AAON RQ SERIES Installation Operation & Maintenance Download Page 3 | Manualshive

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AAON RQ SERIES Installation Operation & Maintenance Download Page 3

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Table of Contents

AAON® RQ Series Features and Options Introduction ................................................................. 7

Safety .............................................................................................................................................. 8

RQ Series Feature String Nomenclature ....................................................................................... 13

General Information ...................................................................................................................... 22

Codes and Ordinances .............................................................................................................. 22

Receiving Unit .......................................................................................................................... 23

Packaged Direct Expansion (DX) Units ................................................................................... 24

Gas or Electric Heating ............................................................................................................. 25

Wiring Diagrams ....................................................................................................................... 26

Condensate Drain Pan ............................................................................................................... 26

Installation..................................................................................................................................... 27

Unit Location ............................................................................................................................ 27

Setting the Curb ........................................................................................................................ 27

Forklifting the Unit ................................................................................................................... 30

Lifting the Unit ......................................................................................................................... 31

Vertical Duct Connection ......................................................................................................... 32

Seismic Curb Installation .......................................................................................................... 33

Horizontal Duct Connection ..................................................................................................... 35

Outside Air Rain Hood ............................................................................................................. 35

Metal Mesh Filters .................................................................................................................... 36

Electrical ................................................................................................................................... 37

Variable Speed Compressors ................................................................................................ 39

Thermostat Control Wiring ................................................................................................... 39

Gas Heating ............................................................................................................................... 40

Maximum Piping Capacities ................................................................................................. 40

Piping Sizing Examples ........................................................................................................ 41

Inlet and Manifold Pressures ................................................................................................ 41

Gas Pressure Regulator & Overpressure Protection Device ................................................. 42

Additional Gas Piping Considerations .................................................................................. 42

Leak Testing .......................................................................................................................... 44

Refrigerant-to-Water Heat Exchanger ...................................................................................... 44

Water-Source Heat Pump Applications ................................................................................ 44

Open Loop Applications ....................................................................................................... 45

Freezing Water in the Heat Exchanger ................................................................................. 45

Water Piping ......................................................................................................................... 46

Condensate Drain Piping .......................................................................................................... 48

Discharge and Suction Line Piping .......................................................................................... 48

Heating Coils ............................................................................................................................ 51

Chilled Water Coil .................................................................................................................... 51

Electric Preheat ......................................................................................................................... 52

Status Display Screens .......................................................................................................... 52

System Setting Screens ......................................................................................................... 53

LED Flash Alarm Codes ....................................................................................................... 55

Operation ............................................................................................................................... 55

Energy Recovery Units ............................................................................................................. 56

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Summary of Contents for RQ SERIES

Page 1: ...rom 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 op...

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Page 3: ...etal Mesh Filters 36 Electrical 37 Variable Speed Compressors 39 Thermostat Control Wiring 39 Gas Heating 40 Maximum Piping Capacities 40 Piping Sizing Examples 41 Inlet and Manifold Pressures 41 Gas Pressure Regulator Overpressure Protection Device 42 Additional Gas Piping Considerations 42 Leak Testing 44 Refrigerant to Water Heat Exchanger 44 Water Source Heat Pump Applications 44 Open Loop App...

Page 4: ...g Operation 74 Steam or Hot Water Preheating and Heating Operation 74 Modulating Electric Preheat 74 Chilled Water or Non Compressorized DX Cooling Operation 74 Maintenance 74 Gas Heating 74 Gas Heat Exchanger Removal 75 DX Cooling 76 Condenser Fan 76 Condensate Drain Pans 76 Evaporator Coil 77 E Coated Coil Cleaning 77 Microchannel Coil Cleaning 79 Supply Fan 81 Variable Capacity Compressor Contr...

Page 5: ...col Freezing Points 46 Table 11 Condenser Water Connections 46 Table 12 Hot Water Coil Connection Sizes 51 Table 13 Steam Coil Connection Sizes 51 Table 14 Chilled Water Coil Connection Sizes 51 Table 15 Stages of Electric Preheat 54 Table 16 Acceptable Refrigeration Circuit Values 65 Table 17 R 410A Refrigerant Temperature Pressure Chart 66 Table 18 EC Condenser Fan Cycling Options 70 Table 19 De...

Page 6: ...losed Rain Hood 36 Figure 16 RQ Series unit Open Rain Hood 36 Figure 17 Rain Hood with Metal Mesh Filter Rack Installation 36 Figure 18 Unit Base Utility Entry 37 Figure 19 Back View of Power Switch from Control Compartment 37 Figure 20 RQ Series Gas Heat Exchanger 40 Figure 21 Example 2 6 ton through the Base Gas Piping 43 Figure 22 Post Corner Hole Location 49 Figure 23 Post Back Hole Location 4...

Page 7: ...gy Recovery Wheels Modulating Hot Gas Reheat Safety Burglar Bars Freeze Stats Hot Water Steam Preheat Coils Electric Preheat Phase and Brown Out Protection Supply Return Smoke Detectors Supply Return Firestats Installation and Maintenance Clogged Filter Switch Color Coded Wiring Diagram Compressors in Isolated Compartment Compressor Isolation Valves Convenience Outlet Direct Drive Supply Fans Hing...

Page 8: ...perty damage Improper servicing could result in dangerous operation serious injury death or property damage Before servicing disconnect all electrical power to the furnace More than one disconnect may be provided When servicing controls label all wires prior to disconnecting Reconnect wires correctly Verify proper operation after servicing Secure all doors with key lock or nut and bolt WARNING WHA...

Page 9: ...with these code requirements WARNING During installation testing servicing and troubleshooting of the equipment it may be necessary to work with live electrical components Only a qualified licensed electrician or individual properly trained in handling live electrical components shall perform these tasks Standard NFPA 70E an OSHA regulation requiring an Arc Flash Boundary to be field established a...

Page 10: ...igerant and dry nitrogen for leak testing A violent explosion may result causing injury or death WARNING WATER PRESSURE Prior to connection of condensing water supply verify water pressure is less than maximum pressure shown on unit nameplate To prevent injury or death due to instantaneous release of high pressure water relief valves should be field supplied on system water piping WARNING Always u...

Page 11: ... to enter the refrigerant to water heat exchanger See Appendix A Heat Exchanger Corrosion Resistance for more information CAUTION OPEN LOOP APPLICATIONS Failure of the condenser as a result of chemical corrosion is excluded from coverage under AAON Inc warranties and the heat exchanger manufacturer s warranties WARNING WATER FREEZING Failure of the condenser due to freezing will allow water to ent...

Page 12: ...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 should be an L shaped duct 7 Clean furnace duct and components upon completion of the construction setup Verify furnace operating conditions including input rat...

Page 13: ...nd Vertical Return N Option M Interior Corrosion Protection Model Option A COOLING HEAT PUMP A1 REFRIGERANT STYLE 0 Air Handling Unit B R 410A Non Compressorized DX Air Handling Unit C R 410A Standard Efficiency E R 410A Variable Capacity Scroll Compressor High Efficiency F R 410A Variable Capacity Scroll Compressor Standard Efficiency G R 410A Two Step Compressor High Efficiency H R 410A Two Step...

Page 14: ...eat U 1 Stage 4 Stage Auxiliary Heat V 2 Stage 4 Stage Auxiliary Heat Y Modulating Lead VCC 4 Stage Aux Heat Model Option B HEATING B1 HEATING TYPE 0 No Heating 1 Electric Heat 2 Natural Gas Aluminized 3 Natural Gas Stainless Steel 4 High Altitude Natural Gas Aluminized 5 High Altitude Natural Gas Stainless Steel 6 LP Gas Aluminized 7 LP Gas Stainless Steel 8 High Altitude LP Gas Aluminized 9 High...

Page 15: ...IGURATION 0 Standard None A 1 Blower Standard Eff Motor C 1 Blower Premium Eff Motor E 1 Blower Premium Eff Motor 1 VFD H 1 Blower High Efficiency EC Motor J 1 Blower Single Phase Motor Speed Control K Option E Shaft Grounding 1C RETURN EXHAUST AIR BLOWER 0 Standard None B 15 Backward Curved Plenum C 18 5 Backward Curved Plenum J 15 Backward Curved Plenum 70 Width K 18 5 Backward Curved Plenum 60 ...

Page 16: ...ackward Curved Plenum K 18 5 Direct Drive BC Plenum 60 Width 5C SUPPLY AIR BLOWER MOTOR A 0 25 hp 850 rpm B 0 5 hp 1075 rpm C 1 hp 1750 rpm D 2 hp 1760 rpm W 0 75 hp 1760 rpm Z 0 167 hp 825 rpm Feature 6 FILTERS 6A PRE FILTER 0 Standard None A 2 Pleated 30 Eff MERV 8 B Metal Mesh Outside Air Filter C Lint Screen Filter D Exhaust Air ERW Filter E Option A B F Option A D G Option B D H Option A B D ...

Page 17: ...FRIGERATION ACCESSORIES 0 Standard A Sight Glass B Compressor Isolation Valves C Options A B D ECM Condenser Fan Multiple Speed E ECM Condenser Fan Head Pressure Control G Options A D H Options B D J Options A B D K Options A E L Options B E M Options A B E Feature 10 POWER OPTIONS 0 Standard Power Block A 100 Amp Power Switch B 150 Amp Power Switch C Power Switch 250 Amp G Circuit Breaker 15 Amp ...

Page 18: ...ate Level Switch S Options A R T Options B R U Options C R V Options D R W Options H R Y Options E R Z Options F R 1 Options G R 2 Options J R 3 Options K R 4 Options L R 5 Options M R 6 Options N R 7 Options P R 8 Options Q R Feature 12 CONTROLS 0 Standard A Low Limit Controls B Phase and Brown Out Protection C Energy Recovery Wheel Defrost D Energy Recovery Wheel Rotation Detection E Compressor ...

Page 19: ...le Zone VAV Heat Pump Unit Controller VAV Cool VAV Heat Z Constant Volume Heat Pump Unit Controller CV Cool CV Heat 1 Makeup Air Heat Pump Unit Controller CV Cool CV Heat 2 Single Zone VAV Unit Controller VAV Cool CV Heat 3 Single Zone VAV Unit Controller VAV Cool VAV Heat 4 Field Installed DDC Controls by Others 5 Field Installed DDC Controls Furnished by Others with Isolation Relays 6 Factory In...

Page 20: ...andard ETL U S A Listing A M E A B Chicago Cool Gas C Chicago Cool Electric Heat D Chicago Cool Only E Chicago Gas Only F Chicago Electric Heat Only G Chicago No Cool No Heat H ETL U S A Canada Listing K California OSHPD Certification L Shake Table Cert ASCE 7 05 ICC ES AC 156 M Seismic Construction Non Certified N California OSHPD Certification Chicago P Shake Table Cert ASCE 7 05 ICC ES AC 156 C...

Page 21: ... Orion VCB X Controls System Integrated BACnet MSTP U WattMaster Orion VCB X Controls System Integrated BACnet MSTP with Specials V VCC X w BACnet MSTP W VCC X w BACnet MSTP w Specials Y Remote Mounted AAON Touchscreen Controller Z VCC X w BACnet MSTP for Split System 1 VCC X w BACnet MSTP w Specials for Split System Feature 23 TYPE B Standard AAON Gray Paint U Special Pricing Authorization Specia...

Page 22: ...thout cooling b Certified for outdoor installation only c Certified for installation on a combustible roof with a minimum of 12 high curb Certification of Cooling Models a Certified as a commercial central air conditioner with or without electrically operated compressors b Certified for outdoor installation only c Certified for installation on a combustible roof with a minimum of 12 high curb d Ce...

Page 23: ... then the factory should be notified before any repair action is taken in order to protect the warranty Certain equipment alteration repair and manipulation of equipment without the manufacturer s consent may void the product warranty Contact the AAON Warranty Department for assistance with handling damaged goods repairs and freight claims 918 583 2266 Note Upon receipt check shipment for items th...

Page 24: ...eave the unit off until the main power switch has been turned on again for at least 24 hours for units with compressor crankcase heaters This will give the crankcase heater time to clear any liquid accumulation out of the compressor before it is started Always control the unit from the thermostat or control panel never at the main power supply except for servicing emergency or complete shutdown of...

Page 25: ...or electric heating coil may overheat and may cut the burner or heater off entirely by action of the safety high temperature limit devices which are factory mounted at the heat exchanger and supply fan areas Airflow should be adjusted after installation to obtain an air temperature rise within the range specified on the unit rating plate at the required external static pressure Should overheating ...

Page 26: ... to the condensate drain pan of the unit Units include one drain pan connection Condensate drain pipes or p trap is factory supplied and shipped loose in the control compartment for field installation If codes require a condensate drain line the line 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 lo...

Page 27: ...aterials The National Gas and Propane Installation Code B149 1 specifies a 6 ft horizontal vent terminal clearance to gas and electric meters and relief devices Local codes may supersede or further place restrictions on vent termination locations Table 3 Unit Clearances Location Unit Size 2 6 tons Front Heat Exchanger 36 Back Outside Air 36 Left Side 24 Right Side 48 Top Unobstructed Figure 2 RQ S...

Page 28: ...oofing contractors to avoid any possible leakage CAUTION Where the supply or warm air duct passes through a combustible roof a clearance of 1 inch must be maintained between the outside edges of the duct and combustible material in accordance with National Fire Protection Association Standard No 90A Provide flashings or enclosure between structure and roof and all joints must be sealed with mastic...

Page 29: ...29 Figure 3 RQ Cabinet Standard and Power Exhaust Gasket Locations ...

Page 30: ...rks must extend through to the opposite side of the unit When lifting from the end of the unit the forks must extend at least 44 under the unit When lifting with 48 forks the back of the fork must be no more than 4 from the unit Figure 4 Forklifting an RQ Series Unit from the Side Figure 5 Forklifting an RQ Series Unit from the Front Incorrect lifting can cause damage to the unit CAUTION FORKLIFTI...

Page 31: ...it with the outside air hood in the downward shipping position However the unit may be lifted with the outside air hood in the open position Before lifting unit be sure that all shipping material has been removed from unit Secure hooks and cables at all lifting points provided on the unit Hoist unit to a point directly above the curb and duct openings Be sure that the gasket material has been appl...

Page 32: ...se the unit should include the base insulation option or the base must be field insulated Figure 8 Vertical Duct Connection Do not drill or punch holes in the base of the unit from inside the unit or from below the unit to attach ductwork Leaking may occur if unit base is punctured CAUTION ...

Page 33: ...certified to ICC ES AC156 when using a seismic curb for seismic certifications to apply Any deviations or modifications to the unit or curb will void all seismic certification Structural engineer of record must approve building anchorage to unit or curb in compliance with OSP 0180 10 Use provided self tapping screws to attach base of unit to seismic curb bracket Figure 9 Solid Bottom Seismic Curb ...

Page 34: ...34 Figure 10 Seismic Solid Bottom Curb without Filters Cross Section Figure 11 Seismic Solid Bottom Curb without Filters Detail A Figure 12 Seismic Solid Bottom Curb without Filters Detail B ...

Page 35: ...take adjustments should be made according to building ventilation or local code requirements Remove the two screws at the bottom of the rain hood that secure it in the shipping position Remove the screws that attach the side pieces of the hood to the top of the hood Rotate the side pieces so that the holes along one edge line up with the holes on the top piece and the flange is on the inside of th...

Page 36: ...en Rain Hood Metal Mesh Filters Metal mesh outside air filters require installation of the filter rack on the intake of the rain hood Clips which hold the metal mesh filters in the filter rack should face outward Figure 17 Rain Hood with Metal Mesh Filter Rack Installation ...

Page 37: ...er of the unit compressor compartment See unit drawing for specific location Figure 18 Unit Base Utility Entry Figure 19 Back View of Power Switch from Control Compartment Electric shock hazard Before attempting to perform any installation service or maintenance shut off all electrical power to the unit at the disconnect switches Unit may have multiple power supplies Failure to disconnect power co...

Page 38: ...hown 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 maximum deviation from the average voltage divided by the average voltage Example 218V 237V 235V 3 230V then 100 230V 218V 230V 5 2 which exceeds the allowable imbalance Check voltage imbalance at the unit dis...

Page 39: ...tances Table 5 Control Wiring Wire Size Stranded Copper Conductors Only Total Wire Distance Allowable 20 AWG 200 ft 18 AWG 350 ft 16 AWG 500 ft 14 AWG 750 ft 12 AWG 1250 ft Take the total wire distance allowable and divide by the number of wires to be connected This indicates the distance allowable for that size wire The wiring to the unit must not exceed the total wire distance allowable If the v...

Page 40: ...he gas input rate Unit nameplate input rate value has been calculated at the altitude where the unit was shipped Above 2 000 ft the input rate is adjusted 4 for every 1 000 ft Figure 20 RQ Series Gas Heat Exchanger Maximum Piping Capacities Table 7 Natural Gas ft3 hr Specific Gravity 0 6 Supply Pressure 0 5 psi Pressure Drop 0 5 w c Pipe Size Length of Pipe 20 ft 50 ft 100 ft 150 ft 200 ft 1 2 120...

Page 41: ...t and 270 kBtu hr the required minimum pipe size is 1 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 is required to be inst...

Page 42: ...ort Intervals 1 2 to 3 4 Every 6 ft 3 4 to 1 Every 8 ft 1 3 4 or Larger Horizontal Every 10 ft 1 1 4 or Larger Vertical Every Floor Additional Gas Piping Considerations Local codes will usually require a field provided and installed manual main shutoff valve and union external to the unit Main shutoff valve should be labeled A drip leg should be installed near the unit connection to trap sediment ...

Page 43: ...43 Figure 21 Example 2 6 ton through the Base Gas Piping ...

Page 44: ...plications Water source heat pump units using 100 outside air must have electric preheat if the application has a potential for operation with air entering the indoor coil below 43 F with a water loop temperature of 70 F LEAK CHECK GAS PIPE The gas pipe in the unit should be checked for leaks before startup Leak checking is the responsibility of the installing contractor All connections should be ...

Page 45: ...hangers A refrigerant to water heat exchanger contains refrigerant in one passage and water in another passage Water is subject to freezing at 32 F When water freezes in a heat exchanger significant forces are exerted on the components of the heat exchanger where the water is confined Failure of the condenser due to freezing will allow water to enter the refrigerant circuit and will cause extensiv...

Page 46: ... installed between the condenser water supply and return connections This sensor provides a signal to the unit controller that water flow is present in the refrigerant to water heat exchanger and the unit can operate without damaging unit components Table 11 Condenser Water Connections Model RQ Supply and Return Connection Size 002 3 4 Sweat 003 004 005 006 1 Sweat Only use approved water pipe mat...

Page 47: ... should be installed in the condenser water supply and return lines for unit isolation and water flow balancing All manual flow valves should be of the ball valve design Globe or gate valves should not be used due to high pressure drops and poor throttling characteristics Pressure and temperature ports are recommended in condenser water supply and return lines for system balancing These openings s...

Page 48: ...led up through the condensate drain piping Condensate drain trapping and piping should conform to all applicable governing codes Discharge and Suction Line Piping There are two different locations to pipe out of the unit the post corner hole location and the post back hole location The post corner hole location is to run pipe along the roof and then down by the disconnect switch Figure 22 and Figu...

Page 49: ...49 Figure 22 Post Corner Hole Location Figure 23 Post Back Hole Location ...

Page 50: ...50 Figure 24 Post Corner Hole Piping Figure 25 Post Back Hole Piping ...

Page 51: ...Sizes Model RQ Steam Coil Connection Size 002 006 2 1 8 standard coil 1 1 8 preheat coil Chilled Water Coil Four or six row chilled water cooling coils can be factory installed All valve controls for cooling operation are field supplied and field installed Chilled water coil connections are spun copper tube Table 14 Chilled Water Coil Connection Sizes Model RQ Chilled Water Coil Connection Size 00...

Page 52: ...scrolling through the following displays 1 LAT Measured leaving air temperature LAT average of LAT A and B probes MOD Modulation rate currently being applied to stage one SCR 2 WKGset Working LAT setpoint F LATeet RESETset as adjusted by 0 10V RESET signal 3 LATset Leaving air temperature F control setpoint 4 RESETset Reset air temperature F control setpoint 5 OATset Outside air temperature F cont...

Page 53: ...es 0 indicates normal operation 1 6 corresponds to stages 1 6 being forced on Stage 1 the SCR is forced to 50 System Setting Screens These screens are access by pressing the up button and then entering the technician password 2425 The screens are scrolled through by pressing either right or left buttons on the controller Adjustment is made by pressing the up and down buttons After a short time of ...

Page 54: ...ure setpoint Range 35 F 60 F and the default is 35 F 6 LLTset Low Limit Time temperature setpoint Range 35 F 50 F and the default is 35 F If LLTSet temperature is not reached within BelowLLT time after reaching full output the status relay will operate 7 RESETset Reset Setpoint temperature Range 35 F 80 F and the default is 50 F 8 ManSTG Temporary manual override a specified stage testing 0 normal...

Page 55: ...ves 24VAC preheat enable Controller evaluates if outside air temperature OAT is below setpoint OATset If OAT OATset controller will delay heating startup by time setpoint STARTDLY then stage up preheat to maintain the setpoint LATset to a maximum number of stages set in setpoint Stages If a safety is reached with the controller s safety sensors then the electric preheat will be de energized for a ...

Page 56: ...municate if the electric preheat is in operation PHO is a normally open contact PHC is a normally closed contact and COM is the common These terminals are not required to be connected PHE is the electric preheat operation enable PH and PH are the preheat set point reset terminals Energy Recovery Units General Information AAONAIRE units have been equipped with an energy recovery wheel This section ...

Page 57: ... does not rotate when power is applied it may be necessary to readjust the diameter air seals Air Seal Adjustments Pile type air seals across both sides of the energy wheel diameter are factory adjusted to provide close clearance between the air seal and wheel Cross Section of Air Seal Structure Racking of the unit or cassette during installation and or mounting of the unit on a non level support ...

Page 58: ...care All cassettes should be lifted by the bearing support beam Holes are provided on both sides of the bearing support beams to facilitate rigging as shown in the following illustration Routine maintenance of the Energy Recovery Cassettes includes periodic cleaning of the Energy Recovery Wheel as well as inspection of the Air Seals and Wheel Drive Components as follows Lifting Hole Locations Clea...

Page 59: ...oss surface of segment to separate polymer strips for better cleaning action Rinse dirty solution from segment and remove excess water before reinstalling in wheel Air Seals Four adjustable diameter seals are provided on each cassette to minimize transfer of air between the counter flowing airstreams To adjust diameter seals loosen diameter seal adjusting screws and back seals away from wheel surf...

Page 60: ...g can be compensated for by adjusting the diameter seals If greater than 1 4 inch dimension C racking must be corrected to ensure that drive belt will not disengage from wheel Avoid Racking of Cassette Frame Operation Startup Procedure 1 By hand turn wheel clockwise as viewed from the pulley side to verify wheel turns freely through 360º rotation 2 Before applying power to drive motor confirm whee...

Page 61: ...e wheel rim and is held in place by a Segment Retaining Catch Segment Retainer To install wheel segments follow steps one through five below Reverse procedure for segment removal 1 Unlock two segment retainers one on each side of the selected segment opening 2 With the embedded stiffener facing the motor side insert the nose of the segment between the hub plates Disconnect electrical power before ...

Page 62: ...d loosen and remove 4 mounting bolts 5 Install replacement motor with hardware kit supplied 6 Install pulley to dimension as shown and secure set screw to drive shaft 7 Stretch belt over pulley and engage in groove 8 Follow start up procedure Belt Replacement 1 Obtain access to the pulley side bearing access plate if bearing access plates are provided Remove two bearing access plate retaining scre...

Page 63: ...and tighten retaining screws Rotate wheel in clockwise direction to determine that wheel rotates freely with slight drag on seals 9 Reinstall bearing locking collar Rotate collar by hand in the direction the wheel rotates see label provided on each cassette for wheel rotation 10 Lock in position by tapping drift pin hole with hammer and drift Secure in position by tightening set screw 11 Reinstall...

Page 64: ...at dehumidification mode to check for correct operation Units equipped with heat pump options should be charged in heating mode to get the proper charge After charging unit should be operated in cooling mode to check for correct charge Charge may need to be adjusted for cooling mode If adjustments are made in the cooling mode heating mode must be rerun to verify proper operation After adding or re...

Page 65: ...re pressure chart Subtract the saturated temperature from the measured suction line temperature to determine the evaporator superheat Compare calculated superheat to the table below for the appropriate unit type and options Table 16 Acceptable Refrigeration Circuit Values Air Cooled Cond Air Source Heat Pump Sub Cooling 8 15 F Sub Cooling with Hot Gas Reheat 8 15 F Superheat 8 15 F Water Cooled Co...

Page 66: ...49 3 134 500 5 27 91 0 54 152 8 81 238 6 108 354 2 135 506 9 28 92 9 55 155 5 82 242 3 109 359 1 136 513 4 29 94 9 56 158 2 83 246 0 110 364 1 137 520 0 30 96 8 57 161 0 84 249 8 111 369 1 138 526 6 31 98 8 58 163 8 85 253 7 112 374 2 139 533 3 32 100 9 59 166 7 86 257 5 113 379 4 140 540 1 33 102 9 60 169 6 87 261 4 114 384 6 141 547 0 34 105 0 61 172 5 88 265 4 115 389 9 142 553 9 35 107 1 62 17...

Page 67: ...67 Gas Heater Instructions Figure 27 Gas Heater Instructions ...

Page 68: ...ubing of the first cooling circuit and wired to de energize all cooling circuits if tubing temperature falls below setpoint Option is used to prevent freezing of evaporator coil Recommended Setting 32 F to 35º F Supply Fan EC Motor Startup Figure 28 PIN Connectors on EC Supply Fan Motor Electronics ...

Page 69: ...s full speed 5 If DC Voltage is present on S1 S2 then ensure that BC blower relay is energized and is passing the DC voltage through to the motor If BC is not energized then check wiring for 24VAC blower call 6 If no DC voltage is present on S1 S2 then check S1 S3 this is the 10VDC output from the motor that is supplied to the Potentiometer for speed control If the following troubleshooting sugges...

Page 70: ...2 208 230 VAC 208 230 VAC 208 230 VAC 208 230 VAC 208 230 VAC Green 10 EYELET Ground GND GND GND GND GND Blue 0 50 BWS Common Common 24 VAC 24 VAC 24 VAC 24 VAC Yellow 0 50 BWS Signal PWM 24 VAC 24 VAC White 0 50 BWS Signal 24 VAC 24 VAC Orange 0 50 BWS Signal 24 VAC 24 VAC RPM 300 1100 300 500 850 1100 Rotation CCW CCW CCW CCW CCW ECM Toolbox ID Variable Speed 4 Speed 3 Speed 2 Speed 1 20 PWM RPM...

Page 71: ...ewdriver Recommended Settings The switch will come factory set to cut in at 425psi 5psi and a differential of 155psi or open at 270psi 5psi Settings for CUT IN and DIFFERENTIAL PRESSURE are indicated with two slider gauges Each adjustment screw sits above the setting that it controls Cut In Differential ...

Page 72: ...e the pressure set point for the DIFFERENTIAL Gauge turn the adjustable screw clockwise To lower the pressure set point for the DIFFERENTIAL Gauge turn the adjustable screw counter clockwise NOTE The pressure values on the gauge should be verified with gauges on the refrigerant line The gauge scale is for illustration purposes only Cut In Gauge Cut In Gauge Differential Gauge Differential Gauge ...

Page 73: ...ion and Control When a call for cooling G and Y1 Y2 etc is made the supply blower motors and compressors will energize Note When using field controls any variable capacity compressors should run at 100 for 1 minute when starting Gas Heater Operation When heat G and W1 W2 etc is called for the combustion motor starts and the ignition control is energized The control sends 24 VAC to the main gas val...

Page 74: ...ck out the unit Fans evaporator coils and filters should be inspected at least monthly Gas Heating Make sure all gas supply lines have been purged of air before turning on the electrical power switch Turn the gas valve to the on position see startup instructions Turn the main electrical power on and set the controls to the heating mode of operation The combustion ventilation motor should operate T...

Page 75: ...ultation with an AAON service representative If induced draft blower motor assembly has to be replaced care must be taken to provide an airtight seal between the blower housing and the burner box Gas Heat Exchanger Removal Removal Disconnect all wiring on the heat exchanger Disconnect flex gas lines and pull out of the way Remove screws around the perimeter of the heat exchanger face plate that co...

Page 76: ...ews that attach it to the top of the unit Disconnect the wiring from the motor and loosen the bolt that clamps the motor mount to the motor Remove the motor and fan through the top of the orifice Figure 30 Removal of a Condenser Fan Assembly Reinstallation Set the motor back into the motor mount and tighten bolt Adjust fan until the top of the blade is even with the top of the orifice Reconnect wi...

Page 77: ...front and back of the evaporation coil Reinstall economizer assembly if necessary Connect the suction and liquid copper connections to the evaporator coil Reinstall the TXV bulb on the suction line Evacuate the refrigerant system Weigh in the nameplate refrigerant charge See Adjusting Refrigerant Charge section to check for proper sub cooling and superheat of the refrigerant systems E Coated Coil ...

Page 78: ...g agent assuming it is used in accordance with the manufacturer s directions on the container for proper mixing and cleaning has been approved for use on e coated coils to remove mold mildew dust soot greasy residue lint and other particulate Enviro Coil Concentrate Part Number H EC01 Recommended Chloride Remover CHLOR RID DTS should be used to remove soluble salts from the e coated coil but the d...

Page 79: ...esult in coil damage system performance fall off and potentially leaks requiring coil replacement Documented routine cleaning of microchannel coils with factory provided e coating is required to maintain coating warranty coverage Use the E Coated Coil Cleaning section for details on cleaning e coated coils Field applied coil coatings are not recommended with microchannel coils Allowed Chemical Cle...

Page 80: ...cleaner that is not covered in this section you must get written approval from the AAON warranty and service department Use of unapproved chemicals will void the warranty AAON testing has determined that unless a chemical has a neutral pH 6 8 it should 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 f...

Page 81: ...ure 32 2 6 ton Supply Fan Remove wire connections from motor For EC motors unplug the wire harness at the control module that connects to the unit control panel Through the blower access opening remove the two 5 16 bolts that connect the blower assembly to the inlet wall see Figure 33 Figure 33 RQ Supply Fan Removal Bolts Through the coil access door remove the two 5 16 bolts that connect the blow...

Page 82: ...s recover the DPM will re energize the output relay after 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 ...

Page 83: ...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 84: ...Out M1 M2 Contractor L1 Control Voltage N L2 Control Voltage L U1 U2 Digital Unloader Solenoid V1 V2 Vapor Injection Solenoid The compressor controller modulates the compressor unloader solenoid in an on off pattern according to the capacity demand signal of the system The following table shows the linear relationship between the demand signal and compressor capacity modulation The compressor cont...

Page 85: ... door and pull filters straight out to inspect all of the filters Replace filters with the size indicated on each filter or as shown in the tables below Arrow on the replacement filters must point towards the blower PE Power Exhaust Table 20 RQ Series 2 6 ton Pre Filters Feature 6A Quantity Size Type 0 No Pre Filters A 2 20 x 20 x 2 Pleated 30 Eff MERV 8 B 1 16 x20 x1 Metal Mesh Outside Air Electr...

Page 86: ... Recovery Wheel Exhaust Air Filters Feature 6A D F G H OA 1 16 x 16 x 2 EA 1 16 x 16 x 2 Figure 37 RQ Series 2 6 ton Standard Filter Layout Viewed from the Upstream Side of the Cooling Coil Replacement Parts Parts for AAON equipment may be obtained from your local AAON representative Reference the unit serial number and part number when ordering parts AAON Warranty Service and Parts Department 242...

Page 87: ...d 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 0 Within 24 Hours 0 0 0 6 0 7 5 0 0 7 5 9 0 9 0 0 Ammonium NH4 2...

Page 88: ...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 89: ...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 90: ... 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 electrical connections been tested for tightness Yes No 6 Does the electrical service correspond to the unit nameplate Yes No 7 On 208 230V units has transformer tap been checked Yes No 8 Has overcurrent protection been installed to match t...

Page 91: ...meplate Amps________ Number hp L1 L2 L3 1 Band Size_____________________ VFD Frequency________________ Outside Air Economizer Dampers Operation Check Damper Wiring Check Gears Check Damper Actuator Type __________________________________________________________ Economizer Changeover Type and Operation _______________________________________ Unit Configuration Water Cooled Condenser Air Cooled Cond...

Page 92: ...re Saturated Temperature Line Temperature Sub cooling Superheat Discharge N A N A Suction N A Liquid N A Refrigeration System 1 Full Capacity 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 1 Reduced Capacity Heating Mode Heat Pump Only Pressure Saturated Temperature Line Temperature Sub...

Page 93: ...Has the water piping been insulated Yes No 7 What is the freeze point of the glycol N A if water ______________________________ Gas Heating Natural Gas Propane Purge Air from Lines Verify Pilot Spark Stage Manifold Pressure w c Stage Manifold Pressure w c 1 3 2 4 Electric Heating Stages__________ Limit Lockout Aux Limit Lockout Stage Amps Stage Amps 1 3 2 4 Electric Preheating Limit Lockout Aux Li...

Page 94: ...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 startup maintenance and servicing of the equipment falls to the owner and qualified licensed technician Entry Date Action Taken Name Tel ...

Page 95: ...cted condenser water connections table added section for variable capacity compressor controller and added Appendix B October 2013 Added cautions calling for the need to seal water electrical and gas entries into the unit January 2014 Added electric preheat options and installation information February 2014 Added energy recovery wheel installation maintenance and startup information July 2014 Adde...

Page 96: ...maximum allowable voltage imbalance updated Updated Factory Technical Support Phone number July 2017 Updated the Allowed Chemical Cleaners and Procedures Added Outdoor Airflow Monitoring options Feature 14A Added Shaft Grounding options Feature 1B and Feature 5A Added High Condensate Level Switch Feature 11 Added Shrink Wrap Options Feature 20 Added High Turndown Modulating Gas option Feature B3 U...

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Page 100: ... Technical Support 918 382 6450 Note Before calling Technical Support please have the model and serial number of the unit available Parts For replacement parts please contact your local AAON Representative It is the intent of AAON to provide accurate and current product information However in the interest of product improvement AAON reserves the right to change pricing specifications and or design...

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