AAON CL SERIES Installation Operation & Maintenance Download Page 1

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CL SERIES

Condensing Units

Installation, Operation

& Maintenance

Summary of Contents for CL SERIES

Page 1: ...CL SERIES Condensing Units Installation Operation Maintenance ...

Page 2: ...quid Sub cooling 19 Checking Evaporator Superheat 19 Special Low Ambient Charging Instructions 20 Low Ambient Operation 20 LAC Valve 21 Electrical 22 Refrigerant Piping Connections 24 Evaporative Condenser Field Piping Connections 24 STARTUP 26 Pre Startup 26 Startup 26 Axial Flow Fans 27 Insert Blades 28 SERVICING AND MAINTENANCE 29 General 29 Compressors 29 Refrigerant Suction Line Filter 29 Suc...

Page 3: ...R QUALITY 36 Recirculating Water Quality Guidelines 36 Mechanical Cleaning 36 Parts 36 AIR COOLED CONDENSER 36 E Coated Coil Cleaning 36 REFRIGERANT PIPING FOR THE CL SERIES 39 General 39 Determining Refrigerant Line size 39 Equivalent Line Length 39 Liquid line sizing 40 Liquid Line Routing 40 Liquid Line Insulation 40 Liquid Line Guidelines 40 Liquid Line Accessories 40 Suction Line Sizing 40 Su...

Page 4: ...s Bypass Piping Diagram with air handler above condenser 44 Figure 11 Hot Gas Bypass Piping Diagram with air handler below condenser 45 Figure 12 Hot Gas Reheat Piping Diagram with air handler above condenser 46 Figure 13 Hot Gas Reheat Piping Diagram with air handler below condenser 47 Figure 14 Hot Gas Reheat Piping Diagram with air handler above condenser and field installed suction line accumu...

Page 5: ...th Hinges Lockable Handles and Rain Gutters Walk In Weatherproof Compressor Compartment Run Test Report and Installation Manuals Included in Controls Compartment Color Coded Wiring and Wiring Diagrams Double Pane Viewing Windows Compressors are Deck Mounted with Rubber Isolation Three Chemical Water Treatment System for Evaporative Condenser Aluminum Tread Plate Floor Foam Insulated Double Wall Co...

Page 6: ... 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 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 seriou...

Page 7: ...LOSION 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 GROUNDING REQUIRED All field installed wiring must be c...

Page 8: ...e CAUTION 3 PHASE ROTATION 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...

Page 9: ...mical coil cleaners with a pH value greater than 8 5 after mixing without first using an aluminum corrosion inhibitor in the cleaning solution CAUTION COIL CLEANERS 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 COIL CL...

Page 10: ...gs unique to the model purchased 4 READ THE ENTIRE INSTALLATION OPERATION AND MAINTENANCE MANUAL OTHER IMPORTANT SAFETY PRECAUTIONS ARE PROVIDED THROUGHOUT THIS MANUAL 5 Keep this manual and all literature safeguarded near or on the unit 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 mainta...

Page 11: ...ns 155 155 Nominal Tons 170 170 Nominal Tons 190 190 Nominal Tons 210 210 Nominal Tons 230 230 Nominal Tons Voltage 2 230V 3Φ 60Hz 3 460V 3Φ 60Hz 4 575V 3Φ 60Hz 8 208V 3Φ 60Hz Interior Corrosion Protection 0 Standard A1 Cooling Compressor Style B R 410A Dual Circuited Scroll Compressor R R 410A Independently Circuited Compressors A2 Cooling Condenser Style A Air Cooled Condenser E Evaporative Cond...

Page 12: ... Standard A Hot Gas Bypass on Lead Stage D Hot Gas Bypass on Lead and Lag Stages 9 Refrigeration Accessories 0 Standard A Sight Glass B Compressor Isolation Valves C Sight Glass Compressor Isolation Valves F Compressor Isolation Valves Condenser Fan VFDs G Compressor Isolation Valves Condenser Fan VFDs Sight Glass 10 Power Options 0 Standard Single Point Power Block A Single Point Power Non Fused ...

Page 13: ...ank 0 Standard 16 Blank 0 Standard 17 Blank 0 Standard 18 Warranty 0 Standard Warranty A Extended Compressor Warranty Years 2 5 19 Code Options 0 Standard ETL USA Listing A M E A New York D Chicago Cool Only H ETL USA Canada Listing 20 Blank 0 Standard 21 Evaporative Condenser Option 0 Standard No Evaporative Condenser A Basic Package B Low Ambient Package 22 Blank 0 Standard 23 Paint and Special ...

Page 14: ...any liquid accumulation out of the compressor before it is required to run Always control the system from the thermostat or control panel never at the main power supply except for emergency or for complete shutdown of the system Improper installation adjustment alteration service or maintenance can cause property damage personal injury or loss of life Installation and service must be performed by ...

Page 15: ... must be placed on a level and solid foundation that has been prepared to support its weight When installed at ground level a one piece concrete slab must be used with footings that extend below the frost line With ground level installation care must be taken to protect the coil fins from damage due to vandalism or other causes The placement relative to the building air intakes and other structure...

Page 16: ... 3 8 evacuation port The larger diameter evacuation port will expedite system evacuation 4 Connect the manifold set to the condensing unit with one hose on the suction line service valve one hose on the liquid line service valve and if an extra Schrader valve is field installed on the suction line connect a third hose Connect the vacuum pump to the manifold set using a 3 8 vacuum rated hose Figure...

Page 17: ...to the extra hose port in combination with a 3 8 evacuation port The larger diameter evacuation port will expedite system evacuation 5 Connect the manifold set to the condensing unit with one hose on the suction line service valve one hose on the liquid line service valve and a third hose on the reheat line service valve Connect the vacuum pump to the manifold set using a 3 8 vacuum rated hose Fig...

Page 18: ...en Before Charging Refer to the Unit Nameplate to determine the proper refrigerant to charge the system with The unit being charged must be at or near full load conditions before adjusting the charge Units equipped with hot gas bypass must have the hot gas bypass valve closed to get the proper charge Units equipped with hot gas reheat must be charged with the hot gas valve closed while the unit is...

Page 19: ... using the appropriate refrigerant temperature pressure chart 4 Subtract the saturated temperature in Step 3 from the measured suction line temperature in Step 1 to determine the evaporator superheat 5 Compare calculated superheat to Table 2 for the appropriate unit type and options Table 2 Acceptable Refrigerant Circuit Values Sub cooling F Superheat F Sub cooling W Hot Gas Reheat F Air Cooled Co...

Page 20: ...esponds to the ambient temperature The result is the additional charge that must be added to the circuit Table 3 Charge to Flood Condenser Coil for Ambient Below 70 F Condenser Ambient Temperature F of flooded charge needed at 70 F ambient 60 60 50 37 40 24 30 15 20 8 0 0 2 Check the unit for proper operation once the ambient temperature is above 80 F Low Ambient Operation The AAON low ambient con...

Page 21: ... valve setting 180 psig for R 22 and 295 psig for R 410A the valve modulates to bypass discharge gas around the condenser The discharge gas warms the liquid in the receiver and raises the pressure to the valve setting The following schematic shows an example system using the LAC valve Figure 4 Piping Schematic of Example system using the LAC valve ...

Page 22: ...ted to give acceptable performance Route power and control wiring separately through the utility entry 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 accordance with local codes o...

Page 23: ...onnect switch and at the compressor terminal Contact your local power company for line voltage corrections NOTE Startup technician must check for proper motor rotation and check fan 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 Wire control signals to the unit s low voltage terminal ...

Page 24: ...a 2 PVC socket drain connection as shown on the next page Connect this drain to a sanitary sewer or other code permitted drain These connections can go through the base or the wall of the unit There is a cutout in the base with a cap that is 1 tall and the cap is sealed to the unit base to prevent any leaks in the unit from penetrating into the building Any piping through the base must go through ...

Page 25: ...25 Figure 6 Evaporative Condenser Section Water Treatment Components ...

Page 26: ...ns of amps and refrigerant pressures When all is running properly place the controller in the Run mode and observe the system until it reaches a steady state of operation Before leaving installation a complete operating cycle must be observed to verify that all components are functioning properly COMPRESSOR ROTATION Scroll compressors are directional and will be damaged by operation in the wrong d...

Page 27: ...tion of the hub through which the fan is mounted to the shaft and typically contains either setscrews or a center tapered hole where the bushing inserts Select boss location A or B A is the boss on air inlet including AS configurations B is the boss on air discharge including BS For flange mounted fans use boss location A for R rotation fans and boss location B for L rotation fans Step 2 Find Blad...

Page 28: ... match marks that were made Replace any balancing weight to its original position To finish tighten the bolts in a cross pattern to 5 to 6 ft lbs of torque Multi Wing W Series Black Glass Reinforced Polypropylene Fan Blade Pitch Angle Setting Instructions Step 1 Note original position of retaining plates center boss and all hardware including additional hardware used for balancing Step 2 Remove al...

Page 29: ...s are provided with pressure taps and shutoff valves for isolation when removing the filter For safety purposes a service manifold must be attached prior to filter maintenance Suction Filter Removal Instructions 1 Shut down operation of the unit 2 Close both shut off valves to isolate the suction filter 3 Reclaim the refrigerant from the suction filter section 4 Remove the bolts from the suction f...

Page 30: ...otate the fan shaft by hand and add only enough grease to purge the seals DO NOT OVERLUBRICATE Service Information If the unit will not operate correctly and a service company is required only a company with service technicians qualified and experienced in both condensing units and air conditioning are permitted to service the systems to keep warranties in effect If assistance is required the serv...

Page 31: ...irborne contaminates and particulates will be absorbed by the recirculating water system and may form solutions and deposits harmful to the products and personnel Safety The recirculating water system contains chemical additives for water quality control and biological contaminants removed from the air by the washing action of the water Personnel exposed to the saturated effluent drift or direct c...

Page 32: ...mp water temperature This unit is not equipped with a compressor discharge pressure controller for fan speed modulation and therefore must not be operated without water flow EVAPORATIVE CONDENSER 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 correct selection of water treatme...

Page 33: ...med on the wiring diagram The short probe is for the high water level shown as hi on the wiring diagram There is a solenoid valve in the make up water line that is activated by the water level controller The water level controller determines the level of water in the sump based on conductivity between two probes If the controller sees conductivity between two probes it knows that water is at least...

Page 34: ...ochloric acid muriatic acid as it will corrode stainless steel Sequence of Operation On a call for cooling the condenser pump is activated A pressure switch in the pump discharge is bypassed for six seconds by a time delay relay in order for the pump to establish recirculating water flow If flow is not proven within the six seconds the pressure switch opens breaking the safety circuit thereby shut...

Page 35: ...and lubricate per the lubrication nameplate or manufacture s recommendations 6 Inspect axial fans and eliminators removing any debris which may have accumulated during operation 7 Inspect the water distribution system to insure that nozzles and spray orifices are functioning correctly The inspection must be made with the circulation pump on and fans off Mist Eliminators The mist eliminators must b...

Page 36: ...he Serial Number from the product nameplate OR visit www aaonparts com for more information AIR COOLED CONDENSER The air cooled condenser section rejects heat by passing outdoor air over the fin tube coils for cooling of the hot refrigerant gas from the compressors The heated air will discharge from the top of the section through the axial flow fans Inspect the condenser coils annually to ensure u...

Page 37: ...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 GulfClean Coil Cleaner AAON PN G074480 Recommended Chloride Remover GulfClean Salt Reducer AAON PN G074490 GulfClean Salt Reducer is used to remove soluble salts from the e coated coil follow the manufacturer s instructions This product is n...

Page 38: ...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 100 psi rinse the coils and continue to always work in sections panels Continue until all coil areas...

Page 39: ...ine pressure drop causes loss of compressor capacity and increased power usage resulting in reduced system efficiency Excessive pressure drops in the liquid line can cause the liquid refrigerant to flash resulting in faulty expansion valve operation and improper system performance In order to operate efficiently and cost effectively while avoiding malfunction refrigeration systems must be designed...

Page 40: ...ve the condenser to prevent this The liquid line is typically pitched along with the suction line or hot gas line to minimize the complexity of the configuration Liquid Line Insulation When the liquid line is routed through regions where temperature losses are expected no insulation is required as this may provide additional sub cooling to the refrigerant When routing the liquid line through high ...

Page 41: ...m load and size the larger diameter pipe for acceptable pressure drop at full load Figure 8 Double Suction Riser Suction Line Traps Include a trap immediately after the evaporator coil outlet to protect the TXV bulb from liquid refrigerant Include traps every 20 feet in vertical riser sections Suction Line Insulation Insulate the entire suction line with a minimum 1 inch thick Armaflex insulation ...

Page 42: ... be vertical its diameter must be the same as the diameter of the riser and a maximum of 10 long Install a sight glass in the oil drip line for observation Run an oil return line using 1 8 inch capillary tube 10 feet in length from the hot gas bypass line oil drip line to the suction line Connect the oil return line below the sight glass and 1 inch above the bottom of the oil drip line Figure 9 Oi...

Page 43: ...ne must be vertical its diameter must be the same as the diameter of the riser and a maximum of 10 long Run an oil return line using 1 8 inch capillary tube 10 feet in length from the hot gas reheat line oil drip line to the suction line Connect the oil return line below the sight glass and 1 inch above the bottom of the oil drip line Insulate the entire length of the hot gas line with a minimum 1...

Page 44: ...44 Figure 10 Hot Gas Bypass Piping Diagram with air handler above condenser Note Components shown within air handler and condensing unit are factory installed all other components are field installed ...

Page 45: ...45 Figure 11 Hot Gas Bypass Piping Diagram with air handler below condenser Note Components shown within air handler and condensing unit are factory installed all other components are field installed ...

Page 46: ...46 Figure 12 Hot Gas Reheat Piping Diagram with air handler above condenser Note Components shown within air handler and condensing unit are factory installed all other components are field installed ...

Page 47: ...47 Figure 13 Hot Gas Reheat Piping Diagram with air handler below condenser Note Components shown within air handler and condensing unit are factory installed all other components are field installed ...

Page 48: ... Diagram with air handler above condenser and field installed suction line accumulator Note Components shown within air handler and condensing unit are factory installed all other components are field installed TO BE INSTALLED IN FIELD ...

Page 49: ... Diagram with air handler above condenser and field installed suction line accumulator Note Components shown within air handler and condensing unit are factory installed all other components are field installed TO BE INSTALLED IN FIELD ...

Page 50: ... Figure 16 Reheat Hot Gas Bypass Piping Diagram with air handler above condenser Note Components shown within air handler and condensing unit are factory installed all other components are field installed ...

Page 51: ... Figure 17 Reheat Hot Gas Bypass Piping Diagram with air handler below condenser Note Components shown within air handler and condensing unit are factory installed all other components are field installed ...

Page 52: ...air handler evaporator above condenser and field installed suction line accumulator Note Components shown within air handler and condensing unit are factory installed all other components are field installed TO BE INSTALLED IN FIELD TO BE INSTALLED IN FIELD ...

Page 53: ...ping Diagram with air handler below condenser and field installed suction line accumulator Note Components shown within air handler and condensing unit are factory installed all other components are field installed TO BE INSTALLED IN FIELD ...

Page 54: ... 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 ___________________________...

Page 55: ...N SYSTEM 3 PRESSURE SATURATED LINE SUB COOLING SUPERHEAT TEMPERATURE TEMPERATURE DISCHARGE SUCTION LIQUID REFRIGERATION SYSTEM 4 PRESSURE SATURATED LINE SUB COOLING SUPERHEAT TEMPERATURE TEMPERATURE DISCHARGE SUCTION LIQUID CONDENSER FAN AMPS ALIGNMENT________ CHECK ROTATION__________ NAMEPLATE AMPS________ NUMBER HP L1 Volts Amps L2 Volts Amps L3 Volts Amps 1 2 3 4 5 6 CONDENSER PUMP AMPS CHECK R...

Page 56: ...NOTES ...

Page 57: ...AAON E Coated Coil Maintenance Record ...

Page 58: ...lit system evacuation procedure for low ambient and modulating hot gas reheat January 2019 Removed section on OROA and ORI ORD valves Updated special low ambient option charging instructions Corrected the nitrogen holding charge to 100 psi May 2019 Added the minimum maximum voltage range table in the Electrical section July 2019 Removed most references to PVE oils except in the caution boxes Septe...

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Page 60: ... available Parts For replacement parts please contact your local AAON Representative It is the intent of AAON to provide accurate and current product information However in the interest of product improvement AAON reserves the right to change pricing specifications and or design of its product without notice obligation or liability Copyright AAON all rights reserved throughout the world AAON and A...

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