulsa, OK.
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