AAON RZ Series, Installation Operation & Maintenance

Page 1: ... 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 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 ...

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Page 3: ...Rain Hood 36 End Flashing Installation 36 Vestibule Exhaust Fan 37 Electrical 38 Variable Speed Compressors 40 Condensate Drain Piping 41 Draw Through Coils 41 Startup 43 Filters 43 Cartridge Filter Installation 43 HEPA Filters 43 Metal Mesh Filters 43 Air Flow Monitoring 44 Supply Return and Exhaust Backward Curved Fans 44 Airflow Adjustment 44 Back Draft Damper Setup 46 Adjusting Refrigerant Cha...

Page 4: ...0 Evaporator Coil 61 Condenser Fans 62 Evaporative Condenser 62 Evaporative Condenser Location 63 Evaporative Condenser Installation 64 Evaporative Condenser Operation 64 Evaporative Condenser Sequence of Operation 66 Evaporative Condenser Maintenance 67 Evaporative Condenser Water Quality 69 Energy Recovery Units 71 Aluminum Energy Recovery Wheel 71 Polymer Energy Recovery Wheel 74 Energy Recover...

Page 5: ...emperatures 48 Table 10 Acceptable Microchannel Air Cooled Condenser Coil Liquid Sub Cooling Values 48 Table 11 R 410A Refrigerant Temperature Pressure Chart 50 Table 12 Filter Drier Maximum Pressure Drop 50 Table 13 EC Condenser Fan Cycling Options 52 Table 14 Hot Water Coil Connection Sizes 59 Table 15 Steam Distributing Coil Connection Sizes 59 Table 16 Chilled Water Coil Connection Sizes 60 Ta...

Page 6: ...igure 19 Top Clip and Side Spring Fastener Securing Filters in Place 43 Figure 20 Air Volume Band 44 Figure 21 Air Volume Band Tab Locations 45 Figure 22 Securing Air Volume Band Ends 45 Figure 23 Plenum Fan Gap Tolerances 45 Figure 24 Closed Back Draft Damper 46 Figure 25 Open Back Draft Damper 46 Figure 26 Replaceable Core Liquid Filter Driers Suction Filter 51 Figure 27 RPE 48 BD filter element...

Page 7: ...rgy Recovery Wheels Modulating Hot Gas Reheat Safety Burglar Bars Freeze Stats Phase and Brown Out Protection Supply Return Smoke Detectors Supply Return Firestats Remote Safety Shutdown Terminals Installation and Maintenance Clogged Filter Switch Color Coded Wiring Diagram Compressors in Isolated Compartment Compressor Isolation Valves Convenience Outlet Direct Drive Supply Fans VFD Shaft Groundi...

Page 8: ...as detection soap solution and check all gas connections and shut off valves CAUTION Electric shock hazard Shut off all electrical power to the unit to avoid shock hazard or injury from rotating parts WARNING 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 t...

Page 9: ...undary to be field established and marked for identification of where appropriate Personal Protective Equipment PPE be worn must be followed WARNING ROTATING COMPONENTS Unit contains fans with moving parts that can cause serious injury Do not open door containing fans until the power to the unit has been disconnected and fan wheel has stopped rotating WARNING CARBON MONOXIDE POISONING HAZARD Failu...

Page 10: ... electric motors FLA rating as shown on the motor nameplate CAUTION UNIT HANDLING To prevent injury or death lifting equipment capacity must exceed unit weight by an adequate safety factor Always test lift unit not more than 24 inches high to verify proper center of gravity lift point to avoid unit damage injury or death WARNING Failure to properly drain and vent coils when not in use during freez...

Page 11: ...ith a pH value greater than 8 5 after mixing without first using an aluminum corrosion inhibitor in the cleaning solution CAUTION Some chemical coil cleaning compounds are caustic or toxic Use these substances only in accordance with the manufacturer s usage instructions Failure to follow instructions may result in equipment damage injury or death WARNING Door compartments containing hazardous vol...

Page 12: ...hemical corrosion is excluded from coverage under AAON Inc warranties and the heat exchanger manufacturer s warranties WARNING 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 ex...

Page 13: ... 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...

Page 14: ...ty 220 220 ton Capacity 241 241 ton Capacity 240 240 ton Capacity 261 261 ton Capacity SERIES Air Cooled A 45 75 ton units B 90 105 ton units C 120 140 ton units D 145 180 ton units E 200 240 ton units EvaporativeCondenser A 51 79 ton units B 101 109 ton units C 124 148 ton units D 161 197 ton units E 221 261 ton units MINOR REVISION 0 VOLTAGE 2 230V 3 Φ 60Hz 3 460V 3 Φ 60Hz 4 575V 3 Φ 60Hz 8 208V...

Page 15: ... HEAT TYPE 0 No Heat B Electric Heat D NaturalGas Single Rack E NaturalGas Double Rack G LP Gas Single Rack H LP Gas Double Rack K Hot WaterCoil M SteamDistributingCoil B2 HEAT CONSTRUCTION 0 Standard B StainlessSteelHeat Exchanger D High Altitude StainlessSteelHeat Exchanger G PolymerE Coated Heating Coil B3 HEAT DESIGNATION 0 No Heat 1 Heat 1 2 Heat 2 3 Heat 3 4 Heat 4 5 Heat 5 6 Heat 6 7 Heat 7...

Page 16: ...lk in Vestibule Left Access V Blow Through SA Fan Non compressorized Walk in Vestibule Right Access 2 SUPPLY RETURN LOCATIONS 0 BottomSupply BottomReturn A BottomSupply No Return B BottomSupply Left Return C BottomSupply Right Return D BottomSupply End Return E Left Supply No Return F Left Supply BottomReturn G Left Supply Left Return H Left Supply Right Return J Left Supply End Return K Right Sup...

Page 17: ...ect Drive Airfoil PlenumAluminum P 22 Direct Drive Airfoil PlenumAluminum Q 24 Direct Drive Airfoil PlenumAluminum R 27 Direct Drive Airfoil PlenumAluminum 3D SUPPLYFAN MOTOR TYPE 0 High Efficiency Open Motor 1170 nominalrpm A High Efficiency Open Motor 1760nominal rpm K High Efficiency Totally Enclosed Motor 1170 nominalrpm L High Efficiency Totally EnclosedMotor 1760 nominalrpm P Permanent Magne...

Page 18: ...th Fan E 4 Fans perVFD Full Width Fan F No VFDs NarrowWidth Fan G 1 Fan perVFD NarrowWidth Fan H 2 Fans perVFD NarrowWidth Fan J 3 Fans perVFD NarrowWidth Fan K 4 Fans perVFD NarrowWidth Fan L Option A Inlet Backdraft Dampers M Option B Inlet Backdraft Dampers 5B RETURN FAN CONFIGURATION Continued N Option C Inlet Backdraft Dampers P Option D Inlet Backdraft Dampers Q Option E Inlet Backdraft Damp...

Page 19: ...n B Inlet Backdraft Dampers N Option C Inlet Backdraft Dampers R Option F Inlet Backdraft Dampers S Option G Inlet Backdraft Dampers T Option H Inlet Backdraft Dampers 6C EXHAUST FAN SIZE 0 No Exhaust Fan N 27 Direct Drive Backward Curved Plenum Aluminum Q 30 Direct Drive Backward Curved PlenumSteel R 33 Direct Drive Backward Curved PlenumSteel S 36 5 Direct Drive Backward Curved Plenum Aluminum 6...

Page 20: ...idge MERV 11 J 2 Pleated MERV8 12 Cartridge MERV 13 K 2 Pleated MERV8 12 Cartridge MERV 14 L 4 Pleated MERV 8 12 Cartridge MERV11 M 4 Pleated MERV8 12 Cartridge MERV 13 N 4 Pleated MERV8 12 Cartridge MERV 14 P 2 Pleated MERV8 30 Bag MERV 13 Q 2 Pleated MERV8 30 Bag MERV 14 9A UNIT FILTER TYPE Continued R 4 Pleated MERV8 30 Bag MERV 13 S 4 Pleated MERV8 30 Bag MERV 14 9B UNIT FILTER BOXSIZE LOCATIO...

Page 21: ... H Magnehelic Gauge Unit Energy Recovery Final Filters J CFS Magnehelic Gauge Unit Filters K CFS Magnehelic Gauge Unit Energy Recovery Filters L CFS Magnehelic Gauge Unit Final Filters M CFS Magnehelic Gauge Unit Energy Recovery FinalFilters Feature 10 REFRIGERATION CONTROL 10A REFRIGERATION CONTROL A 0 Standard E Freeze Stats each circuit 10B REFRIGERATION CONTROL B 0 Standard Feature 11 REFRIGER...

Page 22: ... E 3 Option A B C D 4 Option A B C E 5 Option A B D E 6 Option A C D E 7 Option B C D E 8 Option A B C D E 15 ELECTRICAL ACCESSORIES 0 Standard B Phase Brown Out Protection C AirDisinfection UVLights E CompressorSound Blankets K Option B C M Option B E P Option C E 15 ELECTRICAL ACCESSORIES Continued Z Option B C E Feature 16 UNIT CONTROLS 16A CONTROL SEQUENCE 0 StandardTerminalBlockfor Thermostat...

Page 23: ...E 0 No Option Box A 2 ft First Box B 2 ft First Box 2ft Second Box C 2 ft First Box 4ft Second Box D 2 ft First Box 6ft Second Box E 2 ft First Box 8ft Second Box F 4 ft First Box G 4 ft First Box 2ft Second Box H 4 ft First Box 4ft Second Box J 4 ft First Box 6ft Second Box K 4 ft First Box 8ft Second Box L 6 ft First Box M 6 ft First Box 2ft Second Box N 6 ft First Box 4ft Second Box 18B BOXSIZE...

Page 24: ... 0 Standard A Factory Wired 115VConvenienceOutlet B Field Wired 115V Convenience Outlet C Service Lights D Remote Start Stopcontacts E Supply Fan Auxiliary Contacts F Option A C G Option A D H Option A E J Option B C K Option B D L Option B E M Option C D N Option C E P Option D E Q Option A C D R Option A C E S Option A D E T Option B C D U Option B C E V Option B D E 22 MAINTENANCE ACCESSORIES C...

Page 25: ...S 0 None A High Condensate LevelSwitch 31 BLANK 0 Standard 32 BLANK 0 Standard 33 BLANK 0 Standard 34 BLANK 0 Standard 35 WARRANTY 0 StandardWarranty 36 CABINET MATERIAL D Galvanized Cabinet Double Wall R 13 Foam Insulation 6 Base Rail Double Sloped Roof 37 SPECIALS PAINT B Premium AAONGray Paint Exterior D Premium AAONGray Paint Exterior Interior Corrosion Protection G Premium AAONGray Paint Exte...

Page 26: ...steam coils are designed for 150 psig working pressure Certification of Electric Heat Models a RZ Series electric warm air furnaces have been certified for use with or without cooling located downstream of the indoor coil b RZ Series electric warm air furnaces are designed with individual 40 KW electric heating elements that can be configured for up to 240 KW of electric heat maximum output varies...

Page 27: ...ceiving Unit When received the unit must be checked for damage that might have occurred in transit If damage is found it must be noted on the carrier s Freight Bill A request for inspection by carrier s agent must be made in writing at once Nameplate must 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 go...

Page 28: ... 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 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 obstr...

Page 29: ...bstruct airflow in the condensing section Consideration must be given to obstruction caused by snow accumulation when placing the unit Curb Installation Make openings in the roof decking large enough to allow for duct penetrations and workspace only Do not make openings larger than necessary Set the curb to coincide with the openings Make sure curb is level Unit must be level in both horizontal ax...

Page 30: ...he unit to reduce vibration from the unit to the building Lifting the Unit If cables or chains are used to hoist the unit they must be the same length See figure on the next pages for dimensions 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 materia...

Page 31: ...31 Figure 4 4 Point Lift RZ Series Air Cooled Condenser Unit ...

Page 32: ...32 Figure 5 8 Point Lift RZ Series Air Cooled Condenser Unit Lifting slot locations are unit specific Unit must be rigged at all marked lifting points ...

Page 33: ...33 Duct Connection Figure 6 Curb Mounting Figure 7 Curb Detail Table 3 Mounting Dimensions Tons A B C D 45 140 100 96 92 97 145 240 142 138 134 139 Figure 8 Curb Steel Mounting Rail with Dimensions ...

Page 34: ...tory provided Neoprene gasket is provided to be applied on ends of both sections Once the unit is completely assembled it is important to visually inspect all exposed areas and fill any gaps with butyl caulking Splicing 1 Align base rail and side sections 2 Check roof alignment and connecting flange 3 Fill post seam with butyl caulking Apply butyl caulking between roof flange sections 4 Attach spl...

Page 35: ...lit that is charged with nitrogen by attaching a gauge manifold set and purging through the hoses 2 Next remove the copper caps on eachside by using a pipe cutter at the brazed joint Joint A and B 3 Then braze the provided copper lines onto their respective open lines 4 After the lines are joined charge the newly joined section with 200 psi of dry nitrogen Test the charge for an hour After one hou...

Page 36: ...ecting the middle of the hood to the unit and secure with sheet metal screws Apply butyl 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 Outdoor air intake adjustments must be made according to building ventilation or local code requirements Air hoods vary according to unit size and options Figure below is shown as a...

Page 37: ...st damper must be installed in the field Once the motorized exhaust is screwed into place and has been sealed with butyl caulking attach a rain hood above the motorized exhaust Upon screwing the rain hood into place over the motorized exhaust apply a seal of butyl caulking around the edges of the rain hood Wide 142 The RZ unit will arrive with the motorized exhaust already in place The rain hood s...

Page 38: ...and rated to give acceptable performance Route power and control wiring separately through the utility entry in the base of the unit Do not run power and signal wires in the same conduit Size supply conductors based on the unit MCA rating Supply conductors must be rated a minimum of 167 F 75 C Protect the branch circuit in accordance with code requirements The unit must be electrically grounded in...

Page 39: ...erage 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 Installing contractor must check for proper motor rotation and check blower motor amperage listed on the motor nameplate is not exceeded Motor ...

Page 40: ...100 Hz 130 136 25 88 Hz 140 148 25 100 Hz 145 161 25 95 Hz 160 172 25 80 Hz 180 197 25 98 Hz 200 221 25 76 Hz 220 241 25 88 Hz 240 261 25 92 Hz 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...

Page 41: ...ed up through the condensate drain piping Blow through coils will have a positive static pressure in the drain pan The condensate piping on these drain pans must be trapped to prevent pressure loss through the drain Draw Through Coils Figure 17 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 ...

Page 42: ...for blow through coils is the minimum pressure drop so do not include dirt allowance pressure drops for filters Figure 18 Blow Through Drain Trap The bottom of the leaving pipe must be at least one half inch lower than the bottom of the drain pan connection This ensures proper drainage when the unit is not running Note It may be necessary to fill the trap manually or the trap can be filled automat...

Page 43: ...dge filters Place the filter on the holding frame and then hold the filter in place by the swing bolt assembly on the sides If the unit includes HEPA pre filters an adapter frame is included The adapter frame holds the HEPA filters and the swing bolts attach to the adapter frame Metal Mesh Filters Metal mesh filters are washable expanded aluminum mesh filters that are mounted over the outside air ...

Page 44: ...be ordered from the factory for field installation Wheels come standard with a 10 air volume band as a safety factor in case additional air volume is required from the unit Airflow Adjustment If reduced air volume is required an air volume band or larger air volume band can be installed within the blower wheel to reduce the amount of air delivered by the wheel If the unit is factory equipped with ...

Page 45: ...brated torque wrench Tighten the second set screw to the full required torque setting then tighten the first set screw to the full required torque setting Table 8 Plenum Fan Set Screw Specifications SET SCREW DIAMETER TORQUE IN LBS 1 4 80 5 16 126 3 8 240 7 16 384 1 2 744 9 16 1 080 5 8 1 500 3 4 2 580 7 8 3 600 1 5 400 The gap tolerances that are allowed between the blower and the inlet cone for ...

Page 46: ...lose completely when back pressure is applied Figure 24 Closed Back Draft Damper Figure 25 Open Back Draft Damper Adjusting Refrigerant Charge Adjusting the charge of a system in the field must be based on determination of liquid sub cooling and evaporator superheat On a system with a TXV liquid sub cooling is more representative of the charge than evaporator superheat but both measurements must b...

Page 47: ...ated temperature to determine the liquid sub cooling Compare calculated sub cooling to the table below for the appropriate unit type and options Checking Evaporator Superheat Measure the temperature of the suction line close to the compressor Read gauge pressure at the suction line close to the compressor Convert the pressure obtained to a saturated temperature using the appropriate refrigerant te...

Page 48: ...ooling 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 ...

Page 49: ...ercharged system by reducing the amount of refrigerant in the system to lower the sub cooling The system is undercharged if the superheat is too high and the sub cooling is too low Correct an undercharged system by adding refrigerant to the system to reduce superheat and raise sub cooling If the sub cooling is correctand the superheat is too high the expansion valve may need adjustment to correct ...

Page 50: ...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 Freeze Stat Startup Fre...

Page 51: ...ment for the lowest possible pressure drop Removing the suction line filter will improve the efficiency and capacity of the unit AAON installs isolation ball valves on both sides of the suction line filter so the complete system will not have to be reclaimed evacuated Suction Filter Removal Instructions 1 Shut down operation of the unit 2 Close both shut off valves to isolate the suction filter 3 ...

Page 52: ...iable 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 T...

Page 53: ...ed to reset the heater control 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 fan motors and electric resistance heaters will energize Heating is accomplished by passing electrical current through a specified ...

Page 54: ...nt microbial growth Cleaning of the drain pans will also prevent any possible plugging of the drain lines and overflow of the pan itself Cleaning of the drain pans and inside of the unit must be done only by qualified personnel Filter Replacement Monthly filter inspection is required to maintain optimum unit efficiency Replace filter media monthly Filters are located either upstream of the evapora...

Page 55: ...oils is required to maintain coating warranty coverage for fin and tube and microchannel coils See the AAON E Coated Coil Maintenance Record sheet 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 cle...

Page 56: ...e 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...

Page 57: ...g section for details on cleaning e coated coils Field applied coil coatings are not recommended with microchannel coils Allowed ChemicalCleaners 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 ...

Page 58: ...N 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 microcha...

Page 59: ...e Hot Water Coil Connection Size Coil Quantity 045 055 065 075 A B C D 2 1 8 1 1 090 105 120 130 140 A 2 1 8 2 2 B C D 2 1 8 1 1 145 160 180 200 220 240 A B 2 1 8 2 2 C D 2 1 8 1 1 In Out Connections Model RZA Heating Coil Size Steam Coil Connection Size Coil Quantity 045 055 065 075 A 2 1 8 2 2 B C D 2 1 8 1 1 090 105 120 130 140 A 2 1 8 4 4 B 2 1 8 2 2 C D 2 1 8 1 1 145 160 180 200 220 240 A 2 1...

Page 60: ...e unit When power is cut off from the unit crankcase heaters cannot prevent refrigerant migration into the compressors This means the compressor may cool down and liquid refrigerant may accumulate in the compressor The compressor is designed to pump refrigerant gas and damage may occur when power is restored if liquid enters the compressor If power to the unit must be off for more than an hour tur...

Page 61: ...r off Do not leave part of the units switched to the opposite mode Cooling only units must be switched off during the heating season Evaporator Coil Removal Isolate the evaporator section and recover the refrigerant in that section Make sure to weigh the amount of refrigerant recovered Remove the expansion valve bulbs and or the valve controller from the suction lines Disconnect the suction and li...

Page 62: ...ts where screws were removed Reconnect the fan motor wires Attach the fan grill at all of the points where screws were removed Evaporative Condenser Evaporative cooling equipment rejects heat by evaporating a portion of the recirculated water spray and discharging it from the unit with the hot saturated air In the right conditions this can be substantially more efficient than other condenser setup...

Page 63: ...rative condenser but as minimum the evaporative condenser sump must be 15 feet from the nearest intake Figure 29 Improper Unit Locations Performance Improper location of the evaporative condenser may seriously degrade the capacity of the equipment Make sure the equipment is located such that discharge air from the condenser does not enter the condenser air inlet Batch loading chemicals into the un...

Page 64: ...at the system is sealed before charging with refrigerant If the unit is operated during low ambient temperature conditions freeze protection for the recirculating water system must be provided Evaporative Condenser Operation Pre Start Up Do not start the evaporative condenser or compressors without installation of proper water treatment chemicals Contact your local water treatment expert for corre...

Page 65: ...ure that fan is tightly mounted to the motor shaft and the motor mounting bolts are aligned and secure Water Makeup Valve The sump water level is controlled by a set of conductivity probes at different levels in the sump The standard sump waterlevel is about 15 inches deep This water level controller is located in the vestibule behind the condenser pump There are four conductivity probes in this c...

Page 66: ...he mineral content of the water must be controlled All makeup water has minerals in it Aswater is evaporated from the condenser these minerals remain As the mineral content of the water increases the conductivity of the water increases The water treatment controller monitors this conductivity As the water conductivity rises above set point the controller will open a motorized ball valve on the dis...

Page 67: ... excessive rusting Pump port protection plates must not be removed until the pump is ready to connect to the piping Rotate the shaft periodically At least monthly to keep rotating element free and bearings fully functional For long term storage the pump must be placed in a vertical position in a dry environment Internal rusting can be prevented by removing the plugs at the top and bottom of the ca...

Page 68: ...f the issues persists repeat these steps as needed Bearings Lubrication Every 6 months or after a prolonged shut down Use waterproof lithium based grease Below 32 F Esso Exxon or Beacon 325 Above 32 F Mobil Mobilox EP2 Shell Alvania EP2 or Texaco RB2 Recommended Monthly Inspection 1 Clean sump section interior Dirt and other impurities which have accumulated in the sump must be removed from the su...

Page 69: ...the copper tubing Severe damage may result Contact your water treatment expert for recommendations on chemical cleaning procedures Warranties Please refer to the limitation of warranties in effect at the time of purchase Evaporative Condenser Water Quality Cycles of concentration the ratio of dissolved solids in recirculated water to dissolved solids in makeup must be determined and monitored freq...

Page 70: ...t of Rejection Unit Capacity in Tons 12000 1 3 413 EER 100 12000 1 3 413 15 1 473 040 Btu hr Total Full Load Heat of Rejection via Evaporation Total Heat of Rejection 1 fraction of heat rejected by desuperheater 1 473 040 Btu hr 1 0 22 1 148 971 Btu hr Note that approximately 22 of the total heat of rejection is accomplished with the desuperheater at full load So thefractionof heatrejected bythe d...

Page 71: ...e unique operations characteristics Professional air balance specialists must be employed to establish actual operating conditions and to configure the air delivery system for optimal performance Controls A variety of controls and electrical accessories may be provided with the equipment Identify the controls on each unit by consulting appropriate submittal or order documents and operate according...

Page 72: ...orrect locations for the purge sector Figure 34 Aluminum ERW Purge Sector Location Aluminum Wheel Air Seals Both non contact sealing on wheel peripheries and brush sealing middle beam are maintenance free but their condition must be checked every year During the inspection check their tightness and overall visual condition Non contact seals must not be flipped rolled or pierced at any place If sea...

Page 73: ...ration and at least once per year If segmented drive belt becomes too loose it is necessary to pull out few segment modules Fig 10 of the belt and shorten the overall length to desired amount in order to achieve optimal tension Correct tension should prevent ability to insert anything underneath the belt on the entire length between the belt and the wheel Belt must not slip Annually inspect the vi...

Page 74: ... 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 rec...

Page 75: ... viewed from the pulley side Verify that the media slightly grabs the paper during rotation If it is necessary to adjust a purge seal to the face of the wheel loosen the two or three screws along the bearing beam and adjust to the proper distance from the media surface Tighten the screws and retest the seal Polymer Wheel Air Seal Adjustments Pile type air seals across both sides of the energy whee...

Page 76: ... packaged units packaged air handlers and energy recovery ventilators In each case it is recommended that the following considerations be addressed Polymer Wheel Accessibility The cassette and all its operative parts i e motor belt pulley bearings seals and energy transfer segments must be accessible for service and maintenance This design requires that adequate clearance be provided outside the e...

Page 77: ... 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 confirm seal adjustment and to confirm belt is tracking properly on wheel rim approximately 1 4 from outer edge of rim Diameter Seal Adjustment Hub Seal Adjustment Polym...

Page 78: ...belt is a urethane stretch belt designed to provide constant tension through the life of the belt No adjustment is required Inspect the 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 Polymer Wheel Service Polymer Wheel Segment Installation Replacement An uneven number of s...

Page 79: ... flat tip of a screw driver between the wheel rim 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 ins...

Page 80: ...ull the entire 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 b...

Page 81: ...ity Class 3 air has significant contaminant concentration and significant offensive odor or sensory irritation intensity Class 4 air has highly objectionable fumes or gases and potentially contains dangerous particles bio aerosols or gases at a concentration high enough to be considered harmful not suitable for recirculation or transfer to any other space Table 17 Energy Recovery Wheel Cleaning Fr...

Page 82: ...ustrial applications involving the ventilation of machine shop areas for example annual washing of energy transfer may be necessary to maintain latent transfer efficiency Proper cleaning of the energy recovery wheel will restore latent effectiveness to near original performance Aluminum Wheel Cleaning See general energy recovering cleaning section for how often to clean To clean gain accessto the ...

Page 83: ...he dial Set T1 dial to 3 which equals 30 minutes of run time T2 is the off time Set T2 range to 1m 1 minute The scale shows 0 6 on the dial Set T2 dial to 2 which equals 2 minutes of off time Adjust temperature dial to set the point at which any temperature below will activate the defrost timer Recommended setting is 35 F Once the OA Temperature goes below the setpoint the wheel timer will stop fo...

Page 84: ...rn air duct must be sealed to the unit and the return air temperature must be maintained between 55 F and 80 F Table 18 RZ 45 140 ton Electric Heating Capacities Model Option B3 Electric Heat Capacity kW 208V kW 230V 380V 460V 575V 1 Heat 1 60 1 80 2 Heat 2 90 1 120 3 Heat 3 120 1 160 4 Heat 4 150 2 200 5 Heat 5 180 2 240 Table 19 RZ 145 240 ton Electric Heating Capacities Model Option B3 Electric...

Page 85: ...uantity Size 540 1 2 810 1 1080 1 1350 1 1620 1 2100 1 3 2580 1 3060 1 Table 23 RZ 145 240 ton Unit Gas Piping Connections RZ Medium Gas Input MBH Connections Quantity Size 800 1 2 1 2 1200 1 1600 1 2000 1 2400 1 3100 1 3 3800 1 4500 1 See unit nameplate for unit gas heating capacities or the Unit Rating Sheet which can be obtained from the AAON sales representative Table 24 Natural Gas Maximum Pi...

Page 86: ...ies table at 100 ft and 800 kBtu hr the required minimum pipe size is 1 1 2 Inlet and Manifold Pressures For natural gas units the minimum inlet gas pressure to the unit is 6 w c and maximum inlet gas pressure to the unit is 10 5 w c For propane units the minimum inlet gas pressure to the unit is 11 w c and the maximum inlet gas pressure to the unit is 13 w c A field provided 1 8 NPT pressure tap ...

Page 87: ...all be plumbed to the appropriate drain according to the 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 the International Building Code and any applicable local and regional codes and regulations The condensate drain connection is located next to the gas entry location Each gas heater has a silicone conden...

Page 88: ...r of the unit shall be leak tested with a soap solution before operating the appliance and at least on an annual basis thereafter All gas fired heat exchangers are completely tested at the factory before shipment This will remove nearly all of the oils that have been used in the manufacturing process However trace amounts may remain When performing the initial startup at the jobsite people or any ...

Page 89: ...hanges see Figure 39 All of the provided hoods must be installed after the unit is set in place Figure 39 Gas Heater Rain Hood Figure 40 Gas Heater Rain Hood Screws When locating gas fired units install the unit so that the flue discharge vents are located at least 120 inches away from any opening through which combustion products could enter the building WARNING All exterior heater rain hoods mus...

Page 90: ...90 Gas Heater Operating Instructions ...

Page 91: ...n the vent outlet A good practice is to check for debris each time the air filters are changed In the event the vent outlet becomes blocked do not attempt to start the appliance in heat mode until the entire vent opening is cleared In the event the unit shut down because the vent was blocked a qualified technician or service agency shall monitor the unit prior to re starting The gas burner and hea...

Page 92: ...sed only new connectors may be used Connect wiring per the wiring diagram on the controls compartment door Purge gas lines to the gas valves at the unit Phase and Brownout Protection Module The DPM is a Digital Phase Monitor that monitors line voltages from 200VAC to 240VAC 1ɸ and 200VAC to 600VAC 3ɸ The DPM is 50 60 Hz self sensing DPM must be wired according to unit specific wiring diagram inclu...

Page 93: ...w to backup if needed When each parameter is displayed use the up down keys to change and set the parameter After adjustments are made or if no adjustments are made it will take 2 to 4 minutes before the DPM energizes the output relay unless there is an out of tolerance issue with the incoming line voltage Recommended Default Set up Line Voltage 460VAC 3Ø Over Undervoltage 10 Trip Time Delay 5 Sec...

Page 94: ...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 95: ... 145 180 tons 53 500 16 18 0 659 1 292 99 20 E 200 240 tons 72 900 13 84 0 900 1 377 99 40 All dosage and estimated inactivation rates are at bulb end of life have a wind chill degradation for 55 degrees factored in and factor in velocity on the coil Warmer temperatures or lower airflows will increase the UV effectiveness Filter Replacement Monthly air filter inspection is required to maintain opt...

Page 96: ...300 cfm 16 24x24 40 000 cfm 20 24x24 50 000 cfm 55 66 65 73 75 79 90 101 36 16x25 60 000 cfm 105 109 120 124 36 16x25 60 000 cfm 130 136 140 148 145 161 60 16x20 80 000 cfm 5 20x24 15 24x24 46 000 cfm 25 24x24 60 000 cfm 8 20x24 24 24x24 73 600 cfm 5 20x24 15 24x24 47 900 cfm 20 24x24 50 000 cfm 25 24x24 62 500 cfm 160 172 180 197 200 221 72 16x20 96 000 cfm 220 241 240 261 Note When used in Final...

Page 97: ...180 197 200 221 220 241 240 261 Note When used in Final position the unit CFM limit will be the lesser between these and the corresponding MERV 8 Pre Filters Replacement Parts Always use AAON specified parts Parts for AAON equipment may be obtained from you local AAON representative When ordering parts reference the unit serial number and part number AAON Warranty Service and Parts Department 2424...

Page 98: ...rrosion 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 6...

Page 99: ...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 100: ...8 107 44 25 77 86 00 30 86 69 28 35 95 56 16 40 104 45 81 45 113 37 58 50 122 30 99 55 131 25 68 60 140 21 40 65 149 17 91 Deg C Deg F Resistance kOhms 70 158 15 07 75 167 12 73 80 176 10 79 85 185 9 20 90 194 7 87 95 203 6 77 100 212 5 85 105 221 5 09 110 230 4 45 115 239 3 87 120 248 3 35 125 257 2 92 130 266 2 58 135 275 2 28 140 284 2 02 145 293 1 80 150 302 1 59 155 311 1 39 160 320 1 25 165 ...

Page 101: ... items 1 Is there any visible shipping damage Yes No 2 Is the unit level Yes No 3 Are the unit clearances adequate for service and operation Yes No 4 Do all access doors open freely and are the handles operational Yes No 5 Have all shipping braces been removed Yes No 6 Have all electrical connections been tested for tightness Yes No 7 Does the electrical service correspond to the unit nameplate Ye...

Page 102: ...el Assembly Wheel s Spin Freely Check Rotation FLA____________ Number hp L1 Volts Amps L2 Volts Amps L3 Volts Amps 1 2 Power Return Assembly Alignment Check Rotation Nameplate Amps________ Number hp L1 Volts Amps L2 Volts Amps L3 Volts Amps 1 2 VFD Frequency________________ Power Exhaust Assembly Alignment Check Rotation Nameplate Amps________ Number hp L1 Volts Amps L2 Volts Amps L3 Volts Amps 1 ...

Page 103: ...ration Water Cooled Condenser Air Cooled Condenser No Water Leaks Evaporative Condenser Condenser Safety Check Water Flow ________GPM Water Inlet Temperature ________ F Water Outlet Temperature ________ F Compressors DXCooling Number stage L1 Volts Amps L2 Volts Amps L3 Volts Amps Head Pressure PSIG Suction Pressure PSIG Crankcase Heater Amps 1 2 3 4 5 6 7 8 ...

Page 104: ...re Line Temperature Sub cooling Superheat Discharge N A N A Suction N A Liquid N A Refrigeration System 3 Pressure Saturated Temperature Line Temperature Sub cooling Superheat Discharge N A N A Suction N A Liquid N A Refrigeration System 4 Pressure Saturated Temperature Line Temperature Sub cooling Superheat Discharge N A N A Suction N A Liquid N A Refrigeration System 5 Pressure Saturated Tempera...

Page 105: ...Volts Amps 1 2 Water Glycol System 1 Has the entire system been flushed and pressure checked Yes No 2 Has the entire system been filled with fluid Yes No 3 Has air been bled from the heat exchangers and piping Yes No 4 Is the glycol the proper type and concentration N A if water Yes No 5 Is there a minimum load of 50 of the design load Yes No 6 Has the water piping been insulated Yes No 7 What is ...

Page 106: ...pane Purge Air from Lines Verify Pilot Spark Stage Manifold Pressure w c inlet Manifold Pressure w c outlet 1 2 3 4 5 6 7 8 9 10 11 12 Electric Heating Stages__________ Limit Lockout Aux Limit Lockout Stage Volts Amps 1 2 3 4 5 6 7 8 ...

Page 107: ...ocument 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 start up maintenance and servicing of the equipment falls to the owner and qualified licensed technician Entry Date Action Taken Name Tel ...

Page 108: ...108 Maintenance Log E Coated Coil ...

Page 109: ...Speed Compressor VFD Frequency Range table Added Hot Water Steam and Chilled Water Coil Connection Sizes tables Updated the Evaporator Coil removal and reinstallation instructions Updated the Condenser Fan removal instructions Updated the Electric and Gas Heating Capacities tables Updated the RZ 45 140 ton Unit Gas Piping Connections table Updated the RZ Series Filter Sizes table Added installatio...

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Page 112: ...It is the intent of AAON to provide accurate and current product information However in the interest of product improvement AAONreservesthe 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 ...