AAON ProFit WH Series Horizontal Water Source Heat Pump Units Instruction Manual

AAON ProFit WH Series Horizontal Water Source Heat Pump Units

Specifications

• Energy Efficiency

  • Direct Drive Supply Fan
  • Scroll or Rotary Compressor
  • High Efficiency Electronically Commutated (EC) Motor
  • Copper Coaxial Refrigerant-to-Water-Heat Exchanger
  • AHRI Certified Performance

• Indoor Air Quality

  • Stainless Steel Drain Pan

• Controls

  • 5 Wire Thermostat Control

• Installation and Maintenance

  • Color-Coded Wiring and Wiring Diagram

• Environmentally Friendly

  • R-410A Refrigerant

• Extended Life

  • Sturdy Galvanized Steel Construction
  • Induction Brazing
  • Stainless Steel Drain Pan
  • 5 Year Parts Warranty

• Reduced Sound

  • Compressors Mounted with Rubber-in-Shear Isolators on an
    Isolation Plate with Rubber-in-Shear Isolation to the Cabinet

  • Sound Absorbing Fiberglass Cabinet Insulation

  • Floating Water Connections

Product Usage Instructions

Safety

Attention must 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.

Compressor aznd Motor Rotation Check

Rotation must be checked on all COMPRESSORS AND MOTORS 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 for proper operation, without using external refrigerant pressure gauges. Often, a compressor running in reverse rotation will be much louder than a normal compressor and will not develop much of a temperature differential between the suction and discharge lines.

Fan motor rotation must also be checked for proper operation.
Alterations must only be made at the unit power connection.

Cleaning and Maintenance

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.

Cleaning the cooling tower or the water loop with harsh chemicals, such as hydrochloric acid (muriatic acid) or chlorine, can damage the refrigerant-to- water heat exchanger. Care must be taken to avoid allowing chemicals to enter the refrigerant-to-water heat exchanger. See Appendix A – Heat Exchanger Corrosion Resistance for more information.

Piping System

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.

FAQs

1. Q: Can I use acidic chemical coil cleaners on the unit?

A: No, using acidic chemical coil cleaners can cause damage to the unit. It is recommended to avoid using them.

1. Q: Can I clean the cooling tower or water loop with hydrochloric acid or chlorine?

A: No, cleaning the cooling tower or water loop with harsh chemicals like hydrochloric acid or chlorine can damage the refrigerant-to-water heat exchanger. It is important to avoid allowing chemicals to enter the heat exchanger.

1. Q: What type of refrigerant does the unit use?

A: The unit uses R-410A refrigerant, which is environmentally friendly.

ProFit
WH Series
Horizontal Water-Source Heat Pump Units

Installation, Operation & Maintenance

WARNING
If the information in this manual is not followed exactly, a fire may result causing property damage, personal injury, or loss of life.

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. Keep a copy of this IOM with the unit.
4

AAON ProFit Features and Options Introduction

Energy Efficiency Direct Drive Supply Fan Scroll or Rotary Compressor High Efficiency Electronically
Commutated (EC) Motor Copper Coaxial Refrigerant-to-Water-
Heat Exchanger AHRI Certified Performance
Indoor Air Quality Stainless Steel Drain Pan
Controls 5 Wire Thermostat Control

Installation and Maintenance Color-Coded Wiring and Wiring
Diagram
Environmentally Friendly R-410A Refrigerant
Extended Life Sturdy Galvanized Steel Construction Induction Brazing Stainless Steel Drain Pan 5 Year Parts Warranty
Reduced Sound Compressors Mounted with Rubber-in-
Shear Isolators on an Isolation Plate with Rubber-in-Shear Isolation to the Cabinet Sound Absorbing Fiberglass Cabinet Insulation Floating Water Connections

5

Safety
Attention must 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.

CAUTION
Rotation must be checked on all COMPRESSORS AND MOTORS 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 for proper operation, without using external refrigerant pressure gauges. Often, a compressor running in reverse rotation will be much louder than a normal compressor, and will not develop much of a temperature differential between the suction and discharge lines.
Fan motor rotation must also be checked for proper operation. Alterations must only be made at the unit power connection.

CAUTION
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
Cleaning the cooling tower or the water loop with harsh chemicals, such as hydrochloric acid (muriatic acid) or chlorine, can damage the refrigerantto- water heat exchanger. Care must be taken to avoid allowing chemicals to enter the refrigerant-to-water heat exchanger. See Appendix A – Heat Exchanger Corrosion Resistance for more information.

6

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.
WARNING
OPEN LOOP APPLICATIONS
Failure of the refrigerant-to-water heat exchanger as a result of chemical corrosion is excluded from coverage under AAON Inc. warranties and the heat exchanger manufacturer’s warranties.
WARNING
Some chemical coil cleaning compounds are caustic or toxic. Use these substances only in accordance with the manufacturer’s usage instructions. Failure to follow instructions may result in equipment damage, injury or death.
WARNING
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
UNIT HANDLING
To prevent injury or death lifting equipment capacity must 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
ELECTRIC SHOCK AND FIRE 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 to avoid shock hazard or injury from rotating parts. Follow proper Lockout-Tagout procedures.
When servicing controls, label all wires prior to disconnecting. Reconnect wires correctly.
Verify proper operation after servicing. Secure all service panels.
7

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 must 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, must be followed.

WARNING
ROTATING COMPONENTS
Unit contains fans with moving parts that can cause serious injury. Do not remove panel containing fans until the power to the unit has been disconnected and fan has stopped rotating.
WARNING
WATER FREEZING
Failure of the refrigerant-to-water heat exchanger 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 is excluded from coverage under AAON warranties and the heat exchanger manufacturer warranties.
WARNING
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 must be field supplied on system water piping.

8

1. READ THE ENTIRE INSTALLATION, OPERATION AND MAINTENANCE MANUAL. OTHER IMPORTANT SAFETY PRECAUTIONS ARE PROVIDED THROUGHOUT THIS MANUAL.
2. Startup and service must be performed by a Factory Trained Service Technician.

3. The unit is for indoor use only. See General Information section for more unit information.
4. Every unit has a unique equipment nameplate with electrical, operational, and unit clearance specifications. Always refer to the unit nameplate for specific ratings unique to the model you have purchased.

9

WSHP Series Feature String Nomenclature

Unit Configuration

:

Accessory Options

Gen Major Rev
Siz e Series Minor Rev Voltage Eff. Level Comp Style Loop Type Coil Type Heat Type Heat Staging
1 2 3 A 3 B
4 5 6 A 6 B 7 8 9 1 0 1 1 1 2 1 3 1 4 1 5 1 6

WH B – 024 – C – 0 – 3 – 1 – 0 0 0 – 0 0 : 0 0 – 0 E – 0 0 – 0 0 – 0 0 0 0 0 – 0 A 0 0 0

MODEL OPTIONS
Generation and Orientation WH = Horizontal Water-Source Heat Pump
Major Revision B = ProFit
Unit Size 006 = 6,000 Btu/hr = ½ ton 009 = 9,000 Btu/hr = ¾ ton 012 = 12,000 Btu/hr = 1 ton 015 = 15,000 Btu/hr = 1 ¼ ton 018 = 18,000 Btu/hr = 1 ½ ton 024 = 24,000 Btu/hr = 2 ton 030 = 30,000 Btu/hr = 2 ½ ton 036 = 36, 000 Btu/hr = 3 ton 042 = 42,000 Btu/hr = 3 ½ ton 048 = 48,000 Btu/hr = 4 ton 060 = 60,000 Btu/hr = 5 ton
Series A = A Cabinet (006, 009 & 012) B = B Cabinet (015 & 018) C = C Cabinet (024 & 030) D = D Cabinet (036 & 042) E = E Cabinet (048 & 060)
Minor Revision 0 = Minor Revision 0
Voltage 3 = 460V/3/60Hz 4 = 575V/3/60Hz A = 265V/1/60Hz B = 115V/1/60Hz C = 208-230V/1/60Hz D = 208-230V/3/60Hz
Efficiency Level 0 = Std Efficiency Compact Box
Compressor Style 0 = R-410A On/Off Compressor – Heat Pump

Loop Type 0 = Water Loop (Cooling Tower Only, EWT 60°F) A = Ground Loop Application B = Ground Water Application
Coil Type 0 = Copper Coaxial Refrigerant-to-Water Heat
Exchanger + Fin & Tube Condenser Coil
Heat Type 0 = No Heating
Heating Staging 0 = No Heating
1: Unit Orientation 0 = Right Hand Return + Left Hand Supply A = Right Hand Return + End Supply B = Left Hand Return + Right Hand Supply C = Left Hand Return + End Supply
2: Supply Fan B = Standard Fan + ECM Motor
3A: Filter Rack 0 = Open Return – Slide-Out Filter Rack
3B: Filters A = 2″ MERV 8 Pleated Filter E = 1″ MERV 8 Pleated Filter F = 1″ MERV 11 Pleated Filter G = 1″ MERV 13 Pleated Filter I = 1″ Fiberglass Filter J = 2″ Fiberglass Filter K= 2″ MERV 11 Pleated Filter L = 2″ MERV 13 Pleated Filter
4: Refrigeration and Dehumidification Options 0 = Standard

10

WSHP Series Feature String Nomenclature

Unit Configuration

:

Accessory Options

Gen Major Rev
Size Series Minor Rev Voltage Eff. Level Comp Style Loop Type Coil Type Heat Type Heat Staging
1 2 3 A 3 B
4 5 6 A
6 B 7 8 9 1 0 1 1 1 2 1 3 1 4 1 5 1 6

WH B – 024 – C – 0 – 3 – 1 – 0 0 0 – 0 0 : 0 0 – 0 E – 0 0 – 0 0 – G 0 0 0 0 – 0 A 0 0 0
5: Service Disconnect 0 = Standard – 5 kAIC D = 5 kAIC Standard / 100 kAIC w/ Field Installed
Fusing F = 100 kAIC Fusing w/ Fused Disconnect – 30 Amp G = 100 kAIC Fusing w/ Fused Disconnect – 60 Amp
6A: Control Sequence 0 = Terminal Block for Thermostat + Pioneer Silver
Controller A = Terminal Block for Thermostat + Pioneer Silver
Controller + Expansion Board
6B: Control Options 0 = Standard – No Communication
7: Cabinet Options G = 1/2″ Fiberglass Cabinet Insulation + Stainless
Steel Drain Pan H = 1/2″ Fiberglass Cabinet Insulation + Stainless
Steel Drain Pan + Low Sound Package + MLV
8: WSE 0 = Standard – None
9 & 10: Blank 00 = Standard – None
11: Code Options 0 = Standard – ETL USA Listing B = ETL USA + Canada Listing
12: Shipping Options 0 = Standard
13: Cabinet Access A = Standard
14 & 15: Blank 00 = Standard – None
16: Cabinet 0 = Galvanized Steel Cabinet Construction
11

General Information

AAON ProFit Water-Source Heat Pump units (WSHP) are designed for indoor installation only. Units are assembled, wired, charged and run-tested at the factory.
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 must be kept with the unit.
CAUTION
These units must not be used as a “construction heater” at anytime during any phase of construction. Very low return air temperatures, harmful vapors, and misplacement of the filters can damage the unit and its efficiency.
Certification of Cooling Models a. Certified as a commercial central air
conditioner with electrically operated compressors. b. Certified for indoor installation only. c. Certified with refrigerant R-410A coils.

Codes and Ordinances Units have been tested and certified, by ETL, in accordance with UL Safety Standard 1995/CSA C22.2 No. 236.
System must be sized in accordance with the American Society of Heating, Refrigeration and Air Conditioning Engineers Handbook.
Installation of units must conform to the ICC standards of the International Mechanical Code, the International Building Code, Installation of Air Conditioning and Ventilating Systems Standard, NFPA 90A, and local building, plumbing and waste water codes. All appliances must be electrically grounded in accordance with local codes, or in the absence of local codes, the current National Electric Code, ANSI/NFPA 70 or the current Canadian Electrical Code CSA C22.1.
CAUTION
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.
WARNING
Coils and sheet metal surfaces present sharp edges and care must be taken when working with equipment.

12

WARNING
Failure to observe the following instructions will result in premature failure of your system and possible voiding of the warranty.
Receiving Unit When received, check the unit for damage that might have occurred in transit. If damage is found, it must be noted on the carrier’s freight bill. A request for inspection by carrier’s agent must be made in writing at once. Check nameplate to ensure the correct model sizes and voltages have been received to match the job requirements.
All units are shrink-wrapped in blue wrap. If a unit shows up with any other color wrap, the unit has been opened. Check unit thoroughly for damage that necessitated rewrapping.
If repairs must be made to damaged goods, notify the factory before any repair action is taken in order to protect the warranty. Certain equipment alteration, repair, and manipulation of equipment without the manufacturer’s consent may void the product warranty. Contact the AAON Warranty Department for assistance with handling damaged goods, repairs, and freight claims: 918-382-6450.
Note: Upon receipt check shipment for items that ship loose. Consult order and shipment documentation to identify potential looseshipped items.

Figure 1 – Access Panels
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 systems are factory assembled, leak tested, charged with R-410A refrigerant, and run tested.
All systems include air coil, reversing valve, liquid line filter dryer, thermal expansion valve (TXV), and compressor.
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 can cause excessive liquid to return to the compressor. As the liquid concentration builds up, oil is washed out of the compressor, leaving it starved for lubrication.
The compressor life will be seriously shortened by reduced lubrication and the pumping of excessive amounts of liquid oil and refrigerant.

13

Wiring Diagrams Unit specific wiring diagrams are affixed inside the control compartment panel.
14

Installation

AAON equipment has been designed for quick and easy installation.
Before startup of the unit, check the supply blower and remove the foam shipping block that may be included to support the blower assembly before installation, or damage may occur.

four (4) vibration grommets (factory provided) and 3/8″ washers (field provided) and as shown in Figure 3.

Vibration Grommet

Threaded Rod (Field Provided)

3/8″ Washer (Field Provided)

Nut (Field Provided)

Figure 2 – Foam Shipping Block
Locating the Unit Placement of the unit relative to ductwork, electrical and plumbing must be carefully considered. Supply and return air plenum or duct can be mounted directly to the duct connection flanges. Use a properly sized duct transition to connect supply duct to unit supply air opening. Return duct flanges are only included on units with the optional 4sided filter rack. Use flexible gasket material to seal the duct to the unit.
Verify ceiling, floor, or foundation can support the total unit weight, including accessory weights.
To properly support the horizontal WSHP unit and reduce sound and vibration, it must be mounted level in both horizontal directions. These units are designed to be suspended via threaded rod (field provided) through all four hanger brackets using the

Figure 3 – Mounting Horizontal Units Verify the top of the vibration grommet is inserted into (or through) the hole provided in the hanger bracket, as pointed out in Figure 4.
Figure 4 – Vibration Grommet Installation The threaded rod and nut must be adequately sized to support the total unit weight. Avoid installing units directly above or adjacent to sound-sensitive areas.
15

Note: Ductwork must be supported independently from the unit. The unit must not support supply and/or return ductwork.
Allow adequate service clearances as shown on the unit nameplate and unit drawing. Consult your local building codes for additional service clearance requirements.
Allow adequate space for piping access and panel removal. Water piping is on the compressor end and condensate drain connections are located on the opposite end.
Condensate Drain Figure 5 – Condensate Drain Piping
CAUTION
Emergency drain pan is recommended for all applications where a risk of water damage to surrounding structure or furnishings. Refer to local codes.
Floor Mounted Units Make sure the unit is level and mounted on a field supplied platform with a minimum height to allow for proper depth of the

condensate line p-trap. Other installation provisions may be necessary according to job specifications.
It is recommended that a vibration isolation pad be used when floor mounting a unit
Condensate Drain Piping A p-trap and drain line must be installed on horizontal units, with the p-trap not to exceed 6″ from the drain connection. Use the same pipe size or larger as/than the drain connection and pitch downward toward drain. Use an air break in long runs of condensate lines. Note: All horizontal units require a field installed p-trap.
CAUTION
Unit must not be operated without ptraps. Failure to install a p-trap may result in overflow of condensate water.
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 must conform to all applicable governing codes.
Note: Drain connection is a ¾” MTP.

16

The total height from the trap inlet to the top of the bottom bend of the trap must be 2″ minimum.

Figure 6 – Drain Trap

The height from top of the bottom bend of the trap to the bottom of the leaving pipe must be at least equal to 1″. This ensures that enough water is stored in the trap to prevent losing the drain seal during unit startup.

Capacity
006, 009, 012 015, 018 024, 030 036, 042 048, 060

Table 1 – Clearances

Minimum Clearances Required

Front/Control Panel

Back

20

24

20

20

20

20

20

20

20

20

Air Intake
6 6 6 6 6

Figure 7 ­ Horizontal Configuration Orientations 17

Blower Assembly Removal and Discharge Modification
The AAON WSHP discharge direction can be selected in ECat and is also designed so that the discharge direction can be field modified if needed.
Note: DO NOT perform this action while unit is hanging. It MUST be done on a solid working surface. Otherwise, serious unit damage may occur.

1. Using a 516″ socket, remove the shipping screw on the outside of the right or discharge side of the unit.

2. Pull the blower assembly out of the unit for service.

3. Invert blower assembly 180 degrees so that the blower can be rewired using the opposite access.

4. Remove the four (4) self-tapping sheet metal screws holding the access panel in place.

5. Fasten blower using the existing holes and self-tapping screws.

6. Rewire the blower and fasten the access panels using self-tapping screws.

7. Remove the side blower access panel and disconnect the blower wiring.

8. Remove the four (4) self-tapping sheet metal screws holding the blower assembly in place.
   18

Lifting and Handling the Unit Before lifting unit, be sure that all shipping material has been removed from unit.
Unit may be lifted with a pallet jack.

WARNING
UNIT HANDLING
Incorrect lifting can cause damage to the unit, injury or death. Lifting equipment capacity must 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.
Blower Motor and Fan Access To access the blower motor and fan, first remove the blower assembly as outlined in the appropriate “Blower Assembly Removal” for your unit.
Once the blower assembly is on a working surface:

1. Remove the five (5) screws that secure the blower motor to the blower assembly.

2. Separate the motor from the blower sub assembly, place the sub assembly (motor side down) and remove the set screw as shown below.

3. The blower can now be separated from the motor.
   Refrigerant-to-Water Heat Exchanger Water Piping Open Loop Applications This product contains refrigerant-to-water heat exchanger made of cupronickel or copper and is subject to severe corrosion and failure when exposed to chlorides.

4. Pull the motor and blower up and out of the blower assembly.
   19

WARNING
OPEN LOOP APPLICATIONS
Failure of the refrigerant-to-water heat exchanger as a result of chemical corrosion is excluded from coverage under AAON Inc. warranties and the heat exchanger manufacturer’s warranties.
Do not allow water containing any form of chlorides to enter this heat exchanger.
Common forms of chlorides include:
1. Seawater mist entering an open cooling tower system.
2. Contaminated make-up water containing salt water.
3. Water loop systems that have been disinfected.
Chlorides will result in a premature failure of the refrigerant-to-water heat exchanger.
Failure of the refrigerant-to-water heat exchanger as a result of chemical corrosion is excluded from coverage under AAON warranties and the heat exchanger manufacturer warranties.
Failure of the refrigerant-to-water heat exchanger may allow water to enter the refrigerant circuit and may cause extensive damage to the refrigerant circuit components. Any damage to the equipment as a result of refrigerant-to- water heat exchanger failure from chemical corrosion due to the fluid in the refrigerant-to-water heat exchanger is excluded from coverage under AAON warranties and the heat exchanger manufacturer warranties.
20

WARNING
OPEN LOOP APPLICATIONS
Cupronickel refrigerant-to-water heat exchangers must be used with all open loop applications. Failure to use a Cupronickel heat exchanger may result in premature failure of your system and possible voiding of the warranty.
CAUTION
Cleaning the cooling tower or water loop with harsh chemicals such as hydrochloric acid (muriatic acid), chlorine or other chlorides, can damage the refrigerant-to-water heat exchanger. Care must be taken to avoid allowing chemicals to enter the refrigerant-to-water heat exchanger. See Appendix A – Heat Exchanger Corrosion Resistance for more information.
Freezing Water in the Heat Exchanger This product contains one refrigerant- towater heat exchanger. A refrigerant-to-water heat exchanger contains refrigerant in one passage and water in another passage. Water is subject to freezing at 32°F. When water freezes in a heat exchanger significant forces are exerted on the components of the heat exchanger where the water is confined.
Failure of the refrigerant-to-water heat exchanger 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 refrigerantto-water heat exchanger 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 cooling mode without the need for an automatic flow regulating water valve. If the EWT is expected to be lower than 57°F or more stable operation is desired, an automatic flow regulating water valve must be installed.
WARNING
WATER FREEZING
Failure of the refrigerant-to-water heat exchanger 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 is excluded from coverage under AAON warranties and the heat exchanger manufacturer warranties.
Glycol solutions are required if ambient temperatures are expected to fall below freezing or if the loop water temperature is below 50°F while operating in the heating mode with the design minimum flow rate. Adding glycol causes an increase in pressure drop resulting in a decrease in unit performance. A minimum concentration of 20% glycol solution is required. The unit controller contains dip switches to set the loop glycol percentage. Set the glycol percentage to the closest option available, rounding down if needed.
The option selected will reset the Leaving Water Temperature safety for the unit. AAON will not be responsible for frozen coaxial coils due to improper selection of glycol percentage. See Leaving Water Temperature Alarm section for more details.

Table 2 – Glycol Concentration

Freezing Points

% Glycol Ethylene Propylene

Glycol

Glycol

0

32°F

32°F

20

18°F

19°F

30

7°F

9°F

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

Never operate the unit in heat pump mode with a saturated suction temperature below 35°F for pure water systems or below the freezing point +3°F of the aqueous solution of water and glycol.

Water Piping

WARNING

WATER PRESSURE Prior to connection of the 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, drain valves must 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.

21

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.

Only use approved water pipe material. Do not use galvanized material for water lines/fittings.

Table 3 – Water Connections

Supply and

Horizontal WSHP

Return Connection Size

(in. FPT)

006, 009, 012, 015, 018

1/2″

024, 030, 036, 042

3/4″

048, 060

1″

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

22

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
WATER PIPING
Follow national and local codes when installing water piping. Incorporate vibration eliminators on connections to the unit 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.
Before connection to the unit, the water system must be flushed to remove foreign material that could cause fouling. Install a screen strainer with a minimum of 20 Mesh ahead of the inlet to prevent fouling and internal tube damage. Mineral content of the 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. A bleed-off (drain valve) must be provided for the water loop. Field provided and installed water treatment program must be compatible with stainless steel, copper, aluminum, ABS plastic, and PVC. Batch feed processes must never be used as concentrated chemicals can cause

corrosion. Never use hydrochloric acid (muriatic acid) or chlorine as it will corrode stainless steel. Water loop piping runs through unheated areas or outside the building must be insulated. NOTE: Ball valves must be installed in the water supply and return lines for unit isolation and water flow balancing. All manual flow valves must be of the ball valve design. Globe or gate valves must not be used due to high pressure drops and poor throttling characteristics. Pressure and temperature ports are recommended in water supply and return lines for system balancing. These openings must be 5 to 10 pipe diameters from the unit water connections. To allow for mixing and temperature stabilization, wells in the water piping must extend at least ½ pipe diameter into the pipe. Piping systems must not exceed 10 ft/sec fluid velocity to ensure tube wall integrity and reduce noise.
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Electrical Verify the unit nameplate agrees with power supply. WSHP Series units are provided with single point power wiring connections. A complete set of unit specific wiring diagrams, showing factory and field wiring are located inside the controls compartment panel.

Table 4 – Nameplate Voltage Markings & Tolerances

Hz

Nameplate Voltage

Nominal System Voltage

Operating Voltage Range 1

Min

Max

Acceptable Performance Range2

Min

Max

115

120

104

127

108

126

208/230

208/240

187

254

187

252

208

208

187

228

187

228

60

230

265

240

208

254

216

252

277

240

293

249

291

460

480

416

508

432

504

575

600

520

635

540

630

Notes: 1. Operating voltage is the min and max voltage for which the unit can function. Never operate outside of this min and max voltage. 2. The Acceptable Performance Range is the min and max voltage for which the unit performance is designed and rated to give acceptable performance 3. Note: All units are factory wired for either 115V, 208V/230V, 265V, 460V, or 575V.

The transformer configuration must be checked by a qualified technician prior to service, especially if unit is to be connected to a 208V or 230V supply. Note: All our units are default wired to 208V for the 208V/230V option. To utilize 230V service, interchange the yellow and red wire terminals from the transformer.
Red-Black for 208V Yellow-Black for 230V

WARNING
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.
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.

24

A unit-mounted disconnect switch is available as an option. It is important to note that this is a method for convenient maintenance of the unit, but does not provide unit protection or isolation.
Electrical supply can enter through the side of the controls compartment where knockouts and/or capped pre-cut holes have been provided. Horizontal units have been provided with both high and low voltage holes at the top and bottom of the unit. Entry must be made into one each of these locations. A single point connection to a definite purpose contactor is provided on the control panel, or to the unit-mounted disconnect switch (if installed) on the corner panel. High voltage conductors must enter the control panel in a separate opening and separate conduit than 24V low voltage conductors. High voltage and low voltage openings are nominally sized at 1-1/8″ and 7/8″ respectively.
Note: Alternate locations for field cut electrical entries must be approved by AAON factory.
CAUTION
Installing Contractor is responsible for proper sealing of the electrical entries into the unit. Failure to seal the entries may result in damage to the unit and property.
Size supply conductors based on the unit Minimum Current Ampacity (MCA) rating. Supply conductors must be rated a minimum of 75°C.
Protect the branch circuit in accordance with code requirements. The unit must be electrically grounded in accordance with

local codes, or in the absence of local codes, the current National Electric Code, ANSI/NFPA 70 or the current Canadian Electrical Code CSA C22.1.
Wire power leads to the unit’s contactor 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 must not exceed the short circuit current rating (SCCR) shown on the unit nameplate.
CAUTION
Three phase voltage imbalance will cause motor overheating and premature failure.
Voltage imbalance is defined as 100 times the maximum deviation from the average voltage divided by the average voltage. The maximum allowable imbalance is 2%.
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.
25

CAUTION
Rotation must be checked on all MOTORS AND COMPRESSORS of three phase units. Supply fan motors must all be checked by a qualified service technician at startup and any wiring alteration must only be made at the unit power connection.

Wire control signals to the unit’s low voltage thermostat connections on the control board, located in the controls compartment. Consult unit wiring diagram for more detailed instructions on control signal wiring connections. If any factory installed wiring must be replaced, use a minimum 105°C type AWM insulated conductors.

CAUTION

Scroll compressors are directional

and can be damaged if rotated in the

wrong direction. Compressor rotation

must be checked for proper operation,

without using external refrigerant

pressure gauges.

Often, a

compressor running in reverse

rotation will be much louder than a

normal compressor, and will not

develop much of a temperature

differential between the suction and

discharge lines.

WARNING
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/
26

Thermostat Control Wiring If a thermostat is used for unit control, locate thermostat 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

Wire

Size Total Wire Distance

(Stranded) – Copper Allowable

Conductors Only

20 AWG

200 ft

18 AWG

350 ft

16 AWG

500 ft

14 AWG

750 ft

12 AWG

1250 ft

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.

Example: A total of 5 wires must be pulled 75ft to a control the unit. What size wire must be used? According to Table 5, 18 AWG allows for 70ft (350 ft. /5 wires) and 16 AWG allows for 100ft (500 ft. /5 wires). Thus, 16 AWG must be used.

Filter Pull Setup Do not operate the unit without filters in place. Each unit has a filter pull located in the filter section of the unit. The filter pull must be setup prior to installing or changing the filters. If side access to the filters is desired, then no further action is required. If bottom access to the filters is desired, then the filter pull must be removed. If unit includes 4-sided filter rack, clips must be opened to remove filters and filter pull.
Figure 8 – Filter Rack Closed with Clip
Figure 9 ­ Filter Rack Open with Clip

1. The filter pull is located in the filter area as shown in Error! Reference source not found.. If necessary, from the SIDE filter access open the filter access door.
Figure 10 – Using the Filter Pull
2. The filter pull is now accessible. Grasp the filter pull and lift it approximately ¼” and with moderate force, pull it out and away from the unit. Note: Use caution that filters are clear of access holes so that filter damage does not occur. See Figure 10.
3. Because the filter pull may be longer than available room, it may be necessary to roll, bend or cut the slide to be completely removed.
4. Reinstall the filters, taking note of correct orientation with regard to airflow.
5. If necessary, close the filter access door and press the fastener clip firmly until locked into position.
Duct Connection Attach duct to flanges provided on the unit. Use a properly sized duct transition to connect supply duct to unit supply air opening. The installer is responsible for sealing ducts to the flanges to prevent air leaks.

27

Intake air enters the side of the units, where the air filters are located. The left or right hand return depends on feature selected when ordering the units. Ductwork must be sized in accordance with the ASHRAE Handbook. Ductwork must 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.
28

Startup
(See back of the manual for startup form)

Operation Limits

Cooling Heating

Min. Entering Air

60°F 45°F

Max Entering Air

100°F 80°F

Min. Entering Water

30°F 20°F

Max Entering Water

110°F 90°F

Min. GPM/Ton

1.5

Max GPM/Ton

4

Min. CFM/Ton

300

Supply Fans Units are equipped with direct drive forward curved or backward curved plenum supply fan assemblies that deliver the air volume specified according to unit size and job requirements.

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. Keep a copy of this IOM with the unit.
WARNING
Electric shock hazard. Shut off all electrical power to the unit to avoid shock hazard or injury from rotating parts.

Figure 11 – WSHP Series Supply Fan
Fan Air Flow Adjustment A specific air volume is delivered by the PSC fans. Field airflow adjustment may be required at startup.
Standard PSC motors have limited RPM Adjustment to adjust airflow. Each motor type has three speed taps to select from: High, Medium, and Low. Adjustment for the PSC speed must be made by altering the motor power connected to the motor. (WH015 060).

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, and water flow. Due to the chargecritical nature of these units, refrigerant pressure gauges must only be hooked up to the unit if there is suspicion of an issue within the circuit.

Adjustment for the A cabinet units (WH006012) is made by adjusting the DC voltage signal to the motor from the Pioneer Expansion board or the Pioneer Gold board. Low fan speed is achieved by connecting the compressor Y call from the thermostat to Y1
29

on the control board. The higher fan speed is achieved by connecting Y from the thermostat to Y2 on the control board.

Motor Tap RPMs

Fan Speed High Med Low

RPM
1200 950 800

PSC Tap
Black Blue Red

Note: RPMs are approximate, and will vary slightly depending on TSP across the blower assembly

For unit operation at ISO 13256-1 rating conditions, PSC blower motors must use “High” Speed and 8. B through E cabinet unit (WH015-060). WH ½ – 1 ton units may also require specific dip-switch settings. Please consult factory for details.

Filters Do not operate the unit without filters in place. Unit must be checked for correct filter placement during startup. Operation of the equipment without filters will result in a clogged air coil.

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

Adjusting Refrigerant Charge Unit must be operating in the cooling mode to adjust the refrigerant charge.

CAUTION
Due to the charge-critical nature of these units, charge must only be adjusted if absolutely necessary.
Adjusting the charge of a system in the field must be based on determination of liquid subcooling 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, operate the unit in reheat (dehumidification) mode to check for correct 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 refrigerant-to-water heat exchanger.
Read the gauge pressure at the liquid line close to the point where the temperature was taken.

30

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 following table for the appropriate unit type and options.
CAUTION
DO NOT OVERCHARGE! Refrigerant overcharging leads to excess refrigerant in the refrigerantto-water heat exchanger coils resulting in elevated compressor discharge pressure.

Table 6 – Acceptable Refrigeration Circuit

Values at AHRI ISO 13256 WLHP

Conditions

Water-Source Heat Pump

Sub-Cooling

4-8°F

Superheat

8-15°F

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

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.

31

Table 7 – R-410A Refrigerant Temperature-Pressure Chart
°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
32

Operation
Unit operations must be controlled with thermostat and unit controller, never at the main power supply, except for emergency or complete shutdown of the unit.
AAON WSHP Pioneer Silver Controller Part Number: V67470
Description The WSHP Pioneer Silver Controller contains all the functionality required to operate the basic configuration of the units. The controller requires commands from a standard heat pump room thermostat and has outputs to control a supply fan, compressor, and reversing valve. The control also contains a port for communication to the Pioneer Silver Expansion Board for additional functionality.
NOTE: If the application currently uses an obsolete mercury bulb type thermostat, it must be upgraded to an electronic thermostat. The unit will not function properly when controlled via a mercury bulb thermostat.
General Specifications Electrical Supply Voltage 24VAC (+25%/-15%), Class 2
Supply Power 15VA
Outputs Relay Outputs: 1A maximum per output.
Input Requirements Resistive Inputs: require 10K Type 3 Thermistor 24VAC Inputs: Inputs provide 4.7k Load

Environmental Operating Temperature 32 to 158°F (0 to 70°C)
Storage Temperature -4 to 158°F (-20 to 70°C)
Humidity (Storage and Operating) 0 to 95% RH non-condensing
Mounting & Dimensions Mounting Board is mounted via four shoulder eyelets located on the corners of the circuit board.
Dimensions 5.5″ x 4.0″
Inputs and Outputs Pluggable Screw Terminal Block H2 AL1 = Dry, normally open contact with terminal AL2. Contact closes when controller is in alarm. AL2 = Dry, normally open contact with terminal AL1. Contact closes when controller is in alarm. COM = 24VAC Common. ESD = Emergency shutdown Input. 24VAC or common must be used as input for unit operation. Jumper to COM is factory installed. NS = Night setback mode enable. 24VAC or common may be used as inputs. NO = Dry, normally open contact with terminal IN. Contact closes when compressor is active. IN = Common input for terminals NO and NC. NC = Dry, normally closed contact with terminal IN. Contact opens when compressor is active.

33

Pluggable Screw Terminal Block H5 24V = 24VAC power output for thermostat. NS_OV = Night setback override input. Input requires 24VAC to activate. O = Thermostat input for reversing valve operation. Input requires 24VAC to activate. COM = 24VAC common for thermostat power. G = Thermostat input for fan operation. Input requires 24VAC to activate. NS_TH = Night setback compressor enable. Input requires 24VAC to activate. Y = Thermostat input for compressor operation. Input requires 24VAC to activate. AL = 24VAC wet alarm output.
Pluggable Screw Terminal Block H1 + = Network terminal used for communication with the expansion board. – = Network terminal used for communication with the expansion board. S = Shield
Quick Disconnect Terminals P1 – AUX = Auxiliary alarm terminal. Dry contact with AUX IN enables alarm. P2 – AUX IN = Auxiliary alarm terminal. Dry contact with AUX enables alarm. P3 – TEST = Delay override terminal. Dry contact with TEST IN enables the delay override function. P4 – TEST IN = Delay override terminal. Dry contact with TEST enables the delay override function.
Alarm Status LED D5 See Table 8 for flash codes.
Relay Status LEDs COMP = Compressor Relay ALARM = Alarm Relay FAN = Fan Relay RV = Reversing Valve Relay
Dip Switch SW1 See Table 9 – Glycol Percentage Setpoints
34

Figure 12 – Pioneer Silver Controller Layout

Sequences of Operation
Supply Fan Operation Supply fan will enable upon receiving a 24VAC input on the “G” terminal or a call for compressor operation unless an alarm prevents the fan from operating. There is a 30 second minimum off timer for the fan. The supply fan is enabled for 15 seconds after the last stage of cooling, heating, or dehumidification stages off. Not all alarms will prevent supply fan operation.
The alarms that disable the fan are:

1. Emergency Shutdown 2) Condensate Overflow 3) Low Voltage 4) High Voltage

Compressor Operation The compressor will enable upon receiving a 24VAC input on the “Y” terminal or a 24VAC input on the “TH_NS” terminal if in night setback mode unless an alarm is active. If the supply fan was not enabled prior to the compressor call, then the supply fan will enable for 5 seconds before the compressor is started.
The compressor has a minimum on time of 3 minutes and a minimum off time of 2 minutes to prevent short cycling. These delays can be shortened to 5 seconds if the controller is in test mode. If the unit goes into an alarm then the minimum on time will be ignored and the compressor will disable. All alarms will disable the compressor.
35

Reversing Valve Operation The reversing valve will enable if the compressor has been operational for a minimum of 5 seconds.
The default reversing valve position is for heating operation. Therefore, in compressor cooling operation 24VAC must be applied to the “O” terminal.
Random Start Delay The controller will enter a random start delay in these situations:

1. The unit powers up 2) Recovery from emergency shutdown
   alarm 3) Recovery from high voltage alarm 4) Recovery from low voltage alarm
2. Night setback mode is disabled
   The random start delay will be between 3 and 60 seconds. The fan and compressor will not be operational during this time. The random start delay will be ignored if the unit is in test mode.
   Building Occupancy Status Occupied Mode The controller will operate according to the thermostat inputs.
   Night Setback Mode Night setback mode is enabled upon receiving a 24VAC or a 24VAC common input on the “NS” terminal. While in night setback mode the controller will ignore the normal thermostat signals. Instead the controller will use the “NS_TH” input as the fan and compressor enable signal operating at full compressor capacity. When the unit is taken out of night setback mode the controller will execute a random start delay.
   The night setback mode can be overridden with a 24VAC input to the night setback override terminal “NS_OV”. Once the override signal is received, night setback will
   36

be overridden for 2 hours even if the signal is removed. While night setback is overridden the controller will respond to the normal thermostat signals.
Test Mode Test mode is enabled by connecting the two quick disconnect terminals “TEST” and “TEST IN” together. The controller will remain in “Test Mode” as long as the terminals are connected to each other. The controller will exit “Test Mode” immediately upon removal of the jumper. While in “Test Mode” there will be no random start delay, and the compressor minimum on and minimum off times are reduced to 5 seconds each. The 5 second delay between compressor and reversing valve operation is still present as well as the 5 second delay between the supply fan and compressor.
Alarms LED Fault Codes The controller provides a status LED (D5) in the center of the board to indicate the unit status. A green status light indicates that the unit is powered up and that the controller is not detecting any fault conditions. A flashing red status light indicates that the controller has detected a fault condition and is now in alarm mode. The number of flashes indicates what alarm is present. Table 8 describes the meaning of the flash codes.

Table 8 – LED Diagnostic Codes

Number Fault

of LED

Flashes

1

High Discharge Pressure

2

Emergency Shutdown

3

Auxiliary Alarm

4

High Condensate Level Alarm

5

Low Control Voltage Alarm

6

High Control Voltage Alarm

7

Low Suction Pressure

8

Leaving Water Temperature

Alarm

9

Air Coil Low Temperature

Alarm

10

Entering Water Temperature

Alarm

Automatic Reset Alarms The following alarms will automatically reset themselves once the fault condition clears.

Low Control Voltage Alarm The low voltage alarm will activate when the 24VAC control voltage drops to 20VAC +/5%. Below this voltage the onboard normally open relays are not guaranteed to close. The low voltage alarm will release when the voltage rises above 22VAC +/-5%. Once the fault is cleared the controller will activate a random start delay. This alarm will disable the compressor, the supply fan, and the reversing valve.

High Control Voltage Alarm The high voltage alarm will activate when the 24VAC control voltage increases to 32VAC +/-5%. Any voltage higher than this risks damaging components on the control board. The alarm will release when the control

voltage decreases to 30VAC +/-5%. Once the fault is cleared the controller will activate a random start delay. This alarm will disable the compressor, the supply fan, and the reversing valve.
Leaving Water Temperature Alarm To prevent freezing of the liquid heat exchanger, the leaving water temperature alarm will activate and turn the compressor off if the refrigerant saturated suction temperature during heating drops below the freeze protection temperature setpoints in Table 9 – Glycol Percentage Setpoints, based on the glycol percentage that is input into the controller. The alarm will deactivate (allowing the compressor to run again) after ten minutes have expired and the refrigerant saturated suction temperature rises 5°F above the freeze protection temperature. If the alarm is activated again within two hours, the refrigerant saturated suction temperature must rise 5°F above the freeze protection temperature and the unit power must be cycled off and on or the compressor activation call from the thermostat must be removed and then restarted.
The glycol percentage DIP switch “SW1” is used to set the glycol percentage that is used in the system for freeze protection. This switch is located in the center of the control board. The freeze protection setpoints change based on the glycol percentage that is input to the controller. It is critical that this setting matches the actual glycol percentage used in the system to prevent damage caused from freezing. Inputting a glycol percentage that is higher than actually used in the system can cause extensive damage from freezing.

37

Table 9 – Glycol Percentage Setpoints

Leaving Water Leaving Water

Switch 1

Switch 2

Glycol

Temperature

Temperature

Position

Position

Percentage

Alarm

Alarm

Activation

Deactivation

Off

Off

0%

35°F

40°F

Off

On

10%*

30°F

35°F

On

Off

20%

23°F

28°F

On

On

30%

15°F

20°F

*Setting not recommended. 20% or more glycol solution is required if ambient temperatures are expected

to fall below freezing or if the loop water temperature is below 50°F while operating in the heating mode.

Air Coil Temperature Alarm The air coil low temperature alarm will trigger if the air coil temperature drops below 30°F. The alarm will release when the coil temperature increases to 35°F. This alarm will disable the compressor but allow operation of the supply fan.
Entering Water Temperature Alarm The entering water temperature alarm is used to prevent freezing in the waterside economizer coil. Entering water temperature is only monitored if a unit is ordered with a waterside economizer coil. This temperature sensor is wired to the Pioneer Silver Expansion Board. If the entering water temperature falls to 35°F, the waterside economizer coil will be deactivated until the entering water temperature rises above 40°F. The supply fan and the compressor are allowed to operate when this alarm is activated.
Emergency Shutdown Alarm The emergency shutdown input requires a constant connection to either 24VAC or 24VAC common for normal operation. If the 24VAC or 24VAC common signal is removed, then the controller will enter emergency shutdown mode. This alarm will disable the compressor and the supply fan. This alarm will release when the 24 VAC input is restored.

Lock Out Alarms The following alarms will not automatically reset themselves on the fault condition clears.
For these alarms to clear one of the following two conditions must be met:

1. Controller is power cycled 2) Fault condition is corrected and the compressor call is removed
   Auxiliary Input Alarm The auxiliary alarm will enable if the compressor has been operational for at least 2 minutes and a dry contact has been made between the “AUX” and “AUX IN” quick disconnect terminals for 10 seconds. This alarm will disable the compressor but allow the supply fan to operate. If a secondary drain pan is to be used, the secondary drain pan overflow switch must be wired into the Auxiliary Input Alarm.
   High Condensate Level Alarm The high condensate level alarm will enable if the resistance between the condensate level sensor and 24VAC common is less than 100k for more than 30 seconds. This alarm will disable both the compressor and the supply fan.

38

High Discharge Pressure Alarm The high discharge pressure alarm will enable if the high pressure switch opens. This alarm will disable the compressor but allow the supply fan to operate.
Low Suction Pressure Alarm The low suction pressure alarm will activate and turn the compressor off if the low suction pressure switch is open for 10 seconds. The alarm will deactivate if 15 minutes has expired and the low pressure switch has closed. If the alarm is activated again within two hours, the unit power must be cycled off and on.
Maintenance
See back of the manual for maintenance log.
At least once each year, a qualified service technician must check out the unit. Supply fans, evaporator coils and air filters must be inspected monthly.
WARNING
Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Installation and service must be performed by a qualified installer. Keep a copy of this IOM with the unit.
See Startup section for information on air flow 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). Check for

24V signal across the reversing valve terminals.
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 must be done only by qualified personnel.
Supply Fans
CAUTION
Blower wheels 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.
WARNING
Electric shock hazard. Shut off all electrical power to the unit to avoid shock hazard or injury from rotating parts.
Supply Fan Lubrication Supply fan motors are permanently lubricated and require no oiling.
Filter Replacement Monthly filter inspection is required to maintain optimum unit efficiency. It is strongly recommended that filter media be replaced monthly.
39

WARNING
Electric shock hazard. Shut off all electrical power to the unit to avoid shock hazard or injury from rotating parts.
See Filter Information section for reference to the correct size and quantity of filters.
Replacement Parts Parts for AAON equipment may be obtained by contacting your local AAON representative. When ordering parts, reference the unit serial number and part

number located on the external or internal nameplate of the unit.
Note: Warranty end date can be found on the unit nameplate.
AAON Warranty, Service, and Parts Department 2425 S. Yukon Ave. Tulsa, OK 74107 Ph: 918-382-6450 techsupport@aaon.com www.AAON.com
Note: Before calling, have the model and serial number of the unit available to help answer questions regarding the unit.

Filter Information

Table 10 – 006-012 WH Unit Series Filters (A Cabinet)

Feature 3B

Quantity/Size (W x H x D)

Type

A

Pleated, MERV 8

K

(1) 18″ x 10″ x 2″

Pleated, MERV 11

L

Pleated, MERV 13

E

Pleated, MERV 8

F

(1) 18″ x 10″ x 1″

Pleated, MERV 11

G

Pleated, MERV 13

I

(1) 18″ x 10″ x 1″

J

(1) 18″ x 10″ x 2″

Fiberglass

40

Table 11 – 015 & 018 WH Series Unit Filters (B Cabinet)

Feature 3B

Quantity/Size (W x H x D)

Type

A

Pleated, MERV 8

K

(1) 25″ x 16″ x 2″

Pleated, MERV 11

L

Pleated, MERV 13

E

Pleated, MERV 8

F

(1) 25″ x 16″ x 1″

Pleated, MERV 11

G

Pleated, MERV 13

I

(1) 25″ x 16″ x 1″

J

(1) 25″ x 16″ x 2″

Fiberglass

Table 12 – 024 & 030 WH Series Unit Filters (C Cabinet)

Feature 3B

Quantity/Size (W x H x D)

Type

A

Pleated, MERV 8

K

(1) 25″ x 18″ x 2″

Pleated, MERV 11

L

Pleated, MERV 13

E

Pleated, MERV 8

F

(1) 25″ x 18″ x 1″

Pleated, MERV 11

G

Pleated, MERV 13

I

(1) 25″ x 18″ x 1″

J

(1) 25″ x 18″ 2″

Fiberglass

41

Table 13 – 036 & 042 WH Series Unit Filters (D Cabinet)

Feature 3B

Quantity/Size (W x H x D)

Type

A

Pleated, MERV 8

K

(2) 14″ x 20″ x 2″

Pleated, MERV 11

L

Pleated, MERV 13

E

Pleated, MERV 8

F

(2) 14″ x 20″ x 1″

Pleated, MERV 11

G

Pleated, MERV 13

I

(2) 14″ x 20″ x 1″

J

(2) 14″ x 20″ x 2″

Fiberglass

Table 14 – 048 & 060 WH Series Unit Filters (E Cabinet)

Feature 3B

Quantity/Size (W x H x D)

Type

A

Pleated, MERV 8

K

(1) 24″ x 20″ x 2″ (1) 14″ x 20″ x 2″

Pleated, MERV 11

L

Pleated, MERV 13

E

Pleated, MERV 8

F

(1) 24″ x 20″ x 1″ (1) 14″ x 20″ x 1″

Pleated, MERV 11

G

Pleated, MERV 13

I

(1) 24″ x 20″ x 1″ (1) 14″ x 20″ x 1″

J

(1) 24″ x 20″ x 2″ (1) 14″ x 20″ x 2″

Fiberglass

42

Appendix A – Heat Exchanger Corrosion Resistance

Potential Problem

Chemical(s) or Condition

Range for Copper Heat Exchangers

Range for Cupro-Nickel Heat Exchangers

Scaling

Calcium & Magnesium Carbonate

Less than 350 ppm

Less than 350 ppm

pH Range

7-9

5-9

Total Dissolved Solids

Less than 1000 ppm

Less than 1500 ppm

Ammonia, Ammonium Hydroxide

Less than 0.5 ppm

Less than 0.5 ppm

Corrosion

Ammonium Chloride, Ammonium Nitrate

Less than 0.5 ppm

Less than 0.5 ppm

Calcium Chloride/ Sodium Chloride

Less than 125 ppm

Less than 125 ppm ­ Note 4

Chlorine

Less than 0.5 ppm

Less than 0.5 ppm

Hydrogen Sulfide

None Allowed

None Allowed

Biological

Iron Bacteria

None Allowed

None Allowed

Growth

Iron Oxide

Less than 1 ppm

Less than 1 ppm

Erosion

Suspended Solids Water Velocity

Less than 10 ppm Less than 8ft/s

Less than 10 ppm Less than 12 ft/s

Notes:

1. Harness in ppm is equivalent to harness in mg/l

2. Grains/gallon = ppm divided by 17.1

3. Copper and cupronickel heat exchangers are not recommended for pool applications for water outside the

range of the table.

4. Saltwater applications (approx. 25,000 ppm) require secondary heat exchangers due to copper piping

between the heat exchanger and the unit fittings.

43

WH Series Startup Form

Job Name:____ Date:____
Address:____

Model Number:____ Serial Number: Tag:____ Startup Contractor:____ Address:____ Phone:____

Pre Startup Checklist Installing contractor must verify the following items.

1. Is there any visible shipping damage? 2. Is the unit level? 3. Are the unit clearances adequate for service and operation?
4. Have all electrical connections been tested for tightness? 5. Does the electrical service correspond to the unit nameplate? 6. On 208/230V units, has transformer tap been checked? 7. Has overcurrent protection been installed to match the unit nameplate
requirement? 8. Have all set screws on the fans been tightened? 9. Does the fan rotate freely? 10. Does the field water piping to the unit appear to be correct per design
parameters? 11. Is all copper tubing isolated so that it does not rub? 12. Are air filters installed with proper orientation? 13. Have condensate drain and p-trap been connected?

Yes No Yes No Yes No Yes No Yes No Yes No
Yes No Yes No Yes No
Yes No Yes No Yes No Yes No

Ambient Temperature Ambient Dry Bulb Temperature ____°F Ambient Wet Bulb Temperature ____°F

44

Supply Fan Assembly

Alignment

Number

hp

1

Check Rotation L1

Nameplate Amps____

L2

L3

Compressors/DX Cooling Only connect gauges for troubleshooting
Check Rotation

Number

L1

L2

1

Head

Suction

L3

Pressure

Pressure

PSIG

PSIG

Refrigeration System 1 – Cooling Mode

Due to the charge-critical nature of these units, charge must only be adjusted if absolutely

necessary

Pressure

Saturated Temperature

Line Temperature

Sub-cooling

Superheat

Discharge

N/A

N/A

Suction

N/A

Liquid

N/A

Refrigeration System 1 – Heating Mode (Heat Pump Only)

Pressure

Saturated

Line

Temperature Temperature

Discharge

Suction

Liquid

Sub-cooling
N/A N/A

Superheat N/A
N/A

Unit Configuration Cooling Mode No Water Leaks Water Flow ____ gpm
Water Inlet Temperature ____°F

Water Outlet Temperature ____°F

Unit Configuration Heating Mode (Heat Pump Only) No Water Leaks Water Flow ____ gpm

Water Inlet Temperature ____°F

Water Outlet Temperature ____°F

Water/Glycol System 1. Has the entire system been flushed and pressure checked? 2. Has the entire system been filled with fluid? 3. Has air been bled from the heat exchangers and piping? 4. Is the glycol the proper type and concentration (N/A if water)? 5. Is there a minimum load of 50% of the design load? 6. If geothermal, does water piping include insulation?
7. What is the freeze point of the glycol (N/A if water)?

Yes No Yes No Yes No Yes No Yes No Yes No

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.

Entry Date

Action Taken

Name/Tel.

46

Literature Change History
July 2022 First Version
January 2023 Second Version

AAON 2425 South Yukon Ave. Tulsa, OK 74107-2728
www.AAON.com
WH Series ProFit Installation, Operation &
Maintenance V01030 Rev. B 230101
Factory Technical Support: 918-382-6450
Note: Before calling Technical Support, please have the model and serial number of the unit available.
Parts: For replacement parts please contact your local AAON Representative.
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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