AAON Rq Nextgen Series Packaged Rooftop Units Heat Pumps and Outdoor Air Handling Units Instruction Manual
- June 15, 2024
- AAON
Table of Contents
- AAON Rq Nextgen Series Packaged Rooftop Units Heat Pumps and Outdoor Air
- Product Information
- Product Usage Instructions
- Installation
- Operation
- Maintenance
- Service
- FAQ (Frequently Asked Questions)
- Safety
- GROUNDING REQUIRED
- OPEN LOOP APPLICATIONS
- General Information
- Operation
- Maintenance
- 1 Simple Green Simple Green is available from AAON Parts and Supply (Part
- 2 Water Flush This procedure can be used when the only material to cause the
- WATER PIPING
- Energy Recovery Wheel
- Read User Manual Online (PDF format)
- Download This Manual (PDF format)
AAON Rq Nextgen Series Packaged Rooftop Units Heat Pumps and Outdoor Air
Handling Units
Product Information
Specifications
- Product: RQ NextGen SERIES
- Type: Packaged Rooftop Units, Heat Pumps, & Outdoor Air Handling Units
- Model Number: G149150
- UL Certification: UL-60335
Product Usage Instructions
Safety Precautions
Attention must be paid to the following statements:
Notes:
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.
Installation
Before installing the RQ NextGen SERIES unit, please read and understand the installation instructions provided in this manual. Improper installation can cause serious injury, death, or property damage. Follow these steps for proper installation:
- Choose a suitable location for the unit.
- Ensure proper clearance around the unit for maintenance and service access.
- Follow all local building codes and regulations.
- If unsure about any step of the installation process, contact a Factory Trained Service Technician.
Operation
To operate the RQ NextGen SERIES unit:
- Ensure that the main power supply is connected and turned on.
- Set the desired temperature or mode using the control panel.
- If any issues or malfunctions occur during operation, refer to the Troubleshooting section of this manual.
Maintenance
Regular maintenance is essential for proper operation and longevity of the RQ NextGen SERIES unit. Follow these maintenance guidelines:
- Shut off all electrical power to the unit before performing any maintenance tasks.
- Clean or replace air filters regularly to ensure proper airflow.
- Inspect and clean the outdoor coils to remove any debris or dirt buildup.
- Check and tighten all electrical connections and wiring.
- Lubricate moving parts as instructed in the manual.
- Refer to the Maintenance Schedule provided in this manual for specific maintenance tasks and intervals.
Service
All startup and service tasks should be performed by a Factory Trained Service Technician. If any issues or faults arise with the RQ NextGen SERIES unit, contact a qualified technician for service and repairs.
FAQ (Frequently Asked Questions)
Q: What should I do if I smell gas?
A: If you smell gas, do not try to light any appliance or touch any
electrical switch. Leave the building immediately and call your gas supplier
from a phone remote from the building. Follow their instructions. If you
cannot reach your gas supplier, call the fire department.
Q: What precautions should I take before servicing the unit?
A: Before servicing the unit, disconnect all electrical power to the
furnace. Label all wires prior to disconnecting and reconnect them correctly
after servicing. Verify proper operation and secure all doors with a key-lock
or nut and bolt.
Q: Can I store gasoline or other flammable vapors near the appliance?
A: No, it is not safe to store gasoline or other flammable vapors and
liquids in the vicinity of this appliance.
Q: How often should I clean or replace the air filters?
A: Air filters should be cleaned or replaced regularly, following the
manufacturer’s recommendations. Refer to the Maintenance Schedule provided in
the manual for specific intervals.
RQ NextGen SERIES
Packaged Rooftop Units, Heat Pumps, & Outdoor Air Handling Units
Installation, Operation, & Maintenance
UL-60335
WARNING
FIRE OR EXPLOSION HAZARD
Failure to follow safety warnings exactly could result in serious injury,
death or property damage.
Be sure to read and understand the installation, operation and service
instructions in this manual.
Improper installation, adjustment, alteration, service or maintenance can
cause serious injury, death or property damage.
Keep a copy of this IOM with the unit.
WARNING
o Do not store gasoline or other flammable vapors and liquids in the vicinity
of this or any other appliance
o WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance. Do not touch
any electrical switch; do not use any phone in your building. Leave the
building immediately. Immediately call your gas supplier from a phone remote
from the building. Follow the gas supplier’s instructions. If you cannot reach
your gas supplier, call the fire department.
o Startup and service must be performed by a Factory Trained Service
Technician.
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.
DANGER – Danger statements are given to prevent actions that will result in
equipment damage, property damage, severe personal injury or death.
WARNING
ELECTRIC SHOCK, FIRE OR EXPLOSION HAZARD
Failure to follow safety warnings exactly could result in dangerous operation,
serious injury, death or property damage.
Improper servicing could result in dangerous operation, serious injury, death
or property damage.
Before servicing, disconnect all electrical power to the furnace. More than
one disconnect may be provided.
When servicing controls, label all wires prior to disconnecting. Reconnect
wires correctly.
Verify proper operation after servicing. Secure all doors with key-lock or nut
and bolt.
CAUTION
WHAT TO DO IF YOU SMELL GAS
Do not try to turn on unit. Shut off main gas supply. Do not touch any
electric switch. Do not use any phone in the
building. Never test for gas leaks with an
open flame. Use a gas detection soap solution
and check all gas connections and shut off valves.
WARNING
Electric shock hazard. Before servicing, shut off all electrical power to the
unit, including remote disconnects, to avoid shock hazard or injury from
rotating parts. Follow proper Lockout-Tagout procedures.
WARNING
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
CARBON MONOXIDE POISONING HAZARD
Failure to follow instructions could result in severe personal injury or death
due to carbon-monoxide poisoning, if combustion products infiltrate into the
building.
Check that all openings in the outside wall around the vent (and air intake)
pipe(s) are sealed to prevent infiltration of combustion products into the
building.
Check that furnance vent (and air intake) terminal(s) are not obstructed in
any way during all seasons.
CAUTION
In order to avoid a hazard due to inadvertent resetting of the THERMAL CUT-
OUT, this appliance must not be supplied through an external switching device,
such as a timer, or connected to a circuit that is regularly switched on and
off by the utility.
WARNING
ROTATING COMPONENTS
Unit contains fans with moving parts that can cause serious injury. Do not
open door containing fans until the power to the unit has been disconnected
and fan wheel has stopped rotating.
WARNING
GROUNDING REQUIRED
All field installed wiring must be completed by qualified personnel. Field
installed wiring must comply with NEC/CEC, local and state electrical code
requirements. Failure to follow code requirements could result in serious
injury or death. Provide proper unit ground in accordance with these code
requirements.
WARNING
This appliance is not intended for use by persons with reduced physical,
sensory or mental capabilities, or lack of experience and knowledge, unless
they have been given supervision or instruction concerning use of the
appliance by a person responsible for their safety. Children must be
supervised around this appliance.
9
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
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.
CAUTION
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.
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.
CAUTION
Failure to properly drain and vent coils when not in use during freezing
temperature may result in coil and equipment damage.
CAUTION
Rotation must be checked on all
MOTORS AND COMPRESSORS of 3
phase units at startup by a qualified
service
technician.
Scroll
compressors are directional and can
be damaged if rotated in the wrong
direction. Compressor rotation must
be checked using suction and
discharge gauges. Fan motor rotation
must be checked for proper operation.
Alterations must only be made at the
unit power connection
WARNING
Do not use oxygen, acetylene or air in place of refrigerant and dry nitrogen
for leak testing. A violent explosion may result causing injury or death.
10
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.
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.
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
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.
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.
CAUTION
Door compartments containing hazardous voltage or rotating parts are equipped
with door latches to allow locks. Door latch are shipped with nut and bolts
requiring tooled access. If you do not replace the shipping hardware with a
pad lock always re-install the nut & bolt after closing the door.
CAUTION
Cleaning the cooling tower or condenser water loop with harsh chemicals such
as hydrochloric acid (muriatic acid), chlorine or other chlorides, can damage
the 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.
CAUTION
Unit power supply wire must be only copper or aluminum.
11
WARNING
OPEN LOOP APPLICATIONS
Failure of the condenser as a result of chemical corrosion is excluded from
coverage under AAON Inc. warranties and the heat exchanger manufacturer’s
warranties.
WARNING
WATER 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
COMPRESSOR CYCLING
3 MINUTE MINIMUM OFF TIME To prevent motor overheating compressors must cycle
off for a minimum of 3 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 7 starts per hour.
WARNING
Units with VFD driven motors/ compressors have adjustable overload settings.
These are set by the AAON factory for the protection of these
motors/compressors and must not be adjusted over this factory setpoint or
bypassed.
CAUTION
Disconnect power to the unit before servicing UV-C lamps
CAUTION
Doors and panels with access to UVC lamps, with possible spectral irradiance
exceeding 1.7 W/cm2 are provided with an interlock switch. Do not over-ride.
WARNING
Do not operate UV-C lamps outside of the unit.
WARNING
Units containing UV-C Germicidal lamps should not be operated with damage to
the cabinet of the unit. UVC radiation may, even in small doses, cause harm to
the eyes and skin.
12
1. Startup and service must be performed by a Factory Trained Service
Technician.
2. Use only with type of the gas approved for the furnace. Refer to the
furnace rating plate.
3. The unit is for outdoor use only. See General Information section for more
information.
4. Provide adequate combustion ventilation air to the furnace. If a vent duct
extension is used, a class III approved vent is required. See the Locating
Units and Gas Heating sections of the Installation section of the manual.
5. Always install and operate furnace within the intended temperature rise
range and duct system external static pressure (ESP) as specified on the unit
nameplate.
6. The supply and return air ducts must be derived from the same space. It is
recommended ducts be provided with access panels to allow inspection for duct
tightness. When a down flow duct is used with electric heat, the exhaust duct
must be an L shaped duct.
7. Clean furnace, duct and components upon completion of the construction
setup. Verify furnace operating conditions including input rate, temperature
rise and ESP.
8. Every unit has a unique equipment nameplate with electrical, operational,
and unit clearance specifications. Always refer to the unit nameplate for
specific ratings unique to the model you have purchased.
9. READ THE ENTIRE INSTALLATION, OPERATION AND MAINTENANCE MANUAL. OTHER
IMPORTANT SAFETY PRECAUTIONS ARE PROVIDED THROUGHOUT THIS MANUAL.
10. Keep this manual and all literature safeguarded near or on the unit.
13
9 D
3 7
RQ Series Unified Feature String Nomenclature
9 C
9 B
9 A
6 E
6 D
6 C
6 B
6 A
5 E
5 D
5 C
5 B
5 A
4 C
4 B
4 A
3 E
3 D
3 C
3 B
3 A
B 5
B 4
B 3
B 2
B 1
A 5
A 4
A 3
A 2
A 1
VLT
MNREV
SERIES
GEN MJREV SIZ E
8
7
2
1
RQ A – 030 – C – 0 – 3 – C A B 0 A – 0 0 0 0 0 : 0 1 – 0 A G 0 K – E 0 0 – 0 0 0 0 0 – 0 0 0 0 0 – C A – 0 0 0 0 – 0 0 – 0 0 – 0 – 0 0 0 – 0 0 – BA 0 B – 0 0 – 0 0 0 – A0 0 0 0 0 – C 0 0 0 0 0 – 0 0 0 0 0 0 B
3 6
3 5
3 4
3 3
3 2
3 1
3 0
2 9
2 8
2 7
2 6
2 5
2 4
2 3
2 2
2 1
2 0
1 9
18C
18B
18A
17B
17A
16D
16C
16B
16A
1 5
1 4
13C
13B
13A
1 2
11B
11A
10B
10A
BASE MODEL
SERIES AND GENERATION RQ
MAJOR REVISION A
UNIT SIZE 002 = 2 ton Capacity 003 = 3 ton Capacity 004 = 4 ton Capacity 005 =
5 ton Capacity 006 = 6 ton Capacity
SERIES A Series
MINOR REVISION 0
VOLTAGE 1 = 230V/1/60Hz 2 = 230V/3/60Hz 3 = 460V/3/60Hz 4 = 575V/3/60Hz 6 =
380V/3/50Hz 8 = 208V/3/60Hz 9 = 208V/1/60Hz
Model Option A: COOLING/HEAT PUMP
A1: COMPRESSOR STYLE 0 = No Compressor F = R-454B Two-Step Scroll Compressor H
= R-454B Variable Speed Scroll Compressor G = R-454B Variable Capacity Scroll
Compressor
A2: CONDENSER STYLE 0 = No Cooling A = Standard Eff. Microchannel Air-Cooled
Condenser B = High Eff. Microchannel Air-Cooled Condenser E = Water-Cooled
Condenser J = Air-Source Heat Pump J (when A1 = H) = Zero Degree Cold Climate
AirSource Heat Pump N = DX Air Handling Unit
A3: INDOOR COIL CONFIGURATION 0 = No Cooling Coil A = Standard Row Eff.
Evaporator B = 6 Row Evaporator E = 4 Row Chilled Water Coil F = 6 Row Chilled
Water Coil
A4: COOLING HEAT EXCHANGER CONSTRUCTION 0 = Standard A = Polymer E-Coated
Cooling Coil B = Stainless Steel Cooling Coil Casing D = Stainless Steel Evap.
Coil Casing + Polymer E-
Coated Evap. Coil E = Polymer E-Coated Cond. Coil J = Polymer E-Coated Evap.
And Cond. Coil T = Stainless Steel Evap. Coil Casing + Option E
14
RQ Series Unified Feature String Nomenclature
9 D
9 C
9 B
9 A
6 E
6 D
6 C
6 B
6 A
5 E
5 D
5 C
5 B
5 A
4 C
4 B
4 A
3 E
3 D
3 C
3 B
3 A
B 5
B 4
B 3
B 2
B 1
A 5
A 4
A 3
A 2
A 1
VL T
MNREV
SERIES
GE N MJREV SIZE
8
7
2
1
3 7
RQ A – 030 – C – 0 – 3 – C A B 0 A – 0 0 0 0 0 : 0 1 – 0 A G 0 K – E 0 0 – 0 0 0 0 0 – 0 0 0 0 0 – C A – 0 0 0 0 – 0 0 – 0 0 – 0 – 0 0 0 – 0 0 – BA 0 B – 0 0 – 0 0 0 – A0 0 0 0 0 – C 0 0 0 0 0 – 0 0 0 0 0 0 B
3 6
3 5
3 4
3 3
3 2
3 1
3 0
2 9
2 8
2 7
2 6
2 5
2 4
2 3
2 2
2 1
2 0
1 9
18C
18B
18A
17B
17A
16D
16C
16B
16A
1 5
1 4
13C
13B
13A
1 2
11B
11A
10B
10A
A5: COOLING STAGING 0 = No Cooling A = Variable Speed Comp A (when A1 = G) =
Modulating F = Single Serpentine 8 fpi G = Half Serpentine 8 fpi K = Single
Serpentine 12 fpi L = Half Serpentine 12 fpi 1 = 1 Stage 2 = 2 Stage
Model Option B: HEATING
B1: HEATING TYPE 0 = No Heating A = Electric Heat C = Natural Gas F = LP Gas J
= Hot Water Coil L = Steam Distributing Coil
B2: HEAT CONSTRUCTION 0 = No Heating A = Aluminized Heat Exchanger B =
Stainless Steel Heat Exchanger G = Polymer E-Coated Heating Coil H = 1 Row
Coil J = 2 Row Coil
B3: HEAT DESIGNATION 0 = No Heating A = 1 Row E = 2 Row 1 = Heat 1 10 kW; 60
Mbtu 2 = Heat 2 20 kW; 3 = Heat 3 30 kW; 100 Mbtu 4 = Heat 4 40 kW 5 =
Heat 5 140 Mbtu 7 = Heat 7 160 Mbtu
B4: HEAT STAGING A = 1 Stage B = 2 Stage C = 3 Stage D = 4 Stage K =
Modulating Gas Heat Temperature Control L = High Turndown Modulating Gas
Heat
Temperature Control M = Modulating SCR Electric with Potentiometer
Control N = Modulating SCR Electric with External 0-10
VDC P = Single Serpentine 8 fpi Q = Half Serpentine 8 fpi T = Single
Serpentine 12 fpi U = Half Serpentine 12 fpi
B5: HEAT PUMP AUXILIARY HEATING 0 = No Auxiliary A = Aux Heat 1 for Heat Pump
1 Stage B = Aux Heat 2 for Heat Pump 1 Stage C = Aux Heat 3 for Heat Pump 1
Stage D = Aux Heat 4 for Heat Pump 1 Stage
K = Aux Heat 1 for Heat Pump 2 Stage L = Aux Heat 2 for Heat Pump 2 Stage M =
Aux Heat 3 for Heat Pump 2 Stage N = Aux Heat 4 for Heat Pump 2 Stage
15
RQ Series Unified Feature String Nomenclature
9 D
9 C
9 B
9 A
6 E
6 D
6 C
6 B
6 A
5 E
5 D
5 C
5 B
5 A
4 C
4 B
4 A
3 E
3 D
3 C
3 B
3 A
B 5
B 4
B 3
B 2
B 1
A 5
A 4
A 3
A 2
A 1
VL T
MNREV
SERIES
GE N MJREV SIZE
8
7
2
1
3 7
RQ A – 030 – C – 0 – 3 – C A B 0 A – 0 0 0 0 0 : 0 1 – 0 A G 0 K – E 0 0 – 0 0 0 0 0 – 0 0 0 0 0 – C A – 0 0 0 0 – 0 0 – 0 0 – 0 – 0 0 0 – 0 0 – BA 0 B – 0 0 – 0 0 0 – A0 0 0 0 0 – C 0 0 0 0 0 – 0 0 0 0 0 0 B
3 6
3 5
3 4
3 3
3 2
3 1
3 0
2 9
2 8
2 7
2 6
2 5
2 4
2 3
2 2
2 1
2 0
1 9
18C
18B
18A
17B
17A
16D
16C
16B
16A
1 5
1 4
13C
13B
13A
1 2
11B
11A
10B
10A
B5: HEAT PUMP AUXILIARY HEATING (continued) U = Aux Heat 1 for Heat Pump 4
Stage V = Aux Heat 2 for Heat Pump 4 Stage W = Aux Heat 3 for Heat Pump 4
Stage Y = Aux Heat 4 for Heat Pump 4 Stage
Feature 1: UNIT ORIENTATION 0 = Standard Access – Hinged Access Doors with
Lockable Handles
2: SUPPLY & RETURN LOCATIONS
0 = Bottom Discharge and Return G = Horizontal Discharge and Return
Feature 3: SUPPLY FAN OPTIONS
3A: SUPPLY FAN QUANTITY 0 = 1 Fan
3B: SUPPLY FAN CONFIGURATION 0 = No VFDs + Full Width Fan A = 1 Fan per VFD +
Full Width Fan E = No VFDs + Narrow Width Fan F = 1 Fan per VFD + Narrow Width
Fan
3C: SUPPLY FAN SIZE C = 18.5″ Direct Drive Backward Curved Aluminum D = 18.5″
Direct Drive Backward Curved Aluminum
3D: SUPPLY FAN MOTOR TYPE 0 = High Efficiency Open Motor
(1200 nominal rpm) A = High Efficiency Open Motor
(1800 nominal rpm) C = Perm Magnet AC Open Motor (1200 nominal
rpm) D = Perm Magnet AC Open Motor (1800 nominal
rpm) F = ECM Motor (1200 nominal rpm) G = ECM Motor (1800 nominal rpm)
16
3E: SUPPLY FAN MOTOR SIZE 0 = 1/4 HP B = 1/2 HP C = 3/4 HP D = 1 HP F = 2 HP Z
= 1/6 HP
Feature 4: RETURN AIR/OUTSIDE AIR OPTIONS
4A: OUTSIDE AIR SECTION 0 = 100% Outside Air No RA Opening A = 100% Outside
Air with Motorized Dampers B = Manual Outside Air + Return Air Opening C =
Motorized Outside Air Dampers + Return Air
Opening D = 100% Return Air (No O/A Opening) E = Economizer G = Economizer +
Power Exhaust (Plenum Fans) K = Economizer + Energy Recovery Q = Economizer +
Energy Recovery + Bypass
Damper
4B: ENERGY RECOVERY TYPE 0 = No Energy Recovery A = Polymer Energy Recovery
Wheel E = Plate Exchanger
4C: ENERGY RECOVERY SIZE 0 = No Energy Recovery A =Total + Low CFM B = Total +
High CFM E = Sensible + Low CFM F = Sensible + High CFM K = Total + High CFM +
Exhaust Filters J = Total + Low CFM + Exhaust Filters N = Sensible + Low CFM +
Exhaust Filters P = Sensible + High CFM + Exhaust Filters
RQ Series Unified Feature String Nomenclature
9 D
9 C
9 B
9 A
6 E
6 D
6 C
6 B
6 A
5 E
5 D
5 C
5 B
5 A
4 C
4 B
4 A
3 E
3 D
3 C
3 B
3 A
B 5
B 4
B 3
B 2
B 1
A 5
A 4
A 3
A 2
A 1
VL T
MNREV
SERIES
GE N MJREV SIZE
8
7
2
1
3 7
RQ A – 030 – C – 0 – 3 – C A B 0 A – 0 0 0 0 0 : 0 1 – 0 A G 0 K – E 0 0 – 0 0 0 0 0 – 0 0 0 0 0 – C A – 0 0 0 0 – 0 0 – 0 0 – 0 – 0 0 0 – 0 0 – BA 0 B – 0 0 – 0 0 0 – A0 0 0 0 0 – C 0 0 0 0 0 – 0 0 0 0 0 0 B
3 6
3 5
3 4
3 3
3 2
3 1
3 0
2 9
2 8
2 7
2 6
2 5
2 4
2 3
2 2
2 1
2 0
1 9
18C
18B
18A
17B
17A
16D
16C
16B
16A
1 5
1 4
13C
13B
13A
1 2
11B
11A
10B
10A
Feature 5: RETURN FAN OPTIONS
5A: RETURN FAN QUANTITY 0 = 0 Return Fans
5B: RETURN FAN CONFIGURATION 0 = No Return Fans
5C: RETURN FAN SIZE 0 = No Return Fans
5D: RETURN FAN MOTOR TYPE 0 = No Return Fans
5E: RETURN MOTOR SIZE 0 = No Return Fans
Feature 6: EXHAUST FAN OPTIONS
6A: EXHAUST FAN QUANTITY A = 1 Fan B = 1 Fan per VFD + Full Width Fan F = No
VFDs + Narrow Width Fan G = 1 Fan per VFD + Narrow Width Fan
6B: EXHAUST FAN CONFIGURATION A = No VFDs + Full Width Fan B = 1 Fan per VFD +
Full Width Fan
6C: EXHAUST FAN SIZE A = 16″ Axial Fan G = 10×8 Forward Curved Fan H = 15″
Backward Curved Plenum K = 18.5 Backward Curved Plenum
6D: EXHAUST FAN MOTOR TYPE G = ECM Motor (1200 nominal rpm) H = ECM Motor
(1800 nominal rpm) J = ECM Motor (3600 nominal rpm)
6E: EXHAUST MOTOR SIZE A = 1/4 HP C = 1/2 HP D = 3/4 HP E = 1 HP G = 2 HP F =
1 1/2 HP
7: O/A CONTROL E = DDC Actuator R = Option E + CO2 Override U = 2 Position
Actuator V = Fault Detection and Diagnostics Controller
(FDD) Fully Modulating Actuator Sensible Limit W = FDD Fully Modulating
Actuator Enthalpy Limit Y = Option V + CO2 Override Z = Option W + CO2
Override
8: RETURN & EXHAUST OPTIONS 0 = No Return Opening A = Standard Return Opening
without EA Opening E = Standard Return Opening + Motorized EA
Dampers
Feature 9: FILTER OPTIONS
9A: UNIT FILTER TYPE 0 = 2″ Pleated MERV 8 A = 4″ Pleated MERV 8 B = 4″
Pleated 65% Eff MERV 11+ 2″ Pleated
MERV 8 C = 4″ Pleated 85% Eff MERV 13+ 2″ Pleated
MERV 8 B = 4″ Pleated 95% Eff MERV 14+ 2″ Pleated
MERV 8 H = 2″ Permanent Filter Frame + Replaceable Media
9B: UNIT FILTER BOX SIZE/LOCATION 0 = Standard Filters in Standard Position B
= High Efficiency Filters in Standard Position M = Standard Filters + Lint
Screen Pre-filter in
Standard Position
17
RQ Series Unified Feature String Nomenclature
9 D
9 C
9 B
9 A
6 E
6 D
6 C
6 B
6 A
5 E
5 D
5 C
5 B
5 A
4 C
4 B
4 A
3 E
3 D
3 C
3 B
3 A
B 5
B 4
B 3
B 2
B 1
A 5
A 4
A 3
A 2
A 1
VL T
MNREV
SERIES
GE N MJREV SIZE
8
7
2
1
3 7
RQ A – 030 – C – 0 – 3 – C A B 0 A – 0 0 0 0 0 : 0 1 – 0 A G 0 K – E 0 0 – 0 0 0 0 0 – 0 0 0 0 0 – C A – 0 0 0 0 – 0 0 – 0 0 – 0 – 0 0 0 – 0 0 – BA 0 B – 0 0 – 0 0 0 – A0 0 0 0 0 – C 0 0 0 0 0 – 0 0 0 0 0 0 B
3 6
3 5
3 4
3 3
3 2
3 1
3 0
2 9
2 8
2 7
2 6
2 5
2 4
2 3
2 2
2 1
2 0
1 9
18C
18B
18A
17B
17A
16D
16C
16B
16A
1 5
1 4
13C
13B
13A
1 2
11B
11A
10B
10A
9C: FINAL FILTER TYPE 0 = No Final Filters
9D: FILTER OPTIONS 0 = None A = Clogged Filter Switch – Unit Filters B =
Clogged Filter Switch – Unit + Energy Recovery
Filters E = Magnehelic Gauge – Unit Filters F = Magnehelic Gauge – Unit +
Energy Recovery
Filters J = Clogged Filter Switch + Magnehelic Gauge – Unit
Filters K = Clogged Filter Switch + Magnehelic Gauge –
Unit + Energy Recovery Filters
Feature 10: REFRIGERATION CONTROL
10A: REFRIGERATION CONTROL A = 5 Minute Compressor Off Timer and 20 Second
Compressor Stage Delay D = Adjustable Compressor Lock Outs E = Freeze Stats
(each circuit) P = Option D + E
10B: Refrigeration Control B 0 = None
Feature 11: REFRIGERATION OPTIONS
11A: REFRIGERATION OPTIONS 0 = None E = Modulating Hot Gas Reheat Q = Polymer
E-Coated Modulating Hot Gas Reheat
11B: Refrigeration Options B 0 = Standard Packaged Unit
12: REFRIGERATION ACCESSORIES 0 = None A = Sight Glass B = Compressor
Isolation Valves C = Option A + B D = One Circuit 0°F Low Ambient
18
Feature 13: POWER OPTIONS
13A: UNIT DISCONNECT TYPE 0 = Standard Power Block A = Non-Fused Disconnect
Power Switch B = Circuit Breaker
13B: DISCONNECT 1 SIZE 0 = Power Block A = 15 amps B = 20 amps C = 25 amps D =
30 amps E = 35 amps F = 40 amps G = 45 amps H = 50 amps J = 60 amps K = 70
amps L = 80 amps M = 90 amps N = 100 amps P = 110 amps Q = 125 amps R = 150
amps S = 175 amps T = 200 amps U = 225 amps V = 250 amps Z = 400 amps 3 = 600
Amps
13C: DISCONNECT 2 SIZE 0 = Standard – None
RQ Series Unified Feature String Nomenclature
9 D
9 C
9 B
9 A
6 E
6 D
6 C
6 B
6 A
5 E
5 D
5 C
5 B
5 A
4 C
4 B
4 A
3 E
3 D
3 C
3 B
3 A
B 5
B 4
B 3
B 2
B 1
A 5
A 4
A 3
A 2
A 1
VL T
MNREV
SERIES
GE N MJREV SIZE
8
7
2
1
3 7
RQ A – 030 – C – 0 – 3 – C A B 0 A – 0 0 0 0 0 : 0 1 – 0 A G 0 K – E 0 0 – 0 0 0 0 0 – 0 0 0 0 0 – C A – 0 0 0 0 – 0 0 – 0 0 – 0 – 0 0 0 – 0 0 – BA 0 B – 0 0 – 0 0 0 – A0 0 0 0 0 – C 0 0 0 0 0 – 0 0 0 0 0 0 B
3 6
3 5
3 4
3 3
3 2
3 1
3 0
2 9
2 8
2 7
2 6
2 5
2 4
2 3
2 2
2 1
2 0
1 9
18C
18B
18A
17B
17A
16D
16C
16B
16A
1 5
1 4
13C
13B
13A
1 2
11B
11A
10B
10A
14: SAFETY OPTIONS
0 = None C = SA Smoke Detector K = RA and SA Smoke Detector F = RA and SA
Firestat + RA Smoke Detector G = RA and SA Firestat + SA Smoke Detector R = RA
and SA Aire Fire Stat + Option K E = Remote Safety Shutdown Terminals J = RA
and SA Firestat + Option E M = RA Smoke Detector + Option E P = Option C + E Z
= Option K + E T = Option F + E V = Option G + E 4 = Option R + E
15: ELECTRICAL ACCESSORIES
0 = None A = Low Limit Control B = Phase & Brown Out Protection F = Option A +
B E = Compressor Sound Blankets
Feature 16: UNIT CONTROLS 16A: CONTROL SEQUENCE B = Single Zone VAV Unit
Controller – VAV Cool +
CAV Heat D = VAV Unit Controller – VAV Cool + CAV Heat E = Constant Air Volume
Unit Controller – CAV
Cool + CAV Heat F = Makeup Air Unit Controller H = Constant Air Volume Heat
Pump Unit Controller
– CAV Cool + CAV Heat
16B: CONTROL SUPPLIER 0 = None A = AAON Controls
16C: CONTROL SUPPLIER OPTIONS 0 = None
16D: BMS CONNECTION & DIAGNOSTICS 0 = None B = BACnet MSTP
Feature 17: PREHEAT OPTIONS
17A: PREHEAT CONFIGURATION 0 = Standard – None
17B: PREHEAT SIZING 0 = Standard – None
Feature 18: OPTION BOXES
18A: BOX LOCATION 0 = None
18B: BOX SIZE 0 = None
18C: BOX ACCESSORIES 0 = None
19: OUTSIDE AIR ACCESSORIES
0 = No Outside Air Hood – 100% Return Air A = Outside Air Hood B = Outside Air
Hood with Metal Mesh Filters C = Option A + Outside Air Flow Measuring Station
Size A G = Option B + Outside Air Flow Measuring Station
Size A (OA>190 cfm)
20: CABINET OPTIONS
0 = None A = Base Insulation B = SA & RA Burglar Bars F = Option A + B
21: ACCESSORIES
0 = None
19
RQ Series Unified Feature String Nomenclature
9 D
9 C
9 B
9 A
6 E
6 D
6 C
6 B
6 A
5 E
5 D
5 C
5 B
5 A
4 C
4 B
4 A
3 E
3 D
3 C
3 B
3 A
B 5
B 4
B 3
B 2
B 1
A 5
A 4
A 3
A 2
A 1
VL T
MNREV
SERIES
GE N MJREV SIZE
8
7
2
1
3 7
RQ A – 030 – C – 0 – 3 – C A B 0 A – 0 0 0 0 0 : 0 1 – 0 A G 0 K – E 0 0 – 0 0 0 0 0 – 0 0 0 0 0 – C A – 0 0 0 0 – 0 0 – 0 0 – 0 – 0 0 0 – 0 0 – BA 0 B – 0 0 – 0 0 0 – A0 0 0 0 0 – C0 0 0 0 0 – 0 0 0 0 0 0 B
3 6
3 5
3 4
3 3
3 2
3 1
3 0
2 9
2 8
2 7
2 6
2 5
2 4
2 3
2 2
2 1
2 0
1 9
18C
18B
18A
17B
17A
16D
16C
16B
16A
1 5
1 4
13C
13B
13A
1 2
11B
11A
10B
10A
22: MAINTENANCE ACCESSORIES
0 = None A = Factory Wired 115V Convenience Outlet B = Field Wired 115V
Convenience Outlet C = Control Panel LED Service Lights D = Remote Start/Stop
Contacts E = Supply Fan Auxiliary Contacts G = Option A + D P = Option D + E S
= Option A + D + E V = Option B + D + E
23: CODE OPTIONS
0 = Standard – ETL U.S.A. Listing B = ETL U.S.A. + Canada Listing
24: SHIPPING SPLITS
0 = Standard C = Export Crating K = Export Crating + No Condenser Section
25: AIR COOLED CONDENSER ACESSORIES
0 = Standard C = ECM Condenser Fan Head Pressure Control G = Cond. Coil Screen
- ECM Condenser Fan Head Pressure Control
26: Evap-Colled Condenser Accessories
0 = Standard
27: WATER – COOLED CONDENSER ACCESSORIES
0 = None
28: ENERGY RECOVERY WHEEL ACCESSORIES
A = Energ Recovery Wheel Defrost – Start/Stop B = Energy ecovery Wheel
Rotation Detection F = OptionA + B
29: VFD OPTIONS
0 = None A = Shaft Grounding kit on all SA, RA, EA motors + BACnet VFD on all
Motors
30: MISCELLANEOUS OPTIONS
0 = Standard A = Condensate Overflow Switch B = SCCR (10kA) C = High Unit SCCR
(35kA) D = High Unit SCCR (65kA) F = Option A + B G = Option A + C H = Option
A + D
31: BLANK
0 = Standard
32: BLANK
0 = Standard
33: BLANK
0 = Standard
34: BLANK
0 = Standard
35: WARRANTY
0 = Standard Warranty A = 2 Year Parts Warranty B = 5 Year Parts Warranty C =
10 Year Parts Warranty
20
9 D
9 C
9 B
9 A
6 E
6 D
6 C
6 B
6 A
5 E
5 D
5 C
5 B
5 A
4 C
4 B
4 A
3 E
3 D
3 C
3 B
3 A
B 5
B 4
B 3
B 2
B 1
A 5
A 4
A 3
A 2
A 1
VL T
MNREV
SERIES
GE N MJREV SIZE
8
7
2
1
3 7
3 6
3 5
3 4
3 3
3 2
3 1
3 0
2 9
2 8
2 7
2 6
2 5
2 4
2 3
2 2
2 1
2 0
1 9
18C
18B
18A
17B
17A
16D
16C
16B
16A
1 5
1 4
13C
13B
13A
1 2
11B
11A
10B
10A
RQ Series Unified Feature String Nomenclature
RQ A – 030 – C – 0 – 3 – C A B 0 A – 0 0 0 0 0 : 0 1 – 0 A G 0 K – E 0 0 – 0 0
0 0 0 – 0 0 0 0 0 – C A – 0 0 0 0 – 0 0 – 0 0 – 0 – 0 0 0 – 0 0 – BA 0 B – 0 0
– 0 0 0 – A0 0 0 0 0 – C 0 0 0 0 0 – 0 0 0 0 0 0B
36: CABINET MATERIAL
0 = Galvanized Cabinet – Double Wall + R-13 Foam Insulation
37: SPECIALS & PAINT
B = Premium AAON Gray Paint Exterior Paint C = Premium AAON Gray Paint
Exterior Paint +
Interior Corrosion Protection E = Premium Gray Paint Exterior Paint + Shrink
Wrap F = Premium Gray Paint Exterior Paint + Interior
Corrosion Protection + Shrink Wrap X = SPA + Premium AAON Gray Paint Exterior
Paint Y = SPA + Premium AAON Gray Paint Exterior
Paint + Interior Corrosion Protection 1 = SPA + Premium AAON Gray Paint
Exterior
Paint + Shrink Wrap 2 = SPA + Premium AAON Gray Paint Exterior
Paint + Interior Corrosion Protection + Shrink Wrap 4 = SPA + Special Exterior
Paint Color 5 = SPA + Special Exterior Paint Color + Interior Corrosion
Protection 7 = SPA + Special Exterior Paint Color + Shrink Wrap 8 = SPA +
Special Exterior Paint Color + Interior Corrosion Protection + Shrink Wrap
21
General Information
RQ Series packaged rooftop units, heat pumps and outdoor air handling units
have been designed for outdoor installation only. Units are assembled, wired,
charged and run tested at the factory.
Startup and service must be performed by a Factory Trained Service Technician.
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 for heating or cooling at any time during any
phase of construction. Very low return air temperatures, harmful vapors, and
misplacement of the filters will damage the unit and its efficiency.
Certification of Gas Heat Models a. AAON gas heat exchangers have
successfully completed 10,000 burner operation cycles and corrosion resistance
as specified per test standard ANSI 21.47. All gas heat exchangers used in
AAON appliances are certified for use downstream of evaporator or cooling
coils.
b. Certified as a Category III forced air furnace with or without cooling.
c. Certified for outdoor installation only. d. Certified for installation on a
combustible
roof with a minimum of 30.5 cm (12″) high curb.
Certification of Steam or Hot Water Heat Models a. Certified as a forced air
heating system
with or without cooling. b. Certified for outdoor installation only. c.
Certified for installation on a combustible
roof with a minimum of 30.5 cm (12″) high curb.
Certification of Electric Heat Models a. Certified as an electric warm air
furnace
with or without cooling. b. Certified for outdoor installation only. c.
Certified for installation on a combustible
roof with a minimum of 30.5 cm (12″) high curb.
Certification of Cooling Models a. Certified as a commercial central air
conditioner with or without electrically operated compressors. b. Certified
for outdoor installation only. c. Certified for installation on a combustible
roof with a minimum of 30.5 cm (12″) high curb. d. Certified with refrigerant
R-410A coils or with chilled water cooling coils.
Codes and Ordinances RQ Series units have been tested and certified, by ETL,
in accordance with UL Safety Standard 1995 5th Edition/CSA C22.2 No. 236,
ANSI, UL-60335-2-40 4th Edition, Safety Standard Z21.47b-2008/CSA 2.3b2008,
and ANSI Safety Standard Z83.82006/CSA 2.6-2006.
22
System must be sized in accordance with the American Society of Heating,
Refrigeration and Air Conditioning Engineers Handbook.
Installation of RQ Series units must conform to the ICC standards of the
International Mechanical Code, the International Building Code, and local
building, plumbing and waste water codes. In the absence of local codes
installation must conform to the current (United States) National Fuel Gas
Code ANSI-Z223.1/NFPA 54 or the current (Canada) National Fuel & Propane
Installation Code CSA B149.1 or B149.2, and Mechanical Refrigeration Code CSA
B52. All appliances must be electrically grounded in accordance with local
codes, or in the absence of local codes, the current National Electric Code,
ANSI/NFPA 70 or the current Canadian Electrical Code CSA C22.1.
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.
Receiving Unit When received, check the unit for damage that might have
occurred in transit. If damage is found note 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.
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 such as filters
and remote sensors. Consult order and shipment documentation to identify
potential looseshipped items. Loose-shipped items may have been placed inside
unit cabinet for security. Secure all doors with locks or nuts and bolts to
prevent unauthorized access.
WARNING
Failure to observe the following instructions will result in premature failure
of your system and possible voiding of the warranty.
Figure 1 – Lockable Handle
The warranty card must be completed in full and returned to AAON not more than
3 months after unit is delivered.
23
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.
Wiring Diagrams Unit specific wiring diagrams are laminated and affixed inside
the compressor and control compartment door.
Installation
AAON equipment has been designed for quick and easy installation.
Unit Location The curb must be mounted first and must be located so that duct
connections will be clear of structural members of the building.
Verify rooftop or foundation can support the total unit weight, including
accessory weights.
WARNING
When locating gas fired units, the unit must be installed so that the flue
discharge vents are located at least 305 cm (120 inches) away from any opening
through which combustion products could enter the building.
24
WARNING
Distances from adjacent public walkways, adjacent buildings, operable windows
and building openings, must conform to local codes and/or the National Fuel
Gas Code, ANSI Z223.1/NFPA 54, or the National Gas & Propane Code, CSA B149.1
Do not position flue opening to discharge into a fresh air intake of any other piece of equipment. Unit must also be installed so that the flow of combustion intake air is not obstructed from reaching the furnace.
Vent opening must not be blocked by snow. A minimum 30.5 cm (12″) curb must be used or the vent outlet must be greater than 30.5 cm (12″) off the ground or roof.
Flue gas is dangerously hot and contains contaminants. The user is responsible for determining if vent gases may degrade building materials.
The National Gas and Propane Installation Code, B149.1 specifies a 1.8 m (6 ft). horizontal vent terminal clearance to gas and electric meters and relief devices.
Local codes may supersede or further place restrictions on vent termination locations.
Table 1 – Unit Clearances
Location
Unit Size 2-6 tons
Front (Heat Exchanger)
91.4 cm (36″)
Back – (Outside Air)
91.4 cm (36″)
Left Side
61 cm (24″)
Right Side
122 cm (48″)
Top
Unobstructed
Be careful to install the provided neoprene isolator according to Figure 3 prior to setting the unit on the curb. Right Side
Front
Back
Figure 2 – RQ Series Orientation
Setting the Curb Make openings in roof decking large enough to allow for duct penetration and workspace only. Do not make openings larger than necessary. Set the curb to coincide with the openings. Make sure the curb is level. Unit must be level in both horizontal axes to support the unit and reduce noise and vibration.
CAUTION
Neoprene isolator for unit vibration isolation is provided in the cabinet and
must be installed according to installation manual.
CAUTION
All roofing work must be performed by competent roofing contractors to avoid
any possible leakage.
CAUTION
Where the supply or warm air duct passes through a combustible roof, a
clearance of 2.5 cm (1 inch) must be maintained between the outside edges of
the duct and combustible material in accordance with National Fire Protection
Association Standard No. 90A. Provide flashings or enclosure between structure
and roof and all joints must be sealed with mastic roofing to ensure a
watertight seal.
25
Figure 3 – RQ Cabinet Standard and Power Exhaust Gasket Locations 26
CAUTION
Improper lifting can cause damage to the unit.
Forklifting the Unit Units can be lifted using a forklift. Forks must be 122
cm (48″) in length. Standard units can be lifted from all sides except the
outside air side. Units with energy recovery wheels can only be fork lifted
from the left or right side.
Forks must be perpendicular to unit. When lifting from either side, the forks
must extend
through to the opposite side of the unit. When lifting from the end of the
unit, the forks must extend at least 112 cm (44″) under the unit. When lifting
with 122 (48″) forks, the back of the fork must be no more than 4″ from the
unit.
CAUTION
FORKLIFTING 2-6 TON UNITS
Forks or Fork Extensions must be at least 122 cm (48″) in length and must
extend 112 cm (44″) under the unit.
Forks Figure 4 – Forklifting an RQ Series Unit from the Side
Figure 5 – Forklifting an RQ Series Unit from the Front 27
Lifting the Unit The RQ Series units must be lifted using the lifting points
in the side base rails. A spreader bar must be used to prevent the lifting
straps from damaging the unit. The connection points on the spreader bar must
be 122 cm 152 cm (48″-60″) apart. The minimum cable length used to lift a
standard length (208 cm [82″] base length) is 183 cm (72″). The minimum cable
length to lift energy recovery units (295 cm [116″] base length) is 244 cm
(96″). The shackles used to connect the cables to the lifting points in the
base must be 1.3 cm (1/2″) nominal size.
The rigging must be adjusted to lift the unit level. Lifting the unit off-
balance may cause severe damage.
It is recommended to lift the unit with the outside air hood in the downward
shipping
position. However, the unit may be lifted with the outside air hood in the
open position.
Before lifting unit, be sure that all shipping material has been removed from
unit. Secure hooks and cables at all lifting points provided on the unit.
Hoist unit to a point directly above the curb and duct openings. Be sure that
the gasket material has been applied to curb.
Carefully lower and align the unit with utility and duct openings. Lower the
unit until the unit skirt fits around the curb. Some units are designed to
overhang the curb. Take care that any recessed base rails fit around the curb.
Make sure the unit is properly seated on the curb and is level.
Figure 6 – Lifting Details of a 2-6 ton Standard or Power Exhaust Unit
Figure 7 – Lifting Details of a 2-6 ton Energy Recovery Wheel Unit
28
Vertical Duct Connection Note: If outside air will be in contact with the air tunnel base the unit must include the base insulation option or the base must be field insulated.
CAUTION
Do not drill or punch holes in the base of the unit, from inside the unit or
from below the unit to attach ductwork. Leaking may occur if unit base is
punctured.
Figure 8 – Vertical Duct Connection 29
Seismic Curb Installation Using a standard curb with a seismic unit will void the certification of the unit. All mounting details listed must be followed to achieve seismic certification. The AAON unit must be certified to ICC-ES AC156 when using a seismic curb for seismic certifications to apply. Any deviations or
modifications to the unit or curb will void all seismic certification.
Structural engineer of record must approve building anchorage to unit or curb
in compliance with OSP-0180-10. Use provided self tapping screws to attach
base of unit to seismic curb bracket.
Figure 9 – Solid Bottom Seismic Curb with Filters 30
Figure 10 – Seismic Solid Bottom Curb without Filters Cross Section
Figure 11 – Seismic Solid Bottom Curb without Filters Detail A Figure 12 –
Seismic Solid Bottom Curb without Filters Detail B
31
Figure 13 – Seismic Rigid Mount Curb Cross Section
Horizontal Duct Connection Note: If outside air will be in contact with the air tunnel base the unit must include the base insulation option or the base must be field insulated.
Outside Air Rain Hood Rain hood must be opened before startup of the unit. Fresh air intake adjustments must be made according to building ventilation or local code requirements.
Remove shipping covers and attach duct to flanges provided on the unit. The installer is responsible for sealing ducts to the flanges to prevent water leaks.
Remove the two screws at the bottom of the rain hood that secure it in the shipping position. Remove the screws that attach the side pieces of the hood to the top of the hood.
Rotate the side pieces so that the holes along one edge line up with the holes on the top piece and the flange is on the inside of the rain hood.
Supply
Return Figure 14 – Horizontal duct connections
Attach the side pieces to the top of the hood using the provided screws and
attached the side pieces to the end of the unit through the flange.
Apply silicon caulking along the top and both sides of the rain hood. Take
care to seal the top corners where the rain hood attaches to the unit.
32
Figure 15 – RQ Series unit Closed Rain Hood
Metal Mesh Filters Metal mesh outside air filters require installation of the
filter rack on the intake of the rain hood.
Figure 16 – RQ Series unit Open Rain Hood
Clips that hold the metal mesh filters in the filter rack must face outward.
Figure 17 – Rain Hood with Metal Mesh Filter Rack Installation 33
Electrical Verify the unit nameplate agrees with power supply. Connect power and control wiring to the unit as shown in Figure 19 and in the unit specific wiring diagram, which shows factory and field wiring and is attached to the inside of the door of the control compartment.
Table 2 – 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
240
208
254
216
252
265
277
240
293
249
291
460
480
416
508
432
504
575
600
520
635
540
630
50
230 400
230 400
198
254
208
254
344
440
360
440
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.
WARNING
Electric shock hazard. Before attempting to perform any installation, service,
or maintenance, shut off all electrical power to the unit at the disconnect
switches. Unit may have multiple power supplies. Failure to disconnect power
could result in dangerous operation, serious injury, death, or property
damage.
CAUTION
Electrical and gas entries into the unit must be properly sealed. Failure to
seal the entries may result in damage to the unit and property.
Route power and control wiring, separately, through the utility entry in the base of the unit. Do not run power and control signal wires in the same conduit. The utility entry is located in the unit base in the front right hand corner of the unit (compressor compartment). See unit drawing for specific location.
Figure 18 – Unit Base Utility Entry
34
Field Connection
Location
Utility Entry
Figure 19 – Back View of Power Switch from Control Compartment
Size supply conductors based on the unit MCA rating. Supply conductors must be
rated a minimum of 75°C (167°F).
Protect the branch circuit in accordance with code requirements. The unit must
be electrically grounded in accordance with local codes, or in the absence of
local codes, the current National Electric Code, ANSI/NFPA 70 or the current
Canadian Electrical Code CSA C22.1.
Note: All units are factory wired for 208V, 230V, 380V, 460V, or 575V. The
transformer configuration must be checked by a qualified technician prior to
service, especially if unit is to be connected to a 208V or 230V supply. For
208V service interchange the yellow and red conductor on the low voltage
control transformer.
Wire power leads to the unit’s terminal block or main disconnect. All wiring
beyond this point has been completed by the manufacturer and cannot be
modified without affecting the unit’s agency/safety certification.
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.
Red-Black for 208V Yellow-Black for 230V
35
Three phase voltage imbalance will cause motor overheating and premature
failure. The maximum allowable imbalance is 2%.
Voltage imbalance is defined as 100 times the maximum deviation from the
average voltage divided by the average voltage.
Example: (221V+230V+227V)/3 = 226V, then 100*(226V-221V)/226V = 2.2%, which
exceeds the allowable imbalance.
Check voltage imbalance at the unit disconnect switch and at the compressor
terminal. Contact your local power company for line voltage corrections.
It must be verified that proper motor rotation and blower motor amperage
listed on the motor nameplate is not exceeded. Motor overload protection may
be a function of the variable frequency drive and must not be bypassed.
CAUTION
Rotation must be checked on all MOTORS AND COMPRESSORS of three phase units.
Supply fan, exhaust fan, and condenser 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 terminal block located in the
controls compartment.
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 must be checked by a qualified service
technician at startup using suction and discharge pressure gauges and any
wiring alteration must only be made at the unit power connection.
Table 3 35 KAIC Fuse Sizing
35 KAIC Construction
Component Fuse Fuse
Disconnect
Description
Class CC, 600V, 0.5A – 30A Class J, 600V, 35A – 600A 3P, 600V, 15A 600A
Interrupting Rating (kA)
200
200
35
Table 4 65 KAIC Fuse Sizing
65 KAIC Construction
Component
Description
Interrupting Rating (kA)
Fuse
Class CC, 600V, 0.5A – 30A
200
Fuse
Class J, 600V, 35A – 600A
200
Disconnect
3P, 600V, 15A – 600A
65
Variable Speed Compressors Variable speed compressors with an inverter drive are available on 2-6 ton units. Variable speed compressors must not be operated outside the factory determined frequency range. The factory determined compressor frequency range is given below in Table 5. For more information on the variable speed compressor, reference the RQ Series
36
Variable Speed Compressor Supplement (V83980).
Table 5 – Single Circuited Variable Speed
Compressor Frequency Range
Model (RQ)
Compressor Range (rpm)
A, B
900-5000 rpm
Thermostat Control Wiring If a thermostat is used for unit control, locate thermostat on an inside wall 1.2-1.5 meters (4-5 feet) above the floor where it will not be subjected to drafts, sun exposure, or heat from electrical fixtures of appliances. Control wiring must deliver adequate voltage to components to assure proper operation. Control voltage returning from controller circuit must be a minimum of 21 VAC. To assure proper wiring use the following chart to determine the allowable wiring distances.
Table 6 – Control Wiring
Wire Size (Stranded) – Copper
Conductors Only
Total Wire Distance Allowable
20 AWG
60.96 m 200 ft
18 AWG
106.7 m 350 ft
16 AWG
152.4 m 500 ft
14 AWG
228.6 m 750 ft
12 AWG
381.0 m 1250 ft
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 8 wires must be pulled 75ft to control the unit. What size
wire must be used?
According to the Table 4, 16 AWG allows for 63ft (500 ft/8 wires) and 14 AWG
allows for 94ft (750 ft/8 wires). Thus, 14 AWG must be used.
Condensate Drain Piping 2-6 ton units are equipped with one condensate drain
pan connection on the left side of the unit. P-trap must be field provided and
installed.
All drain connections must be used and individually trapped to ensure a
minimum amount of condensate accumulation in the drain pans. ABS type cement
must be used to join the drain pipe connections.
Note: The drain pan connections are 2.5 cm (1″) MPT fitting.
Drainage of condensate directly onto the roof may be acceptable in certain
areas, refer to local codes. If condensate is to drain directly onto the roof
a small drip pad must be placed below the drain to protect the roof from
possible damage.
If condensate is piped into the building drainage system, the drain pipe must
penetrate the roof external to the unit itself. The drain line must be pitched
away from the unit at least 1/8 inch per foot. On longer runs an air break
must be used to ensure proper drainage.
37
CAUTION
Unit must not be operated without a ptrap. Failure to install a p-trap may
result in overflow of condensate water into the unit.
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.
Draw-Through Coils
Figure 20 – Draw-Through Drain Trap
The X dimension on the draw-through trap must 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 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 – Draw-Through Drain Trap Dimensions (Metric)
Draw-Through
Drain Pan Pressure
Trap Dimensions
Negative Static
X
X/2
(mmHg)
(millimeters) (millimeters)
-0.93
38.1
19.1
-1.87
50.8
25.4
-2.80
63.5
31.8
-3.74
76.2
38.1
-4.67
88.9
44.5
-5.60
101.6
50.8
-6.54
114.3
57.2
-7.47
127
63.5
Note: 1 mm = 0.1 cm
Table 8 – Draw-Through Drain Trap
Dimensions (Imperial)
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
38
Non-Compressorized Liquid and Suction Line Piping There are two different
locations to pipe out of the unit, the post corner hole location and the post
back hole location. The post corner hole location is to run pipe along the
roof and then down by the disconnect switch (Figure 20 and Figure 22). The
post back hole location is to run the pipe along the roof, back across the
coil, and come out near the blower access panel (Figure 21 and Figure 23).
When drilling the holes, use a 3.2 cm (1 ¼”) inch hole for the suction line
and a 1 inch hole
for the liquid line (Figure 20 and Figure 21). For pipe sizing, refer to appropriate guidelines in the condenser or condensing unit installation manual. The grommets will help seal in between the holes in the sheet metal and the piping. If you are piping through the back post foam panel, attach grommet to the inside skin of the foam part. If you are piping through post corner hole location, use caution around electrical wires. You will need to turn off power to the unit.
Figure 21 – Post Corner Hole Location
Figure 22 – Post Back Hole Location 39
Figure 23 – Post Corner Hole Piping
Figure 24 – Post Back Hole Piping 40
Startup
(See back of the manual for startup form.)
WARNING
Improper installation, adjustment, alteration, service or maintenance can
cause property damage, personal injury or loss of life. Startup and service
must be performed by a Factory Trained Service Technician.
WARNING
Electric shock hazard. Shut off all electrical power to the unit to avoid
shock hazard or injury from rotating parts.
During startup, it is necessary to perform routine checks on the performance
of the unit. This includes checking the air flow, air filters, condenser water
flow, dampers, heaters, and refrigerant charge.
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 evaporator coil.
CAUTION
Before completing startup and leaving the unit a complete operating cycle must
be observed to verify that all components are functioning properly.
41
Supply Fan EC Motor Startup
Figure 25 – PIN Connectors on EC Supply Fan Motor Electronics
Speed adjustment is made by varying the DC voltage on pin 8 (+) & 16 (-). If AAON Orion Control systems are installed on the system, then they will provide the 0-10VDC signal for speed control. The controller will be wired directly to pin 8 & 16. If a potentiometer is installed in the unit, the 10VDC output of the motor electronics will be wired through the potentiometer and then back into pin 8 & 16 for speed control. By
adjusting the potentiometer from 0-100% you can manually adjust the speed of
the motor.
If the rotation direction is wrong, check the brown wire on the control
connector and ensure that it is connected from pin 13 to pin 11.
Making/Breaking this wire changes the rotation of the motor.
If there is no rotation and/or no speed change, try the following:
42
1. Check the line-to-line voltage on the fuse block connected to the supply
fan motor and ensure it is between 187VAC to 264VAC
2. Turn the potentiometer to 50% 3. Energize the BC relay by making a
blower call. 4. Check DC voltage on S1 (-) and S2 (+),
0-10VDC signal on S1 & S2 sets the speed of the motor thus 0VDC is no speed
and 10VDC is full speed. 5. If DC Voltage is present on S1 & S2 then ensure
that BC (blower relay) is energized and is passing the DC voltage through to
the motor. If BC is not energized then check wiring for 24VAC blower call. 6.
If no DC voltage is present on S1 & S2 then check S1 (-) & S3 (+), this is the
+10VDC output from the motor that is supplied to the Potentiometer for speed
control.
If the following troubleshooting suggestions do not solve the issue, contact
AAON for assistance.
Adjusting Refrigerant Charge 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.
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.
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 must be operated in reheat (dehumidification) mode to
check for correct operation.
Units equipped with heat pump options must be charged in heating mode to get
the proper charge. After charging, unit must 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 Table 7 and Table 8 below when determining the
proper subcooling.
Checking Liquid Sub-Cooling Measure the temperature of the liquid line as it
leaves the condenser coil.
Read the gauge pressure at the liquid line close to the point where the
temperature was taken. You must use liquid line pressure as it will vary from
discharge pressure due to condenser coil pressure drop.
Convert the pressure obtained to a saturated temperature using the appropriate
refrigerant temperature-pressure chart.
43
Subtract the measured liquid line temperature from the saturated temperature
to determine the liquid sub-cooling.
Compare calculated sub-cooling to Table 7 and Table 8 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.
CAUTION
Thermal expansion valve must be adjusted to approximately 4.4-8.3°C (8-15°F)
of suction superheat. Failure to have sufficient superheat will damage the
compressor and void the warranty.
Table 9 – Acceptable Refrigeration Circuit
Values (Metric)
Air-Cooled Cond./Air-Source Heat Pump
In Cooling Mode
Sub-Cooling 4.4-8.3°C / 1.1-2.2°C
(HP)*
Sub-Cooling with 4.4-8.3°C /1.1-3.3°C
Hot Gas Reheat
(HP)*
Superheat
4.4-8.3°C
Water-Cooled Cond./Water-Source Heat
Pump In Cooling Mode
Sub-Cooling
2.2-4.4°C
Superheat
4.4-8.3°C
Table 10 Acceptable Refrigeration Circuit
Values (Imperial)
Air-Cooled Cond./Air-Source Heat
Pump In Cooling Mode
Sub-Cooling
8-15°F / 2-4°F
(HP)*
Sub-Cooling with
8-15°F /2-6°F
Hot Gas Reheat
(HP)*
Superheat
8-15°F
Water-Cooled Cond./Water-Source
Heat Pump In Cooling Mode
Sub-Cooling
4-8°F
Superheat
8-15°F
Table 11 – Acceptable Microchannel Air-Cooled Condenser Coil Liquid SubCooling Values (Metric)
Cooling Mode Liquid Sub-Cooling Values(°C)
Ambient
(°C)
4.4
Evaporator Coil Saturation Temperature (°C)
7.2
8.9
10.0
12.8
19.4
5.0 – 7.8
4.4 – 7.2
4.4 – 7.2
3.9 – 6.7
2.8 – 5.6
22.2
5.6 – 8.3
5.0 – 7.8
5.0 – 7.8
4.4 – 7.2
3.9 – 6.7
27.8
5.6 – 8.3
5.6 – 8.3
5.6 – 8.3
5.0 – 7.8
3.9 – 6.7
35.0
5.6 – 8.3
5.6 – 8.3
5.6 – 8.3
5.0 – 7.8
4.4 – 7.2
40.6
6.1 – 8.9
6.1 – 8.9
5.6 – 8.3
5.6 – 8.3
4.4 – 7.2
46.1
5.6 – 8.3
6.1 – 8.9
6.1 – 8.9
6.1 – 8.9
5.0 – 7.8
44
Table 12 – Acceptable Microchannel Air-Cooled Condenser Coil Liquid Sub- Cooling Values (Imperial)
Cooling Mode Liquid Sub-Cooling Values(°F)
Ambient (°F)
Evaporator Coil Saturation Temperature (°F)
40
45
48
50
55
67
9 – 14
8 – 13
8 – 13
7 – 12
5 – 10
72
10 – 15
9 – 14
9 – 14
8 – 13
7 – 12
82
10 – 15 10 – 15 10 – 15
9 – 14
7 – 12
95
10 – 15 10 – 15 10 – 15
9 – 14
8 – 13
105
11 – 16 11 – 16 10 – 15 10 – 15
8 – 13
115
10 – 15 11 – 16 11 – 16 11 – 16
9 – 14
Notes:
1. Microchannel condenser coils are more sensitive to charge. The system must
be running in cooling mode with compressor, supply airflow & condenser fan
speed at full load. The sub-cooling value changes depending on the ambient
temperature reading and the microchannel evaporator coil saturation
temperature. To find the correct sub-cooling value, find the ambient
temperature on the first column and follow that across to the SST (4.4-12.8°C
[40-55°F]).
2. Superheat for Microchannel condenser coils must be between 4.4 and 8.3°C
(8 – 15°F).
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 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.
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
45
Table 13 – R-410A Refrigerant Temperature-Pressure Chart (Metric) °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
46
Table 14 – R-410A Refrigerant Temperature-Pressure Chart (Imperial) °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
47
Table 15 – R-454B Refrigerant Temperature-Pressure Chart (Metric) °C KPA °C
KPA °C KPA °C KPA °C KPA -6.7 484.5 8.3 843.3 23.3 1348.0 38.3 2034.6 53.3
2946.9 -6.1 495.6 8.9 859.3 23.9 1370.0 38.9 2064.1 53.9 2985.7 -5.6 506.9 9.4
875.3 24.4 1392.2 39.4 2093.9 54.4 3024.9 -5.0 518.2 10.0 891.6 25.0 1414.6
40.0 2123.9 55.0 3064.5 -4.4 529.7 10.6 908.1 25.6 1437.3 40.6 2154.3 55.6
3104.5 -3.9 541.5 11.1 924.8 26.1 1460.3 41.1 2185.0 56.1 3144.9 -3.3 553.3
11.7 941.7 26.7 1483.5 41.7 2216.1 56.7 3185.8 -2.8 565.4 12.2 958.8 27.2
1507.0 42.2 2247.4 57.2 3227.0 -2.2 577.6 12.8 976.2 27.8 1530.8 42.8 2279.1
57.8 3268.6 -1.7 589.9 13.3 993.7 28.3 1554.8 43.3 2311.1 58.3 3310.7 -1.1
602.5 13.9 1011.5 28.9 1579.0 43.9 2343.5 58.9 3353.2 -0.6 615.2 14.4 1029.4
29.4 1603.6 44.4 2376.2 59.4 3396.1 0.0 628.1 15.0 1047.6 30.0 1628.4 45.0
2409.2 60.0 3439.5 0.6 641.2 15.6 1066.0 30.6 1653.5 45.6 2442.6 60.6 3483.3
1.1 654.4 16.1 1084.7 31.1 1678.8 46.1 2476.2 61.1 3527.6 1.7 667.8 16.7
1103.5 31.7 1704.4 46.7 2510.3 61.7 3572.3 2.2 681.4 17.2 1122.6 32.2 1730.4
47.2 2544.7 62.2 3617.4 2.8 695.2 17.8 1141.9 32.8 1756.6 47.8 2579.4 62.8
3663.0 3.3 709.2 18.3 1161.5 33.3 1783.0 48.3 2614.5 63.3 3709.2 3.9 723.3
18.9 1181.3 33.9 1809.9 48.9 2650.0 63.9 3755.7 4.4 737.6 19.4 1201.3 34.4
1836.9 49.4 2685.7 64.4 3802.7 5.0 752.2 20.0 1221.5 35.0 1864.3 50.0 2721.9
65.0 3850.3 5.6 766.9 20.6 1242.0 35.6 1891.9 50.6 2758.5 65.6 3898.4 6.1
781.8 21.1 1262.8 36.1 1919.8 51.1 2795.4 6.7 796.9 21.7 1283.7 36.7 1948.1
51.7 2832.7 7.2 812.2 22.2 1304.9 37.2 1976.7 52.2 2870.4 7.8 827.7 22.8
1326.3 37.8 2005.5 52.8 2908.4
48
Table 16 – R-454B Refrigerant Temperature-Pressure Chart (Imperial) °F PSIG °F
PSIG °F PSIG °F PSIG °F PSIG 20 70.3 47 122.3 74 195.5 101 295.1 128 427.4 21
71.9 48 124.6 75 198.7 102 299.4 129 433.0 22 73.5 49 127.0 76 201.9 103 303.7
130 438.7 23 75.2 50 129.3 77 205.2 104 308.0 131 444.5 24 76.8 51 131.7 78
208.5 105 312.5 132 450.3 25 78.5 52 134.1 79 211.8 106 316.9 133 456.1 26
80.3 53 136.6 80 215.2 107 321.4 134 462.0 27 82.0 54 139.1 81 218.6 108 326.0
135 468.0 28 83.8 55 141.6 82 222.0 109 330.6 136 474.1 29 85.6 56 144.1 83
225.5 110 335.2 137 480.2 30 87.4 57 146.7 84 229.0 111 339.9 138 486.3 31
89.2 58 149.3 85 232.6 112 344.6 139 492.6 32 91.1 59 151.9 86 236.2 113 349.4
140 498.8 33 93.0 60 154.6 87 239.8 114 354.3 141 505.2 34 94.9 61 157.3 88
243.5 115 359.1 142 511.6 35 96.9 62 160.1 89 247.2 116 364.1 143 518.1 36
98.8 63 162.8 90 251.0 117 369.1 144 524.6 37 100.8 64 165.6 91 254.8 118
374.1 145 531.3 38 102.9 65 168.5 92 258.6 119 379.2 146 538.0 39 104.9 66
171.3 93 262.5 120 384.3 147 544.7 40 107.0 67 174.2 94 266.4 121 389.5 148
551.5 41 109.1 68 177.2 95 270.4 122 394.8 149 558.4 42 111.2 69 180.1 96
274.4 123 400.1 150 565.4 43 113.4 70 183.1 97 278.4 124 405.4 44 115.6 71
186.2 98 282.5 125 410.8 45 117.8 72 189.3 99 286.7 126 416.3 46 120.0 73
192.4 100 290.9 127 421.8
49
CAUTION
DO NOT OVERCHARGE!
Refrigerant overcharging leads to excess refrigerant in the condenser coils
resulting in elevated compressor discharge pressure.
Freeze Stat Startup Freeze Stat is an adjustable temperature sensor (-23.3°C
to 21.1°C [-10 to 70°F]) mounted on the tubing of the first cooling circuit
and wired to de energize all cooling circuits if tubing temperature falls
below setpoint. Option is used to prevent freezing of evaporator coil.
Recommended Setting: 0°C to 1.7°C (32° F to 35º F
Condenser Fan EC Motor Startup The fan cycling option uses a fan cycle switch
to switch between one of the discrete speed
inputs (see Table 17) on the motor thus cycling between two preset speeds
based upon discharge pressure of the unit. By connecting 24VAC to a single or
combination of the yellow, white, or orange wires, the motor will run at the
discrete speeds in Table 17.
AAON Condenser Head Pressure Module is used for variable speed control of the
motor to maintain a head pressure. The motor must be factory wired to the PWM
outputs of the AAON Condenser Head Pressure Module. See AAON literature for
further information (https://www.aaon.com/Controls).
Note High voltage wires out of the motor: Black & Brown 1 Phase Line Voltage
Green – Ground
Low control voltage wires out of the motor: Blue Common Yellow Variable
Speed Control
Color Black Brown
Green Blue Yellow White Orange
Terminal
Table 17 – EC Condenser Fan Cycling Options
Customer
Connection Option 1
Option 2
Option 3
0.50 BWS
L1
208-230 VAC 208-230 VAC 208-230 VAC
0.50 BWS #10
EYELET
L2 Ground
208-230 VAC GND
208-230 VAC GND
208-230 VAC GND
0.50 BWS Common
Common
24 VAC
24 VAC
0.50 BWS
Signal
PWM
24 VAC
0.50 BWS
Signal
0.50 BWS
Signal
24 VAC
RPM 300-1100
300
500
Rotation
CCW
CCW
CCW
ECM Toolbox ID
Variable
Speed 4
Speed 3
20% PWM RPM
300
100% PWM RPM
1100
Option 4 208-230 VAC 208-230 VAC
GND 24 VAC
24 VAC 24 VAC
850 CCW Speed 2
Option 5 208-230 VAC 208-230 VAC
GND 24 VAC 24 VAC 24 VAC
1100 CCW Speed 1
50
Adjustable Fan Cycling Switch Procedure
Recommended Settings The switch will come factory set to cut-in at 2.93 Mpa
[425psi] (+/ 5psi) and a differential of 1.69 Mpa [155psi] (or open at 1.86
Mpa [270psi] (+/ 5psi)).
Note: 5 psi = 34.5 kpa
To adjust the fan cycle switch you will need a flathead screwdriver.
Cut In
Differential
Settings for CUT IN and DIFFERENTIAL PRESSURE are indicated with two slider gauges.
Each adjustment screw sits above the setting that it controls.
51
Cut In Gauge
Cut In Gauge
To lower the pressure set point for the CUT IN gauge, turn the adjustable
screw clockwise.
Differential Gauge
To raise the pressure set point for the CUT IN gauge, turn the adjustable
screw counter clockwise.
Differential Gauge
To raise the pressure set point for the
To lower the pressure set point for the
DIFFERENTIAL Gauge, turn the adjustable DIFFERENTIAL Gauge, turn the adjustable
screw clockwise.
screw counter clockwise.
NOTE: The pressure values on the gauge must be verified with gauges on the refrigerant line. The gauge scale is for illustration purposes only.
52
Operation
Unit operations must be controlled with thermostat, or unit controller, never
at the main power supply, except for servicing, emergency, or complete
shutdown of the unit.
Thermostat Operation Heating Thermostat system switch – “Heat” Thermostat fan
switch – “Auto” or “On” Thermostat temperature set to desired point.
Cooling Thermostat system switch – “Cool” Thermostat fan switch – “Auto” or
“On” Thermostat temperature set to desired point.
Air Circulation Thermostat system switch – “Off” Thermostat fan switch –
“Auto” or “On” No change of the thermostat temperature. With these settings,
the supply blower will run continuously but the supply air will not be heated,
cooled, or dehumidified.
System Off Thermostat system switch – “Off” Thermostat fan switch – “Auto” No
change of the thermostat temperature. With these settings the system is shut
down, with the exception of control system power.
Night and Weekend Unoccupied Operation To reduce the operating time of the
unit when the space is unoccupied, such as nights and weekends, it is
recommended that the temperature setting be raised about 5°F while unoccupied
during the cooling season and lowered about 10°F during the heating season.
Packaged DX Cooling Operation and Control When a call for cooling (G and Y1,
Y2, etc.) is made the supply blower motors and compressors will energize.
WARNING
COMPRESSOR CYCLING
3 MINUTE MINIMUM OFF TIME To prevent motor overheating compressors must cycle
off for a minimum of 3 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 7 starts per hour.
Note: When using field controls any variable capacity compressors must run at
100% for 1 minute when starting.
Gas Heater Operation When heat (G and W1, W2, etc.) is called for the
combustion motor starts and the ignition control is energized. The control
sends 24 VAC to the main gas valve and high voltage to the igniter. If a
burner flame has been detected within 10 seconds, the spark is extinguished
and the flame continues. If a flame has not been detected after 10 seconds,
the gas valve closes, the spark ceases and the induced draft blower continues
to purge the heat exchanger. After 45 seconds of purge, the ignition system
will attempt to light the burners again. Should no flame be detected after 3
tries, the ignition control will lock out the system. Power to the ignition
control must be cycled to reset the heater control.
53
On a fault the gas train is shut down by a main limit located in the heat
exchanger area or by an auxiliary limit mounted in the supply fan compartment.
Electric Heating Operation When a call for heating (G and W1, W2, etc.) is
made the supply blower motors and electric resistance heaters will energize.
Heating is accomplished by passing electrical current through a specified
amount of resistance heaters which will produce the required heat.
On a fault condition the main limit located in the supply air or the auxiliary
limit located downstream the supply blower will remove power from all
contactors.
Steam or Hot Water Preheating and Heating Operation Valve control for steam
and hot water heating coils are by others. Heating is accomplished by passing
steam or hot water through the steam or hot water coil assembly.
Modulating Electric Preheat Electric preheat is used to temper the incoming
outside air to the unit based on an enable control signal and outside air
conditions. Electric preheat has a maximum operation outside air temperature
of 15.6°C (60°F) and a maximum preheat discharge air temperature of 26.7°C
(80°F).
Chilled Water or Non-Compressorized DX Cooling Operation Controls for chilled
water cooling coils and non-compressorized DX coil are by others.
Maintenance
(See back of the manual for maintenance log)
At least once each year, a trained, qualified service technician must check
out the unit. Fans, evaporator coils, and filters must be inspected at least
monthly.
54
Supply Fan
WARNING
Electric shock hazard. Shut off all electrical power to the unit to avoid shock hazard or injury from rotating parts.
CAUTION
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.
Factory Lubrication Note: Bearing lubrication only applies to belt driven fan
motors such as the energy recovery wheel power exhaust fan motor.
All original fan motors and bearings are furnished with factory lubrication.
Some applications will require that bearings be relubricated periodically. The
schedule will depend on the operating duty, temperature variations or other
severe atmospheric conditions.
Bearings must be re-lubricated when at normal operating temperatures, but not
running. Rotate the fan shaft by hand and add only enough grease to purge the
seals. DO NOT OVERLUBRICATE.
Recommended greases are: SHELL OIL – DOLIUM R CHEVRON OIL – SRI No. 2 TEXACO
INC. – PREMIUM RB Removal
Remove fan access panel on the back side of the unit. Panel is attached with eight 8 mm (5/16″) bolts.
Through the coil access door, remove the two 8 mm (5/16″) bolts that connect
the blower assembly to the inlet wall from air entering side of the wall (see
Figure 26).
Slide blower assembly (wire frame motor mount, motor, blower wheel, inlet, and
sheetmetal slide) out of unit through blower access opening (see Figure 27).
Figure 26 – 2-6 ton Supply Fan Remove wire connections from motor. For EC
motors unplug the wire harness at the control module that connects to the unit
control panel. Through the blower access opening, remove the two 8 mm (5/16″)
bolts that connect the blower assembly to the inlet wall (see Figure 26).
Figure 27 – RQ Supply Fan Removal Bolts
Figure 28 – RQ Supply Fan Removal Slide
DX Cooling Set unit controls to cooling mode of operation with supply fans on.
Check the fan for correct operating direction, amperage and voltage. Check
compressor operation, rotation, amperage and voltage to the unit nameplate
(check the amperage on the load side of the compressor contactor).
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 service technician.
55
E-Coated Coil Cleaning Documented routine cleaning of e-coated coils is
required to maintain coating warranty coverage for fin and tube and
microchannel coils. E-Coated Coil Maintenance Record sheets are provided in
the appendix.
WARNING
Electric shock hazard. Shut off all electrical power to the unit to avoid
shock hazard or injury from rotating parts.
Surface loaded fibers or dirt must 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 must 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 must be
applied in the direction of the fins. Coil surfaces can be easily damaged (fin
edges bent over) if the tool is applied across the fins.
Use of a water stream, such as a garden hose, against a surface loaded coil
will drive the fibers and dirt into the coil. This will make cleaning efforts
more difficult. Surface loaded fibers must be completely removed prior to
using low velocity clean water rinse.
A monthly clean water rinse is recommended for coils that are applied in
coastal or industrial environments to help to remove chlorides, dirt, and
debris. It is very important when rinsing, that water temperature is less than
54.4°C (130°F) and pressure is less than 689.5 kpa (100 psig) to avoid
damaging the fin edges. An elevated water temperature (not to exceed 54.4°C
[130°F]) will reduce surface tension, increasing the ability to remove
chlorides and dirt.
CAUTION
High velocity water from a pressure washer or compressed air must 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.
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.
CAUTION
Harsh chemicals, household bleach, or acid cleaners must 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.
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, when used in accordance
with the manufacturer’s
56
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 Cleaner: AAON PN: V82540
GulfClean TM Coil Cleaner ; AAON PN: G074480
Recommended Chloride Remover GulfClean Salt ReducerTM ; AAON PN: G074490
GulfClean Salt ReducerTM is used to remove soluble salts from the e-coated
coil, follow the manufacturer’s instructions. This product is not intended for
use as a degreaser. Any grease or oil film must first be removed with
GulfClean TM Coil Cleaner.
Remove Barrier – First ensure the power to the unit is off and locked out.
Clean the area around the unit if needed to ensure leaves, grass or loose
debris will not be blown into the coil. 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.
Application- Apply GulfClean TM Coil Cleaner 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. Apply the cleaner to unit
interior air exiting side coil surfaces first. Work in sections/panels
moving side to side and from top to bottom. Allow the cleaning solution to
soak for 5 to 10 minutes. Then move on to the exterior using the same method.
Rinse – Using pressurized potable water such as a garden hose, (< 689.5 kpa
[100 psi]), rinse the coils and continue to always work in sections/panels.
Continue until all coil areas on the inside of the unit have been rinsed.
Note: Coils must always be cleaned / back flushed, opposite of airflow to
prevent impacting the dirt into the coil.
Repeat these steps with GulfClean TM Salt Reducer. When finished replace all
panels and tops that were removed.
Microchannel Coil Cleaning Cleaning microchannel coils is necessary in all
locations. In some locations it may be necessary to clean the coils more or
less often than recommended. Condenser coil must be cleaned at a minimum of
once a year. In locations where there is commonly debris or a condition that
causes dirt/grease build up it may be necessary to clean the coils more often.
Proper procedure must be followed at every cleaning interval. Using improper
cleaning technique or incorrect chemicals will result in coil damage, system
performance fall off, and potentially leaks requiring coil replacement.
Documented routine cleaning of microchannel coils with factory provided
ecoating is required to maintain coating warranty coverage. Use the E-Coated
Coil Cleaning section for details on cleaning ecoated coils.
Field applied coil coatings are not recommended with microchannel coils.
57
Allowed Chemical Cleaners and Procedures AAON recommends certain chemicals
that can be used to remove buildup of grime and debris on the surface of
microchannel coils. These chemicals have been tested for performance and
safety and are the only chemicals that AAON will warrant as correct for
cleaning microchannel coils.
There are three procedures that are outlined below that will clean the coils
effectively without damage to the coils. Use of any other procedure or
chemical may void the warranty to the unit where the coil is installed. With
all procedures make sure the unit is off before starting.
WARNING
Electric shock hazard. Shut off all electrical power to the unit to avoid
shock hazard or injury from rotating parts.
The water pressure used to clean must not exceed 689.5 kpa (100 psi), from no
closer than 15.2 cm (6 inches) from the coils, and with the water aimed
perpendicular to the coils.
1 Simple Green Simple Green is available from AAON Parts and Supply (Part
T10701) and is biodegradable with a neutral 6.5 pH A 4 to 1 solution is
recommended. Use the following procedure.
1. Rinse the coil completely with water. Use a hard spray but be careful not
to bend or damage the fins. A spray that is too hard will bend the fins. Spray
from the fan side of the coil.
2. With a pump sprayer filled with a mix of 4 parts water to one part Simple
Green
spray the air inlet face of the coil. Be sure to cover all areas of the face of the coil. 3. Allow the coil to soak for 10-15 minutes. 4. Rinse the coil with water as in step one. 5. Repeat as necessary.
2 Water Flush This procedure can be used when the only material to cause the
coil to need cleaning is debris from plant material that has impinged the coil
face.
1. Rinse the coil completely with water. Use a hard spray but be careful not
to bend or damage the fins. A spray that is too hard will bend the fins. Spray
from the fan side of the coil.
2. Spray and rinse the coil from the face.
CAUTION
Use pressurized clean water, with pressure not to exceed 100 psi. Nozzle must
be 15.2 cm (6″) and perpendicular to the coil face. Failure to do so could
result in coil damage.
Application Examples The two procedures can be used to clean microchannel
coils. They will fit with the application depending on the area. In some areas
where the spring/summer has a large cottonwood bloom #2 might work fine if the
unit is installed on an office building and no other environmental factors
apply.
Generally the best and broadest based procedure is #1. The grease cutting
effect of the Simple Green is good for restaurant applications.
58
Other Coil Cleaners There are many cleaners on the market for condenser coils.
Before using any cleaner that is not covered in this section you must get
written approval from the AAON warranty and service department. Use of
unapproved chemicals will void the warranty.
AAON testing has determined that unless a chemical has a neutral pH (6-8) it
must not be used.
Beware of any product that claims to be a foaming cleaner. The foam that is
generated is caused by a chemical reaction to the aluminum fin material on
tube and fin coils and with the fin, tube, and coating material on
microchannel coils.
Microchannel coils are robust in many ways, but like any component they must
be treated correctly. This includes cleaning the coils correctly to give
optimal performance over many years.
Roofing The cleaning procedures outlined here use relatively benign
ingredients. When working with a rooftop unit care must be taken to make sure
the chemicals will not adversely affect the roof coating. Checking with the
roofing supplier/manufacturer is the best way to proceed. If the roofing
supplier/manufacturer is not available testing of the chemicals on the roof
coating is recommended.
Commercial roofing material manufacturers using PVC and EPDM have been
contacted and indicate that there is no problem with any of the procedures
outlined above.
Options
(See back of the manual for maintenance log)
Heating Coils One or two row hot water and steam heating and preheating coils can be factory installed. All valve controls for heating operation are field supplied and field installed. Hot water and steam coil connections are spun copper tube.
Water coils must not be subjected to entering air temperatures below 3.3°C (38°F) to prevent coil freeze-up. If air temperature across the coil is going to be below this value, use a glycol solution to match the coldest air expected.
Table 18 – Hot Water Coil Connection Sizes
Hot Water Coil
Model (RQ-)
Connection Size
[mm (in.)]
002-006
(22) 7/8
Table 19 – Steam Coil Connection Sizes
Model (RQ-)
Steam Coil Connection Size [mm (in.)]
002-006
54 (2 1/8) (standard coil)/ 29 (1 1/8) (preheat coil)
Chilled Water Coil Four or six row chilled water cooling coils can be factory installed. All valve controls for cooling operation are field supplied and field installed. Chilled water coil connections are spun copper tube.
WARNING
Piping, pressure limiting devices, backflow preventers and all other safety
requirements shall be in accordance with national and local codes.
59
Table 20 – Chilled Water Coil Connection
Sizes
Model (RQ-)
Chilled Water Coil Connection Size [mm (in.)]
002-006
29 (1 1/8)
Table 21 Min and Max Water Pressures and Temps
Min. Entering Air Max Entering Air Min. Entering Water Max Entering Water Min. Water Pressure Max Water Pressure
Chilled Water Hot Water 15.6°C (60°F) 4.4 °C (40°F) 37.8°C (100°F) 26.7°C
(80°F) 1.7°C (35°F) 60°C (140°F) 18.3°C (65°F) 93.3°C (200°F)
0 kpa (15 psig) 2068kpa (300 psig)
CAUTION
The unit shall have proper sealing of the water piping entries into the unit.
Failure to seal the entries may result in damage to the unit and property.
Packaged Direct Expansion (DX) Units
WARNING
COMPRESSOR CYCLING
3 MINUTE MINIMUM OFF TIME To prevent motor overheating compressors must cycle
off for a minimum of 3 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 7 starts per hour.
DX refrigeration system is factory assembled, leak tested, charged with
refrigerant and run tested.
Refrigerant system includes an evaporator, condenser, liquid line filter
drier, thermal expansion valve (TXV), and scroll compressor. Variable speed
compressor systems include an electronic expansion valve (EEV). Compressor is
equipped with a positive pressure forced lubrication system.
Never cut off the main power supply to the unit, except for servicing,
emergency, or complete shutdown of the unit. When power is cut off from the
unit crankcase heater cannot prevent refrigerant migration into the
compressor. This means the compressor will cool down and liquid refrigerant
may accumulate in the compressor. The compressor is designed to pump
refrigerant gas and damage may occur when power is restored.
CAUTION
CRANKCASE HEATER OPERATION
Some units are equipped with a compressor crankcase heater, which must be
energized at least 24 hours prior to cooling operation, to clear any liquid
refrigerant from the compressor.
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
60
accumulation out of the compressor before it is started.
Always control the unit from the thermostat, or control panel, never at the
main power supply, except for servicing, emergency or complete shutdown of the
unit.
During the cooling season, if the air flow is reduced due to dirty air filters
or any other reason, the cooling coil can get too cold which will cause
excessive liquid to return to the compressor. As the liquid concentration
builds up, oil is washed out of the compressor, leaving it starved for
lubrication.
The compressor life will be seriously shorted by reduced lubrication and the
pumping of excessive amounts of liquid oil and refrigerant.
Note: Low Ambient Operation Air-cooled DX units without a low ambient option,
such as condenser fan cycling or the -17.8°C (0°F) low ambient option, will
not operate in the cooling mode of operation properly when the outdoor
temperature is below 12.8°C (55°F). Low ambient and/or economizer options are
recommended if cooling operation below 12.8°C (55°F) is expected.
Note: Multiple Units with Multiple Thermostats When several heating and
cooling units are used to condition a space, all unit thermostat switches must
be set in either heating mode, cooling mode or off. Do not leave part of the
units switched to the opposite mode. Switch off cooling only units at the
thermostat during the heating season.
Variable Capacity Compressor Controller
Units with variable capacity scroll compressors may include the following
compressor controller. The following is an explanation of the terminals and
troubleshooting alert flash codes of the controller. For more information on
the compressor controller, see Emerson Climate Bulletin AE8-1328.
Note: When using field controls any variable capacity compressors must run at
100% for 1 minute when starting.
Figure 29 – Variable Capacity Compressor Controller
WARNING
To avoid damaging the Compressor Controller do not connect wires to terminals C3, C4, T3, T4, T5, or T6.
Low Voltage Terminals
24COM Module Common
24VAC Module Power
C1 & C2 Demand Input
P1
Pressure Common
P2
Pressure Input
P3
Pressure Power 5VDC
P4
Pressure Shield
P5 & P6 Pressure Output
61
T1 & T2 Discharge Sensor
Temperature
High Voltage Terminals
A1 & A2 Alarm Relay Out
M1 & M2 Contactor
L1
Control Voltage N
L2
Control Voltage L
U1 & U2 Digital Unloader Solenoid
V1 & V2 Vapor Injection Solenoid
The compressor controller modulates the compressor unloader solenoid in an on/off pattern according to the capacity demand signal of the system. The following table shows the linear relationship between the demand signal and compressor capacity modulation. The compressor controller protects the compressor against high discharge temperature. Refer to Appendix B for the relationship between thermistor temperature readings and resistance values.
Table 22 – Demand Signal vs. Compressor Capacity Modulation
Demand Signal (VDC)
Loaded %
Unloaded % Time Loaded
Time Unloaded
1.00
Off
Off
Off
Off
1.44
10%
90%
1.5 sec
13.5 sec
3.00
50%
50%
7.5 sec
7.5 sec
4.20
80%
20%
12 sec
3 sec
5.00
100%
0%
15 sec
0 sec
% Compressor Capacity 0% 10% 50% 80% 100%
Figure 30 – Compressor Controller Flash Code Details 62
Evaporator Coil
WARNING
Electric shock hazard. Shut off all electrical power to the unit to avoid
shock hazard or injury from rotating parts.
Removal Evacuate refrigerant from the systems. Remove the TXV bulbs from the
suction lines. Disconnect the suction and liquid line copper connections to
the evaporator coil.
Figure 31 – Evaporator Coil Access Remove screws attaching filter rack to the
evaporation coil at the front and back of the coil. It may be necessary to
remove the economizer assembly (if equipped) to access the screws at the back.
Slide the evaporator coil straight out of the unit. It may be necessary to
make a vertical cut in the front flange of the drain pan on either side of the
coil and bend the flange down between the cuts to remove the evaporator coil.
Reinstallation Slide the new coil into the unit through the notch cut in the
front of the drain pan.
Re-bend the cut flange back to the original position, then seal the cuts with
polyurethane caulking.
Attach the filter at the front and back of the evaporation coil. Reinstall
economizer assembly if necessary.
Connect the suction and liquid copper connections to the evaporator coil.
Reinstall the TXV bulb on the suction line.
Evacuate the refrigerant system. Weigh in the nameplate refrigerant charge.
See Adjusting Refrigerant Charge section to check for proper sub-cooling and
superheat of the refrigerant systems.
Condenser Fan
WARNING
Electric shock hazard. Shut off all electrical power to the unit to avoid
shock hazard or injury from rotating parts.
WARNING
Improper installation, adjustment, alteration, service, or maintenance can
cause property damage, personal injury, or loss of life. Startup and service
must be performed by a Factory Trained Service Technician.
Removal Take off the fan grill by removing the screws that attach it to the
top of the unit.
63
Disconnect the wiring from the motor and loosen the bolt that clamps the motor
mount to the motor. Remove the motor and fan through the top of the orifice.
Figure 32 – Removal of a Condenser Fan Assembly
Reinstallation Set the motor back into the motor mount and tighten bolt.
Adjust fan until the top of the blade is even with the top of the orifice.
Reconnect wires, then attach the fan grill at all the points where screws were
removed.
Refrigerant-to-Water Heat Exchanger Condenser water pump, condenser water
piping, cooling tower or geothermal loop, pressure gauges, strainers, piping
insulation and all components of the waterside piping must be field installed.
Water-Source Heat Pump Applications Water-source heat pump units using 100%
outside air must have electric preheat if the application has a potential for
operation with air entering the indoor coil below 6.1°C (43°F) with a water
loop temperature of 21.1°C (70°F).
CAUTION
WATER-SOURCE HEAT PUMP APPLICATIONS
Water-source heat pump units using 100% outside air must have electric preheat
if the application has a potential for heat pump heating operation with air
entering the indoor coil below 6.1°C (43°F) with an entering water loop
temperature of 21.1°C (70°F).
Open Loop Applications This product contains one or more refrigerant-to-water
heat exchangers made of copper, which is subject to corrosion and failure when
exposed to chlorides.
WARNING
OPEN LOOP APPLICATIONS
Failure of the condenser as a result of chemical corrosion is excluded from
coverage under AAON Inc. warranties and the heat exchanger manufacturer’s
warranties.
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. Disinfecting the water loop with
solutions containing sodium hypochlorite.
Chlorides will result in a premature failure of the condenser.
64
Failure of the condenser as a result of chemical corrosion is excluded from
coverage under AAON warranties and the heat exchanger manufacturer warranties.
Failure of the condenser will allow water to enter the refrigerant circuit and
will cause extensive damage to the refrigerant circuit components. Any damage
to the equipment as a result of condenser failure from chemical corrosion due
to the fluid in the condenser is excluded from coverage under AAON warranties
and the heat exchanger manufacturer warranties.
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 condenser water loop with harsh chemicals such
as hydrochloric acid (muriatic acid), chlorine or other chlorides, 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.
Freezing Water in the Heat Exchanger This product contains one or more
refrigerant-to-water heat exchangers. A refrigerant-to-water heat exchanger
contains refrigerant in one passage and water in another passage. Water is
subject to freezing at 0°C (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
13.9°C (57°F), during the cooling mode, without the need for head pressure
control. If the EWT is expected to be lower than 13.9°C (57°F) or a more
stable operation is desired, a factory provided head pressure control water
valve option is available.
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.
65
Glycol solution must be used if ambient temperatures are expected to fall below freezing or if the loop entering water temperature to the unit is below 10°C (50°F) while operating in the heating mode (heat pump units only). Adding glycol to condenser water causes an increase in pressure drop and also results in a decrease in unit performance. A minimum concentration of 20% glycol solution is recommended.
Table 23 – Glycol Concentration Freezing
Points
% Glycol Ethylene Propylene
Glycol
Glycol
[°C (°F)] [°C (°F)]
0
0 (32)
0 (32)
20
-7.8 (18) -7.2 (19)
30
-13.9 (7) -12.8 (9)
40
-21.7 (-7) -21.1 (-6)
50
-33.3 (-28) -32.8 (-27)
Water loop piping that 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 1.7°C (35°F) for pure water systems or below the freezing point +(-16.1°C [3°F]) of the aqueous solution of water and glycol.
Water Piping Verify that a 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.
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 water piping. Supply water connection may require a backflow
preventer to prevent supply makeup water from backing up into the public water
system.
Table 24 – Condenser Water Connections
Model (RQ-)
Supply and Return Connection Size
002
3/4″ Sweat
003, 004, 005, 006
1″ Sweat
Note: 3/4″ = 19mm, 1″ = 25 mm
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.
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.
Condenser water pump must be field sized and installed between the cooling
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tower/geothermal loop 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.
CAUTION
WATER PIPING
Follow national and local codes when installing water piping. Connections to
the unit must 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.
Before connection to the unit the condenser water system must 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
must never be used as concentrated chemicals can cause corrosion. Never use
hydrochloric acid
(muriatic acid) or chlorine as it will corrode stainless steel.
CAUTION
Each heat exchanger is equipped with a refrigerant pressure relief device to
relieve pressure should excessive condensing pressures (>4.65 kpa [675 psig])
occur. Codes may require a qualified technician to connect and route relief
piping outdoors. The relief valve has a 16mm (5/8″) male flare outlet
connection.
NOTE: Ball valves must be installed in the condenser 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 condenser 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 1/2 pipe
diameter into the pipe.
CAUTION
A qualified technician 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.
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Piping systems must not exceed 3.1 m/s (10 ft/sec) fluid velocity to ensure
tube wall integrity and reduce noise.
Energy Recovery Units
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.
General Information AAONAIRE® units have been equipped with an energy recovery
wheel. This section is provided to assure the energy recovery feature will be
properly setup to perform in accordance with the job specifications for your
particular application.
1. Removable Segment (NA for monolith)
2. Permanent Tension Belt 3. Pulley 4. Embedded Segment Stiffeners (NA
for monolith) 5. Segment Retaining Latches (NA for
monolith) 6. Bearing Beam and Bearing Access
Cover Plate (Diameter Seals are behind Bearing Beam on both sides) 7.
Adjustable Purge 8. Motor
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Energy Recovery Wheel
The Energy Recovery Cassette consists of a frame wheel, wheel drive system,
and energy transfer segments. Segments are removable for cleaning or
replacement. The segments rotate through counter flowing exhaust and outdoor
air supply streams where they transfer heat and/or water vapor from the warm,
moist air stream to the cooler and/or drier air stream.
The initial setup and servicing of the energy recovery wheel is very important
to maintain proper operation efficiency and building occupant comfort.
Normal maintenance requires periodic inspection of filters, the cassette
wheel, drive belts, air seals, wheel drive motor, and its electrical
connections.
Wiring diagrams are provided with each motor. When wired according to wiring
diagram, energy recovery wheel rotates clockwise when viewed from the
shaft/pulley side.
By carefully reviewing the information within this section and following the
instructions, the risk of improper operation and/or component damage will be
minimized.
It is important that periodic maintenance be performed to help assure trouble
free operation.
Initial Mechanical Check and Setup Outdoor u