AAON M2 Series, Installation Operation & Maintenance

Page 1: ...mote from the building Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Startup and service must be performed by a Factory Trained Service Technician M2 Series 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 operatio...

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Page 3: ...ion for Storage 32 Direct Expansion DX Units 32 Gas or Electric Heating 34 Wiring Diagrams 34 Condensate Drain Pan 34 Installation 36 Locating Units 36 Lifting the Assembled Unit 37 Lifting the Individual Modules 40 Floor Mounted Units 40 Suspended Units 40 Module Assembly 41 Evaporator Coils 47 Hot Gas Reheat 47 Hot Gas Bypass 47 Refrigerant to Water Heat Exchanger 47 Open Loop Applications 48 Fr...

Page 4: ...p Procedure 75 Service 76 Startup 78 Filters 78 Check Out 78 Commissioning 80 Operation 80 Adjusting Refrigerant Charge 81 Refrigeration Troubleshooting 84 Maintenance 85 Fan Assembly 85 Bearings 85 Belts 86 Indoor Coils 87 Refrigeration Cycle 87 Brazed Plate Heat Exchanger Cleaning 87 E Coated Coil Cleaning 87 Electric Heating 89 Steam or Hot Water Heating 89 Cleaning 89 Chilled Water 89 DX Water...

Page 5: ...5 Split System Piping Diagrams 98 M2 Series Startup Form 115 Maintenance Log 121 ...

Page 6: ...ontrol Wiring 61 Table 12 Gas Inlet Pressure 62 Table 13 Gas Heater Troubleshooting 68 Table 14 Gas Heater Troubleshooting Continued 69 Table 15 Acceptable Air Cooled Refrigeration Circuit Values 82 Table 16 Acceptable Water Cooled Refrigeration Circuit Values 82 Table 17 R 410A Refrigerant Temperature Pressure Chart 83 Table 18 Refrigeration Problems Causes and Solutions 84 Table 19 Bearing Setsc...

Page 7: ...r Piping 49 Figure 22 Water Cooled Only Water Piping 50 Figure 23 Waterside Economizer Piping 52 Figure 24 Steam Distributing Piping 53 Figure 25 Hot Water Piping 53 Figure 26 Chill Water Piping 54 Figure 27 Draw Through Drain Trap 55 Figure 28 Blow Through Drain Trap 55 Figure 29 EC Motor Wiring Diagram for Controls by Others 56 Figure 30 Jumper for Remote Fan Speed Control 56 Figure 31 Potentiom...

Page 8: ... Figure 60 A C with Modulating Hot Gas Reheat and Hot Gas Bypass Split System Piping Suction Down 105 Figure 61 A C with Modulating Hot Gas Reheat and Hot Gas Bypass Split System Piping Suction Up 106 Figure 62 Heat Pump Split System Piping Suction Down 107 Figure 63 Heat Pump Split System Piping Suction Up 108 Figure 64 Heat Pump with Modulating Hot Gas Reheat Split System Piping Suction Down 109...

Page 9: ... with an open flame Use a gas detection soap solution and check all gas connections and shut off valves CAUTION Attention should be paid to the following statements NOTE Notes are intended to clarify the unit installation operation and maintenance CAUTION Caution statements are given to prevent actions that may result in equipment damage property damage or personal injury WARNING Warning statement...

Page 10: ...d marked for identification of where appropriate Personal Protective Equipment PPE be worn should be followed 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 qu...

Page 11: ...by a qualified service technician Scroll compressors are directional and can be damaged if rotated in the wrong direction Compressor rotation must be checked using suction and discharge gauges Fan motor rotation should be checked for proper operation Alterations should only be made at the unit power connection CAUTION WATER PRESSURE Prior to connection of condensing water supply verify water press...

Page 12: ...equiring tooled access If you do not replace the shipping hardware with a pad lock always re install the nut bolt after closing the door CAUTION Cleaning the cooling tower or the condenser water loop with harsh chemicals such as hydrochloric acid muriatic acid or chlorine can damage the water cooled condenser Care should be taken to avoid allowing chemicals to enter the water cooled condenser See ...

Page 13: ...CPVC Chlorinated Polyvinyl Chloride are vulnerable to attack by certain chemicals Polyolester POE oils used with R 410A and other refrigerants even in trace amounts in a PVC or CPVC piping system will result in stress cracking of the piping and fittings and complete piping system failure CAUTION Do not weld or cut foam panel with plasma cutters or a cutting torch When burnt the foam produces dange...

Page 14: ... 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 should be an L shaped duct 6 Clean furnace duct and components upon completion of the construction setup Verify furnace operating conditions including input rate temperature rise and ESP 7 Every unit has...

Page 15: ...odel feature string followed by a series of individual module feature strings The first three letters of the individual module model number identify the type of module fan filter coil etc The three numbers after the three letters indicate the position of the module in unit assembly If the module is on the bottom level the first number is 1 while the first number in the top level is 2 The last numb...

Page 16: ...Coil 13 000 19 200 cfm 036 36 ft2 Coil 14 500 21 600 cfm Supply Airflow L Left Hand R Right Hand Voltage 1 230V 1Φ 60Hz 2 230V 3Φ 60Hz 3 460V 3Φ 60Hz 4 575V 3Φ 60Hz 8 208V 3Φ 60Hz 9 208V 1Φ 60Hz Assembly A Factory Assembled B Individual Boxes Wiring 0 No Factory Wiring A Control Wiring in Fan Box B Control Wiring in Control Box Paint 0 None Standard A Indoor Unit with Exterior Corrosion Protection...

Page 17: ...0 hp N 25 hp P 30 hp Q 1 0 kW 1 3 hp S 1 7 kW 2 3 hp T 3 0 kW 4 0 hp U 5 4 kW 8 0 hp Blower A 15 Backward Curved Plenum B 18 Backward Curved Plenum C 22 Backward Curved Plenum D 27 Backward Curved Plenum E 30 Backward Curved Plenum F 33 Backward Curved Plenum G 37 Backward Curved Plenum H 24 Backward Curved Plenum J 15 BC Plenum 50 Width K 18 BC Plenum 30 Width L 2 x 18 Backward Curved Plenum M 2 ...

Page 18: ... Position of Module in Air Handling Unit Filter Type P Pleated C Cartridge Filters A0 2 Pleated 30 Eff B0 4 Pleated 30 Eff C0 4 Pleated 65 Eff or 12 Cartridge 65 Eff D0 4 Pleated 85 Eff or 12 Cartridge 85 Eff E0 4 Pleated 95 Eff or 12 Cartridge 95 Eff Safety Control 0 Standard 2 Firestat Blank 0000 Standard Second Filter Type 0 Standard None C Cartridge Second Filter 00 Standard None C0 12 Cartrid...

Page 19: ...I Horizontal Bottom Damper with Filter MBJ Vertical Horizontal Top Damper with Filter MBK Vertical Horizontal Bottom Damper with Filter Position Level and Position of Module in Air Handling Unit Actuator Type 0 Standard None A Two Position Actuator B DDC Actuator Filters 00 Standard None A0 2 Pleated 30 Eff B0 4 Pleated 30 Eff C0 4 Pleated 65 Eff D0 4 Pleated 85 Eff E0 4 Pleated 95 Eff Safety Cont...

Page 20: ... Per Inch 12 12 Fins Per Inch Circuiting 0 No Hot Water Heating F Single Serpentine H Half Serpentine Q Quarter Serpentine Coating 0 Standard H Stainless Steel Coil Casing Copper Fins P Polymer E Coating S Stainless Steel Coil Casing K Stainless Steel Coil Casing Polymer E Coating Heat Capacity 0 Hot Water Heating Coil 1 150 MBH input 2 75 MBH input 3 100 MBH input 4 125 MBH input 5 150 MBH input ...

Page 21: ...0 Hot Water Heating Coil 01 1 Stage 02 2 Stage 03 3 Stage 04 4 Stage 0M Modulating 5 1 Stage Natural Gas Modulating 3 1 Stage LP Gas Fuel Gas 0 Natural Gas Hot Water Electric Heat A LP Gas Combustion Intake 0 Open Combustion Hot Water Electric Heat A Separated Combustion Filter Options 0 Standard A Magnehelic Gauge B Clogged Filter Switch C Options A B Special 0 None X Special Pricing Authorizatio...

Page 22: ...n Pan CBB Medium with Drain Pan CBC Large with Drain Pan CBD XL with Drain Pan CBE XXL with Drain Pan CBF XXXL with Drain Pan CBG Extended Large with Drain Pan Position Level and Position of Module in Air Handling Unit Blank 0 Standard Airway Type 00 Standard AR Top Open Right Hand End Panel AL Top Open Left Hand End Panel Safety Control 0 None 2 Firestat Blank 0000 Standard Bypass Opening 0 None ...

Page 23: ...Water F DX R 410A G HGB Lead H Heat Pump J HGB Lead Heat Pump K HGB Lead HGB Lag Heat Pump L HGBNV Heat Pump ELECTRIC HEAT Capacity 0 No Electric Heat A 7 kW 5 3 kW B 14 kW 10 5 kW C 21 kW 15 8 kW D 28 kW 21 0 kW H 35 kW 26 3 kW E 42 kW 35 0 kW F 56 kW 42 0 kW G 70 kW 52 5 kW J 84 kW 63 1 kW K 112 kW 84 1 kW L 126 kW 94 6 kW M 168 kW 126 2 kW Stages 0 Standard None 1 1 Stage 2 2 Stage 3 3 Stage 4 ...

Page 24: ... SPECIAL CLC 103 F 0 0 0 00 0 0 6 10 I P S 0 24 Circuiting 0 No Cooling Coil D Double Serpentine F Single Serpentine H Half Serpentine Q Quarter Serpentine S DX Single Circuit I DX Dual Circuit Interlaced Coating 0 Standard P Polymer E Coating S Stainless Steel Coil Casing H Stainless Steel Coil Casing Copper Fins K Stainless Steel Coil Casing Polymer E Coating Drain Pan 0 No Drain Pan S Stainless...

Page 25: ...trols Module Description CONTROLS MODULE DESCRIPTION Module ID TRA Small TRB Medium TRC Large TRD XL TRE XXL TRF XXXL Position Level and Position of Module in Air Handling Unit Blank 0 Standard Blank 00 Standard Safety Control 0 Standard 2 Firestat Blank 0000 Standard Blank 00000 Standard Blank 0 Standard Special 0 None X Special Pricing Authorization ...

Page 26: ...DESCRIPTION Module ID HRA AAONAIRE Energy Recovery Wheel Position Level and Position of Module in Air Handling Unit Wheel Size A Standard Recovery Type 00 Total Energy Recovery 0A Total Energy Recovery 1 Purge A0 Sensible Only Energy Recovery AA Sensible Only Energy Recovery 1 Purge Blank 00000 Standard Blank 00000 Standard VFD Control 0 Standard A VFD Controlled Wheel Special 0 None X Special Pri...

Page 27: ...y Scroll Compressor E R 410A Tandem Scroll Compressor G R 410A Tandem Variable Capacity Scroll Compressor Staging G 1 On Off Refrigeration System H 1 Variable Capacity Refrigeration System J 2 On Off Refrigeration Systems K Lead Variable Capacity Refrigeration System Lag On Off Refrigeration System L 2 Variable Capacity Refrigeration Systems Blank 000 Standard Refrigeration Options 0 Standard A Ho...

Page 28: ...MP STAGING BLANK REFRIG OPTIONS REFRIG ACCESS BLANK WATER SIDE HEAT EXCHANGER BLANK SPECIAL WHP 204 A 25 D K 000 D A 0 H 0 0 0 28 Heat Exchanger Type 0 Standard A SMO 254 Brazed Plate Heat Exchanger B Cupronickel Coaxial Heat Exchanger Blank 0 Standard Special 0 None X Special Pricing Authorization ...

Page 29: ...nections Figure 2 Unit Orientation Consider the airflow to be hitting the back of your head M2 Series Top View Return Air Back Supply Air Front Left Hand Side Right Hand Side Connections service access on left side for left hand orientation AIRFLOW Filter Coil Supply Fan ...

Page 30: ...ied as a commercial central air conditioner b Certified for indoor installation Improper installation adjustment alteration service or maintenance can cause property damage personal injury or loss of life Startup and service must be performed by a Factory Trained Service Technician A copy of this IOM should be kept with the unit WARNING These units must not be used as a construction heater at any ...

Page 31: ...n the carrier s freight bill A request for inspection by carrier s agent should be made in writing at once Nameplate should be checked to ensure the correct model sizes and voltages have been received to match the job requirements If repairs must be made to damaged goods then the factory should be notified before any repair action is taken in order to protect the warranty Certain equipment alterat...

Page 32: ...To prevent surface rust and discoloration spray all bare metal parts with a rust preventive compound Cabinet Sections Once a month open a door on each section and verify that no moisture or debris is accumulating in the unit Control Compartment It is recommended that any electronic control equipment in the unit be stored in a 5 to 95 RH non condensing environment It may be necessary to put a heat ...

Page 33: ...down of the unit During the cooling season if the air flow is reduced due to dirty air filters or any other reason the cooling coils can get too cold which will cause excessive liquid to return to the compressor As the liquid 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 pu...

Page 34: ...llation to obtain an air temperature rise within the range specified on the unit rating plate at the required external static pressure Should overheating occur with a gas heat exchanger or the gas supply fail to shut off shut off the manual gas valve to the furnace before shutting off the electrical supply Prolonged overheating of the heat exchanger will shorten its life If unit has not been selec...

Page 35: ...35 Table 1 Electric and Gas Heating Capacities ...

Page 36: ...ions For gas fired unit do not position flue opening to discharge into a fresh air intake of any other piece of equipment Unit should also be installed so that the flow of combustion intake air is not obstructed from reaching the furnace Flue gas is dangerously hot and contains containments The user is responsible for determining if vent gases may degrade building materials The National Gas and Pr...

Page 37: ...a spreader bar assembly Refer to the M2 Series Unit Four Point Lifting Figure and the M2 Series Unit Eight Point Lifting Figure If cables or chains are used to hoist the unit they must be the same length Care should be taken to prevent damage to the cabinet coils and condenser fans Before lifting unit be sure that all shipping material has been removed from unit UNIT HANDLING To prevent injury or ...

Page 38: ...38 Figure 5 M2 Series Unit Four Point Lifting ...

Page 39: ...39 Figure 6 M2 Series Unit Eight Point Lifting ...

Page 40: ...n be shorter Other installation provisions may be necessary according to job specifications Suspended Units Some M2 Series units can be suspended Only single path units of size M2 005 to M2 014 can be suspended A ceiling suspended mounting frame must be provided for unit suspension It is the responsibility of the engineer or installing contractor to design and build a suitable structure based on t...

Page 41: ...ble to the order in which they will be connected Be sure to leave enough space to work between modules before connection Identify each module by the configuration number on its label For example if a module has a configuration number of FTF 101 P A0 00000 00000 0 0 then it is a large flat filter module FTF and should be placed in the first position 101 of the lower tier the bottom left as you face...

Page 42: ...en without knowing the module type and without a configuration schematic If for any reason a module or its position in final assembly is unidentifiable then consult the project engineer AAON sales representative or AAON Longview Product Support After identifying modules and determining module arrangement modules can be prepared for final assembly ...

Page 43: ...F0 610F0 S 0 SFA 104 K C0 A0000 00000 0 0 PEC 201 K BI A0000 00000 0 0 FTE 203 P B0 00000 00000 0 0 HRA PEC FTE CLF FTF SFA Table provides required service access clearances for applicable modules 203 104 201 101 102 103 Arrows indicate airflow Base model number Module configuration numbers Note Energy recovery wheel module will have a 100 series number but will span both tiers also utilizing a 20...

Page 44: ...to secure module joints in order to maintain the airtight seal Straps are provided with pre drilled holes and adhesive backing already affixed Self tapping sheet metal screws are provided to attach the straps to the unit cabinet Leave bar clamps in place until strap is secure Peel away backing from adhesive side of a strap Place the strap over a module joint with the adhesive side of the strap aga...

Page 45: ... unit Figure 18 Power and Control Wiring The control wiring uses quick connects so a female quick connect from one module will connect to a male quick connect from the adjacent module Some modules will have two sets of connection so make sure the correct wire colors match up from one quick connect to the other Figure 19 Quick Connects Side Strap Angle Strap Top Strap Top Strap Angle Strap Angle St...

Page 46: ...units are equipped with a single point power connection 5 Final Sealing It is very important to keep air from infiltrating the unit cabinet Seal all piping penetrations with Armaflex Permagum or other suitable sealant Also seal around drain connections electrical connections and all other inlets where air may enter the cabinet This is especially important when the unit is installed in an unconditi...

Page 47: ...the upper stub out connection of the reheat coil in the air handling unit The line delivers the hot discharge gas to the reheat coil and or the hot gas bypass valve so it is sized as a discharge line Hot Gas Bypass Hot Gas Bypass HGB is available for use with DX systems that may experience low suction pressure during the operating cycle This may be due to varying load conditions associated with VA...

Page 48: ...heat exchanger manufacturer warranties Freezing Water in the Heat Exchanger This product contains one or more refrigerant to water heat exchangers A refrigerant to water heat exchanger contains refrigerant in one passage and water in another passage Water is subject to freezing at 32 F When water freezes in a heat exchanger significant forces are exerted on the components of the heat exchanger whe...

Page 49: ...mp units are built with a water flow switch Some water cooled units may not have a water flow switch This sensor provides a signal to the unit controller that water flow is present in the heat exchanger and the compressors can operate without damaging unit components Installing contractor must ensure a differential pressure switch is installed between the condenser water supply and return connecti...

Page 50: ...to maintain equal distances for supply and return piping and limit bend radiuses to maintain balance in the system Balancing valves permanent thermometers and gauges may be required 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 r...

Page 51: ...ter regulating valve may be used Glycol solution should be used if ambient temperatures are expected to fall below freezing or if the loop water temperature is below 50 F while operating in the heating mode heat pump units only Adding glycol to condenser water causes an increase in pressure drop resulting in a decrease in unit performance A minimum concentration of 20 glycol solution is recommende...

Page 52: ... additional p trap and drain information Figure 23 Waterside Economizer Piping The waterside economizer circuit can operate in three modes waterside economizer only waterside economizer with mechanical cooling and mechanical cooling only During waterside economizer only mode of operation condenser water flows through the waterside economizer coil with modulating valves maintaining supply air tempe...

Page 53: ...supplied from a building hot water source The hot water coil is not connected to the water source condenser piping All controls for heating operation are field supplied and field installed Always connect the steam heating supply to the top of the coil and the return to the bottom Figure 24 Steam Distributing Piping Table 6 Steam Distributing Coil Connection Sizes Model M2 Supply and Return Connect...

Page 54: ... specifications Condensate Drain Piping Unit may be equipped with more than one condensate drain pan connection A p trap and drain line must be installed on every drain connection with the p trap not to exceed 6 from the drain connection The lines should be the same pipe size or larger than the drain connection include a p trap and pitch downward toward drain An air break should be used with long ...

Page 55: ... 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 ...

Page 56: ...he air volume specified according to unit size and or job requirements This is done with air volume bands in the blower wheels with variable frequency drives with electrically commutated motors or with belt drive blowers Field airflow adjustment is required at startup Electrically Commutated Motor ECM Air Adjustment One blower option is ECM blowers These blowers can read a 0 10V signal for modulat...

Page 57: ...r band but additional air delivery is needed the band can be removed from the wheel The air band is sized according to the air delivery specifications and can be ordered from the factory for field installation The related photos of the wheel are provided for practical guidelines only in order to identify the air band location in the wheel Actual field installation of the air band into the wheel wi...

Page 58: ...58 Figure 32 Supply Fan Banding ...

Page 59: ...ck is provided Split units may require connection between the units High voltage conductors should enter the control panel in a separate opening and separate conduit than 24V low voltage conductors Note Locations for field cut electrical entries are marked on the unit Field cut openings must be a minimum of 6 inches away from all components and wiring to prevent damage due to drilling or cutting T...

Page 60: ...uld not exceed the SCCR rating shown on the unit nameplate Three phase voltage imbalance will cause motor overheating and premature failure The maximum allowable imbalance is 5 Voltage imbalance is defined as 100 times the sum of the deviation of the three voltages from the average divided by the average voltage Example 218V 237V 235V 3 230V then 100 230V 218V 230V 5 2 which exceeds the allowable ...

Page 61: ...tity of Control Wires x Control Wire Distance Take the total wire distance allowable and divide by the number of wires to be connected This indicates the distance allowable for that size wire The wiring to the unit must not exceed the total wire distance allowable If the voltage at the connectors is less than 21 VAC isolation relays must be installed If under external control 21 VAC must be field ...

Page 62: ...the atmosphere or can be mixed with combustion air entering heater Gas Supply Piping and Connections Gas piping must be installed in accordance with local codes or in the absence of local code 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 1 Gas piping must be sized...

Page 63: ...without any difference in system performance 2 Typically no condensate drain attachment is necessary in Heat only applications Condensation should not occur during heating cycle However in applications operating at low temperature rise or with 50 or more outside air condensation may occur early in the heating cycle In these applications connection of a condensate drain line is recommended to avoid...

Page 64: ...in the flue collector box and it is recommended that a drain tube be connected to the lower condensate drain fitting as well Gas Valve Figure 36 Gas Valve Input The correct heat capacity of the furnace is controlled by the burner orifices and the gas manifold pressure The manifold pressure is factory set but should be checked at the time of start up Operating and Safety Instructions 1 This duct fu...

Page 65: ... systems manifold pressure should be 1 2 w c Adjust Lo Regulator on 2 stage gas valve if necessary The controls are design to hold operation at this pressure for 2 minutes After that time manifold pressure should increase to 3 5 w c 10 0 wc for LP gas within 30 to 45 seconds For On Off units the manifold pressure should be 3 5 w c 10 0 wc for LP gas Failure to Ignite 1 For the initial start up or ...

Page 66: ...w flames or flames that appear lazy indicate poor air supply to burners or excessive burner input Verify gas supply type and manifold pressure with rating plate 3 Poor air supply can be caused by obstructions or blockage in heat exchanger tubes or vent discharge pipe Inspect and clean as necessary by to eliminate blockage Vacuum any dirt or loose debris found in the tubes or vents Clean heat excha...

Page 67: ...tmosphere If sufficient negative pressure is not present indicating lack of proper air movement through heat exchanger the switch opens shutting off gas supply though the ignition control module On units with two speed draft inducer operation a dual air pressure switch is used monitoring high and low speed pressures The air pressure switches have fixed settings and are not adjustable Rollout Switc...

Page 68: ...ºF Inspect for debris accumulation proper wheel attachment and proper voltage to blower Steady On Internal Control Fault No Operation 24VAC across Terminal 24VAC V2 Gnd when Thermostat calling for heat Control fault Replace ignition control 1 Flash Combustion Air Flow Fault Pressure switch contacts in closed position for 30 seconds with no output to Combustion blower Remains in this mode with comb...

Page 69: ...nition re trials before lockout 1 Verify gas supply available and operation of gas valve manifold pressure at start of ignition cycle Check for power to valve terminals LO COM while spark is energized 2 Is spark present If not check igniter for debris between electrodes cracked ceramic and check ignition wire for short to ground 3 Check flame sensor wiring connections to electrode and control and ...

Page 70: ...Exchanger for cracks If any are present replace heat exchanger before putting unit back into service 4 Check the attachment point of the duct furnace to the cabinet or ducts to verify that they are air tight 5 Check the automatic gas valve to insure that the gas valve seat is not leaking Disconnect all electrical power sources before servicing the unit More than one power source may be provided Fa...

Page 71: ...vicing 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 motor rotates clockwise when viewed from th...

Page 72: ...l is rotated by hand Confirm that the wheel rotates freely Apply power to the unit and confirm rotation Airflow Balancing and Checking High performance systems commonly have complex air distribution and fan systems Unqualified personnel should not attempt to adjust fan operation or air circulation as all systems have unique operations characteristics Professional air balance specialists should be ...

Page 73: ... so as to reduce airflow In a reasonably clean indoor environment such as a school or office building measurable reductions of airflow or loss of sensible temperature effectiveness may not occur for several years Measurable changes in latent energy water vapor transfer can occur in shorter periods of time in applications such as moderate occupant smoking or cooking facilities In applications exper...

Page 74: ...e drive belt annually for proper tracking and tension A properly tensioned belt will turn the wheel immediately after power is applied with no visible slippage during start up Installation Considerations Energy recovery cassettes are incorporated within the design of packaged units packaged air handlers and energy recovery ventilators In each case it is recommended that the following consideration...

Page 75: ... off and inspect for excessive interference between the wheel surface and each of the four 4 diameter seals To correct loosen diameter seal adjusting screws and back adjustable diameter seals away from surface of wheel apply power to confirm wheel is free to rotate then re adjust and tighten hub and diameter seals as shown in hub seal adjustment diagram 5 Start and stop wheel several times to conf...

Page 76: ...im and outer corners of the segment and apply downward force while guiding the segment into place 4 Close and latch each Segment Retainer under Segment Retaining Catch 5 Slowly rotate the wheel 180º Install the second segment opposite the first for counterbalance Rotate the two installed segments 90º to balance the wheel while the third segment is installed Rotate the wheel 180º again to install t...

Page 77: ...re belt down Note Slight hand pressure against wheel rim will lift weight of wheel from inner race of bearing to assist bearing removal and installation 5 Loop the trailing end of the belt over the shaft belt is partially through the opening 6 Reinstall the bearing onto the wheel shaft being careful to engage the two locating pins into the holes in the bearing support beam Secure the bearing with ...

Page 78: ...nections to be sure they are tight 2 Open all access panels and remove all shipping screws or restraints 3 Clean out any debris that may have been left 4 Check belt alignment and tightness of fan drives 5 Check bearing locking collars and fan wheel set screws for tightness 6 Turn fan wheels to assure free rotation 7 Ensure electrical supply matches the unit nameplate 8 Ensure condensate lines are ...

Page 79: ...d equipment is properly installed and mounted Improperly installed equipment or ductwork can affect readings 2 Perform condenser start up checks in addition to these air handler checks according to the condenser manufacturer s instructions 3 Ensure there is no construction debris in the unit 4 Check the unit for external damage 5 Note all accessories installed 6 Ensure that drain P trap is properl...

Page 80: ...g or configuration of controls and operational sequences Air Balancing High performance systems commonly have complex air distribution and fan systems Unqualified personnel should not attempt to adjust fan operation or air circulation as all systems have unique operating characteristics Professional air balance specialists should be employed to establish actual operating conditions and to configur...

Page 81: ...s it leaves the condenser Read the gauge pressure at the liquid line close to the point where the temperature was taken Use liquid line pressure as it will vary from discharge pressure due to condenser pressure drop Convert the pressure obtained to a saturated temperature using the appropriate refrigerant temperature pressure chart Subtract the measured liquid line temperature from the saturated t...

Page 82: ... The system is undercharged if the superheat is too high and the sub cooling is too low Correct an undercharged system by adding refrigerant to the system to reduce superheat and raise sub cooling If the sub cooling is correct and the superheat is too high the TXV may need adjustment to correct the superheat Before adjusting the TXV verity the sensing bulb is in the correct position according to F...

Page 83: ...0 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 ...

Page 84: ...element Replace filter drier Compressor starts but opens high pressure control Refrigerant over charged Air in condenser coil Condenser fan faulty Condenser coil dirty Remove some refrigerant Evacuate and recharge refrigerant Replace fan motor Clean condenser coil High suction pressure but low superheat Oversized expansion valve Poor sensing bulb location Low superheat adjustment Replace with corr...

Page 85: ...g Check heating section every Fall Check all electrical connections for tightness and check heater elements for indications of overheating Fan Assembly M2 Series units use backward curved fan wheels which are non overloading energy efficient and easy to clean Cleaning the wheels is necessary to reduce electrical use maintain capacity and reduce stress on the unit The wheel and fan section need to ...

Page 86: ... misalignment and 1 10th of an inch per foot between sheave centers for parallel misalignment Figure 49 Angular Misalignment Correct by moving the position of the motor Figure 50 Parallel Misalignment Correct by adjusting sheaves on one or both shafts Frequent belt tensioning is highly recommended Most belt manufacturers would suggest a re tensioning after as little as 8 hours of operation A simpl...

Page 87: ...hould be a minimum of 1 5 times the normal flow rate preferably in a back flush mode After cleaning the heat exchanger must be rinsed with clean water A solution of 1 2 sodium hydroxide NaOH or sodium bicarbonate NaHCO before the last rinse ensures that all acid is neutralized E Coated Coil Cleaning Documented routine cleaning of e coated coils is required to maintain coating warranty coverage Sur...

Page 88: ...ease 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 Apply CHLOR RID DTS Apply directly onto the substrate Sufficient product must be applied uniformly across the substrate to thoroughly wet out surface with no areas missed This may be accomplished by use of a pump up sprayer or conventional s...

Page 89: ...should be done only by a qualified service technician Duct Furnace The duct furnace should be inspected annually by a qualified service agency The condition of the burners heat exchanger draft inducer vent system operating controls and wiring should be determined Check for obvious signs of deterioration accumulation of dirt and debris and any heat or water related damage Any damaged or deteriorate...

Page 90: ...ced in both commercial heating and air conditioning should be permitted to service the systems in order to keep warranties in effect The service tech may call the factory if assistance is required Replacement Parts Parts for AAON equipment may be obtained from your local AAON representative When ordering parts reference the unit serial number and part number AAON Longview Product Support 203 Gum S...

Page 91: ...r the restart time delay All settings and the last 4 faults are retained even if there is a complete loss of power DPM Setup Procedure With the supply voltage active to the module you can setup all of the DPM s settings without the line voltage connected To change the setpoint parameters use the right arrow key to advance forward through the setpoint parameters and the left arrow to backup if need...

Page 92: ...ime Delay Screen Vertical Format Default 2 sec Manual 2S 3S 4S 5S 6S 7S 8S 9S 10S 30S 1M 2M 3M 4M Phase Imbalance Percentage Screen Vertical Format Default 5 3 4 5 6 7 8 9 10 Fault Screen Vertical Format 0 most recent faults 1 previous fault 2 third oldest fault 3 fourth oldest fault Fault Words Phase a Loss There is no voltage sensed on 3 L1 S Voltage Low Average line voltage is less than selecte...

Page 93: ... Filter Type Quantity Size M2 005 M2 008 2 Pleated 30 Eff MERV 8 2 20 x 20 4 16 x 20 4 Pleated 30 Eff MERV 8 65 Eff MERV 11 85 Eff MERV 13 or 95 Eff MERV 14 12 Cartridge 65 Eff MERV 11 85 Eff MERV 13 or 95 Eff MERV 14 Table 22 M2 011 and M2 014 Filters Filter Type Quantity Size M2 011 M2 014 2 Pleated 30 Eff MERV 8 2 16 x 20 and 4 20 x 20 4 Pleated 30 Eff MERV 8 65 Eff MERV 11 85 Eff MERV 13 or 95...

Page 94: ... 026 Filters Filter Type Quantity Size M2 026 2 Pleated 30 Eff MERV 8 4 16 x 20 8 20 x 20 4 Pleated 30 Eff MERV 8 65 Eff MERV 11 85 Eff MERV 13 or 95 Eff MERV 14 12 Cartridge 65 Eff MERV 11 85 Eff MERV 13 or 95 Eff MERV 14 Table 25 M2 032 and M2 036 Filters Filter Type Quantity Size M2 032 M2 036 2 Pleated 30 Eff MERV 8 6 16 x 20 and 9 20 x 20 4 Pleated 30 Eff MERV 8 65 Eff MERV 11 85 Eff MERV 13 ...

Page 95: ...95 Figure 52 Filter Layout Viewed from the Upstream Side of the Cooling Coil ...

Page 96: ...orrosion problems may occur especially when more factors are valued 0 Use is not recommended Water Containing Concentration mg l or ppm Time Limits Analyze Before AISI 316 SMO 254 Copper Alloy Nickel Alloy Alkalinity HCO3 70 Within 24 Hours 0 70 300 300 0 Sulfate SO4 2 70 No Limit 70 300 0 300 0 0 HCO3 SO4 2 1 0 No Limit 1 0 0 Electrical Conductivity 10µS cm No Limit 0 10 500 µS cm 500 µS cm 0 pH ...

Page 97: ...it 0 2 0 Manganese Mn 0 1 No Limit 0 1 0 Chloride Content Chloride Content Maximum Temperature 60 C 140 F 80 C 176 F 120 C 248 F 130 C 266 F 10 ppm SS 304 SS 304 SS 304 SS 316 25 ppm SS 304 SS 304 SS 316 SS 316 50 ppm SS 304 SS 316 SS 316 Ti SMO 254 80 ppm SS 316 SS 316 SS 316 Ti SMO 254 150 ppm SS 316 SS 316 Ti SMO 254 Ti SMO 254 300 ppm SS 316 Ti SMO 254 Ti SMO 254 Ti SMO 254 300 ppm Ti SMO 254 ...

Page 98: ...98 Split System Piping Diagrams Figure 53 A C Split System Piping Suction Down ...

Page 99: ...99 Figure 54 A C Split System Piping Suction Up ...

Page 100: ...100 Figure 55 A C with LAC Split System Piping Suction Up ...

Page 101: ...101 Figure 56 A C with Modulating Hot Gas Reheat Split System Piping Suction Down ...

Page 102: ...102 Figure 57 A C with Modulating Hot Gas Reheat Split System Piping Suction Up ...

Page 103: ...103 Figure 58 A C with Hot Gas Bypass Split System Piping Suction Down ...

Page 104: ...104 Figure 59 A C with Hot Gas Bypass Split System Piping Suction Up ...

Page 105: ...105 Figure 60 A C with Modulating Hot Gas Reheat and Hot Gas Bypass Split System Piping Suction Down ...

Page 106: ...106 Figure 61 A C with Modulating Hot Gas Reheat and Hot Gas Bypass Split System Piping Suction Up ...

Page 107: ...107 Figure 62 Heat Pump Split System Piping Suction Down ...

Page 108: ...108 Figure 63 Heat Pump Split System Piping Suction Up ...

Page 109: ...109 Figure 64 Heat Pump with Modulating Hot Gas Reheat Split System Piping Suction Down ...

Page 110: ...110 Figure 65 Heat Pump with Modulating Hot Gas Reheat Split System Piping Suction Up ...

Page 111: ...111 Figure 66 Heat Pump with Hot Gas Bypass Split System Piping Suction Down ...

Page 112: ...112 Figure 67 Heat Pump with Hot Gas Bypass Split System Piping Suction Up ...

Page 113: ...113 Figure 68 Heat Pump with Modulating Hot Gas Reheat and Hot Gas Bypass Split System Piping Suction Down ...

Page 114: ...114 Figure 69 Heat Pump with Modulating Hot Gas Reheat and Hot Gas Bypass Split System Piping Suction Up ...

Page 115: ...learances adequate for service and operation Yes No 4 Do all access doors open freely and are the handles operational Yes No 5 Have all shipping braces been removed Yes No 6 Have all electrical connections been tested for tightness Yes No 7 Does the electrical service correspond to the unit nameplate Yes No 8 On 208 230V units has transformer tap been checked Yes No 9 Has overcurrent protection be...

Page 116: ... Operating Correctly Energy Recovery Wheel Assembly Wheels Spin Freely Check Rotation FLA ________ Number hp L1 L2 L3 1 2 Power Exhaust Fan Assembly Alignment Check Rotation Nameplate Amps________ Number hp L1 L2 L3 1 2 Band Size_____________________ VFD Frequency________________ Springs Operating Correctly Power Return Fan Assembly Alignment Check Rotation Nameplate Amps________ Number hp L1 L2 L...

Page 117: ...n _______________________________________ Unit Configuration Water Cooled Condenser Air Cooled Condenser No Water Leaks Condenser Safety Check Water Flow ________ gpm Water Inlet Temperature ________ F Water Outlet Temperature ________ F Compressors DX Cooling Check Rotation Number L1 L2 L3 Head Pressure PSIG Suction Pressure PSIG Crankcase Heater Amps 1 2 3 4 Refrigeration System 1 Cooling Mode P...

Page 118: ... Line Temperature Sub cooling Superheat Discharge N A N A Suction N A Liquid N A Refrigeration System 1 Heating Mode Heat Pump Only Pressure Saturated Temperature Line Temperature Sub cooling Superheat Discharge N A N A Suction N A Liquid N A Refrigeration System 2 Heating Mode Heat Pump Only Pressure Saturated Temperature Line Temperature Sub cooling Superheat Discharge N A N A Suction N A Liquid...

Page 119: ...ssure checked Yes No 2 Has the entire system been filled with fluid Yes No 3 Has air been bled from the heat exchangers and piping Yes No 4 Is the glycol the proper type and concentration N A if water Yes No 5 Is there a minimum load of 50 of the design load Yes No 6 Has the water piping been insulated Yes No 7 What is the freeze point of the glycol N A if water ______________________________ Gas ...

Page 120: ... Lockout Aux Limit Lockout Stage Amps Stage Amps 1 5 2 6 3 7 4 8 Electric Preheating Limit Lockout Aux Limit Lockout Outside Air Temperature Setpoint__________ F Preheat Leaving Air Temperature Setpoint__________ F Stage Amps Stage Amps 1 3 2 4 ...

Page 121: ...document any service repair or adjustments AAON Service and Warranty Departments are available to advise and provide phone help for proper operation and replacement parts The responsibility for proper startup maintenance and servicing of the equipment falls to the owner and qualified licensed technician Entry Date Action Taken Name Tel ...

Page 122: ...Hot Gas Reheat and Modulating Hot Gas Reheat with Hot Gas Bypass piping diagrams to show the liquid line tee connection factory installed adding the Heat Pump with Field Installed Modulating Hot Gas Reheat Split System Piping Diagram and updating the table of contents November 2013 Updated factory trained technician verbiage updated individual module installation instructions updated split system ...

Page 123: ...bles Added ECM blower information in installation section Added Gas Heating Section Procedures to the start up section Added brazed plate cleaning DX cooling condensate drain pans and duct furnace sections under the Maintenance section Updated filter information for size 32 36 Added suction up flow piping diagrams August 2016 Changed pressure to 100psig for cleaning e coated coils Added heat pump ...

Page 124: ...52 It is the intent of AAON to provide accurate and current product information However in the interest of product improvement AAON reserves the right to change pricing specifications and or design of its product without notice obligation or liability Copyright AAON all rights reserved throughout the world AAON and AAONAIRE are registered trademarks of AAON Inc Tulsa OK ...