AAON SA-023 Installation Operation & Maintenance Download

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SA SERIES

Vertical Self-Contained Units and

Indoor Air Handling Units

Installation, Operation

& Maintenance

If the information in this manual is not
followed exactly, a fire or explosion
may result causing property damage,
personal injury or loss of life.

FOR YOUR SAFETY

Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of this or any other appliance.

WARNING

QUALIFIED INSTALLER

Improper

installation,

adjustment,

alteration, service or maintenance
can

cause

property

damage,

personal injury or loss of  life.  Startup
and  service  must  be  performed  by  a
Factory  Trained  Service  Technician.
A  copy  of  this  IOM  should  be  kept
with the unit.

WARNING

Summary of Contents for SA-023

Page 1: ... loss of life FOR YOUR SAFETY Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance WARNING WARNING QUALIFIED INSTALLER Improper installation adjustment alteration service or maintenance can cause property damage personal injury or loss of life Startup and service must be performed by a Factory Trained Service Technician A copy of this IO...

Page 2: ......

Page 3: ... Heat Exchanger Cleaning 33 Electrical 33 Cutting Electrical Openings 34 Thermostat Control Wiring 35 Duct Connection 36 Condensate Drain Piping 36 Waterside Economizer 37 Hot Water Coil 41 Chilled Water Coil 41 Startup 41 Supply Fans 41 Supply Fan Spring Isolator Adjustment 41 Supply Fan Removal 43 Fan Airflow Adjustment 43 Filters 45 Adjusting Refrigerant Charge 45 Freeze Stat Startup 47 Operati...

Page 4: ...ownout Protection Module 51 Filter Replacement 53 Replacement Parts 54 AAON Warranty Service and Parts Department 54 Appendix A Heat Exchanger Corrosion Resistance 55 SA Series Startup Form 57 Maintenance Log 61 Literature Change History 62 R74130 Rev E 170925 ...

Page 5: ...tails 22 Figure 5 One Piece Dual Unit Lifting Details 23 Figure 6 Two Piece Dual Unit Coil Section Lifting Details 24 Figure 7 Two Piece Dual Unit Fan Section Lifting Details 25 Figure 8 Dual unit without splices and before being bolted together 27 Figure 9 Dual Unit Assembly Details 27 Figure 10 Dual unit with splices after being bolted together 28 Figure 11 Drain Trap 36 Figure 12 SA Series Unit...

Page 6: ...ould result in dangerous operation serious injury death or property damage Before servicing disconnect all electrical power to the unit 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 Electric shock hazard Before servicing ...

Page 7: ...ing an Arc Flash Boundary to be field established and marked for identification of where appropriate Personal Protective Equipment PPE be worn should be followed WARNING UNIT HANDLING To prevent injury or death lifting equipment capacity shall 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 un...

Page 8: ...ygen acetylene or air in place of refrigerant and dry nitrogen for leak testing A violent explosion may result causing injury or death WARNING Always use a pressure regulator valves and gauges to control incoming pressures when pressure testing a system Excessive pressure may cause line ruptures equipment damage or an explosion which may result in injury or death WARNING Do not work in a closed ar...

Page 9: ...cooled condenser 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 enter the refrigerant circuit and wi...

Page 10: ... unique to the model you have 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 5 MINUTE MINIMUM OFF TIME To prevent motor overheating compressors must cycle off for a minimum of 5 minutes 5 MINUTE MINIMUM ON TIME To...

Page 11: ...osion Protection F Option C Interior Corrosion Protection A1 Refrigerant Style 0 Air Handling Unit B R 410A Non Compressorized DX AHU E R 410A Variable Capacity Scroll Compressor A2 Unit Configuration 0 No Cooling J Shell and Tube Water Cooled Cond Std Evap Coil K Shell and Tube Water Cooled Cond 6 Row Evap Coil R Brazed Plate Water Cooled Cond Std Evap Coil T Brazed Plate Water Cooled Cond 6 Row ...

Page 12: ...onomizer 6 Row Coil 1B Plenum Height 0 33 Plenum Height A 37 Plenum Height B 41 Plenum Height C 45 Plenum Height D 49 Plenum Height E 53 Plenum Height F 57 Plenum Height G 37 Plenum Height Sound Attenuation H 41 Plenum Height Sound Attenuation J 45 Plenum Height Sound Attenuation K 49 Plenum Height Sound Attenuation L 53 Plenum Height Sound Attenuation M 57 Plenum Height Sound Attenuation 1C Disch...

Page 13: ...rved Plenum 5C Supply Air Blower Motor C 1 hp 1760 rpm D 2 hp 1760 rpm E 3 hp 1760 rpm F 5 hp 1760 rpm G 7 5 hp 1760 rpm H 10 hp 1760 rpm N 1 hp 1170 rpm P 2 hp 1170 rpm Q 3 hp 1170 rpm R 5 hp 1170 rpm S 7 5 hp 1170 rpm 6A Pre Filter Type 0 No Pre Filter A 2 Pleated 30 Eff MERV 8 6B Unit Filter Type 0 2 Pleated 30 Eff MERV 8 A 4 Pleated 30 Eff MERV 8 B 4 Pleated 65 Eff MERV 11 C 4 Pleated 85 Eff M...

Page 14: ...thers 5 Field Installed DDC Controls by Others with Isolation Relays 6 Factory Installed DDC Controls Furnished by Others with Isolation Relays 14A Water Cooled Condenser 0 Standard None A Balancing Valves B Water Flow Switch C Motorized Shut Off Valve D Head Pressure Control E Options A B F Options A C G Options A D H Options B C J Options B D L Options A B C M Options A B D S Option A SMO 254 Co...

Page 15: ...eld Adjustable for Glycol 16 Interior Cabinet Options 0 Standard A Overflow Switch B UV Lights C Options A B 17 Blank 0 Standard 18 Blank 0 Standard 19 Code Options 0 Standard ETL U S A Listing D Chicago Cool Only G Chicago No Cool No Heat 20 Crating 0 Standard A Export Crating B Forkliftable Base C Shipping Shrink Wrap D Options A B E Options A C F Options B C G Options A B C 21 Shipping Splits 0...

Page 16: ...codes All appliances must be electrically grounded in accordance with local codes or in the absence of local codes the current National Electric Code ANSI NFPA 70 or the current Canadian Electrical Code CSA C22 1 Receiving Unit When received the unit should be checked for damage that might have occurred in transit If damage is found it should be noted on the carrier s Freight Bill A request for in...

Page 17: ...tat system switch to OFF or turn the unit off at the control panel and leave the unit off until the main power switch has been turned on again for at least 24 hours for units with compressor crankcase heaters This will give the crankcase heater time to clear any liquid accumulation out of the compressor before it is started Always control the unit from the thermostat or control panel never at the ...

Page 18: ... of condensate lines Waterside economizer coil units include a separate condensate drain pan which drains into the evaporator coil drain pan No additional drain line is needed for the waterside economizer drain pan Unit Size Units are modular and composed of combination of the four standard unit sizes SA 023 SA 028 SA 030 and SA 035 Table 1 SA Series Models Model Cabinet Type Intake Cabinet 1 Cabi...

Page 19: ...e clearance requirements Allow adequate space for piping access and panel removal Condenser water piping and condensate drain connections are near the bottom on the back of the unit Figure 1 SA Series Unit with Right Intake Lifting and Handling the Unit Before lifting unit be sure that all shipping material has been removed from unit If cables or chains are used to hoist the unit care should be ta...

Page 20: ...20 Figure 2 One Piece Single Unit Lifting Details ...

Page 21: ...21 Figure 3 Two Piece Single Unit Coil Section Lifting Details ...

Page 22: ...22 Figure 4 Two Piece Single Unit Fan Section Lifting Details ...

Page 23: ...23 Figure 5 One Piece Dual Unit Lifting Details ...

Page 24: ...24 Figure 6 Two Piece Dual Unit Coil Section Lifting Details ...

Page 25: ...25 Figure 7 Two Piece Dual Unit Fan Section Lifting Details ...

Page 26: ...mplete unit A crow bar or similar tool can be used to line up the sections Factory provided bolts can then be used to secure the coil sections together See Figure 9 4 Align and set each fan section on top of the coil section s 5 For dual units align the bolt holes of the fan sections if they are shipped separated Fan service access doors of each section should be on the same side of the complete u...

Page 27: ...27 Figure 8 Dual unit without splices and before being bolted together Figure 9 Dual Unit Assembly Details ...

Page 28: ...28 Figure 10 Dual unit with splices after being bolted together ...

Page 29: ...ts Any damage to the equipment as a result of condenser failure from chemical corrosion due the fluid in the condenser is excluded from coverage under AAON warranties and the heat exchanger manufacturer warranties Freezing Water in the Heat Exchanger This product contains one or more refrigerant to water heat exchangers A refrigerant to water heat exchanger contains refrigerant in one passage and ...

Page 30: ...ol solution is recommended Table 2 Glycol Freezing Points Glycol Ethylene Glycol Propylene Glycol 20 18 F 19 F 30 7 F 9 F 40 7 F 6 F 50 28 F 27 F Water loop piping runs through unheated areas or outside the building should be insulated Water Piping Installing contractor must ensure a differential pressure switch or water flow switch is installed between the condenser water supply and return connec...

Page 31: ...must be controlled All make up water has minerals in it and as the water is evaporated in the cooling tower these minerals remain As the mineral content of the water increases the conductivity of the water increases Field provided and installed water treatment program must be compatible with stainless steel copper aluminum ABS plastic and PVC Batch feed processes should never be used as concentrat...

Page 32: ...I GPM PSI 45 4 2 45 4 2 45 4 2 45 1 7 39 3 3 39 3 3 39 3 3 39 35 2 8 35 2 8 35 2 8 35 SA 045 SA 050 SA 055 SA 058 GPM PSI GPM PSI GPM PSI GPM PSI 45 4 2 45 4 2 45 4 2 45 4 2 39 3 3 39 3 3 39 3 3 39 3 3 35 2 8 35 2 8 35 2 8 35 2 8 SA 060 SA 065 SA 070 Heat Exchanger 1 Heat Exchanger 2 GPM PSI GPM PSI GPM PSI GPM PSI 45 4 2 45 4 2 45 1 7 45 1 7 39 3 3 39 3 3 39 39 35 2 8 35 2 8 35 35 Each heat excha...

Page 33: ...et of unit specific wiring diagrams showing factory and field wiring are laminated in plastic and located inside the controls compartment door All units require field supplied electrical overcurrent and short circuit protection Device must not be sized larger than the Maximum Overcurrent Protection MOP shown on the unit nameplate Codes may require a disconnect switch be within sight of the unit It...

Page 34: ...re that the metal skins of the foam part do not separate from the foam this would result in reduced structural integrity of the part Size supply conductors based on the unit Minimum Current Ampacity MCA rating Supply conductors must be rated a minimum of 75 C Protect the branch circuit in accordance with code requirements The unit must be electrically grounded in accordance with local codes or in ...

Page 35: ... determine the allowable wiring distances 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 Total Wire Distance Allowable Quantity of Control Wires x Control Wire Distance Take the total wire distance allowable and divide by the number of wires to be connected This indicates the dist...

Page 36: ... may be equipped with more than one condensate drain pan connection A p trap and drain line must be installed on every drain connection with the p trap not to exceed 6 from the drain connection The lines should be the same pipe size or larger than the drain connection include a p trap and pitch downward toward drain An air break should be used with long runs of condensate lines Draw through coolin...

Page 37: ...chanical cooling only During waterside economizer only mode of operation condenser water flows through the waterside economizer coil with modulating valves maintaining supply air temperature setpoint The condenser water completely bypasses the water cooled condenser During waterside economizer with mechanical cooling mode of operation condenser water flows through the waterside economizer coil wit...

Page 38: ...ts of factory provided piping assemblies Connect the piping assembly to the unit Connect the actuators to the water valves Actuators are factory wired and included inside the unit Installing contractor is responsible for properly sizing and installing water system components Improper fluid flow due to valves piping or improper pump operation may result in unacceptable unit operation and void warra...

Page 39: ...Right Intake Piping Kit Left Intake Piping Kit Assembly 6 Assembly 1 Assembly 2 Assembly 3 Assembly 4 Assembly 5 Waterside Economizer Valve Waterside Economizer Bypass Valve Head Pressure Control Valve Supply Connection Supply Connection Return Connection Balancing Valve Balancing Valve Balancing Valve Balancing Valve ...

Page 40: ...izer Back View Right Intake Piping Kit Left Intake Piping Kit Assembly 6 Assembly 1 Assembly 2 Assembly 3 Assembly 4 Assembly 5 Waterside Economizer Valve Waterside Economizer Bypass Valve Head Pressure Control Valve Supply Connection Supply Connection Return Connection Balancing Valve Balancing Valve Balancing Valve ...

Page 41: ...cks on the performance of the unit This includes checking of the air flow the air filters condenser water flow and refrigerant charge Supply Fans SA Series units are equipped with direct drive backward curved plenum supply fan assemblies that deliver the air volume specified according to unit size and job requirements Supply Fan Spring Isolator Adjustment Piping shall be in accordance with nationa...

Page 42: ...t bolt and rotate the locking nut counter clockwise approximately four full rotations This will allow the locking nut to spin when the adjustment bolt is turned See Figure 17 Turn adjustment bolt counter clockwise to adjust all four isolators until 3 4 inch clearance is obtained between all spring brackets and spring supports Check all isolators to ensure that the spring spring cap and spring base...

Page 43: ...r wheels or with VFDs Field airflow adjustment may be required at startup Air volume bands for the wheels are sized according to the unit s air delivery specifications and can also 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 Adjustment If reduced air volume is required a...

Page 44: ...and equipped with easy bend tabs that are to be inserted into pre punched slots provided on the wheel Once the band has been inserted into the slots it MUST BE secured by bending the tabs over from the back side of the wheel and also MUST BE secured from the inside by connecting the ends together with a pop rivet in the holes provided on the ends of the band Figure 20 Blower Wheel with Band If the...

Page 45: ... 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 removing charge the system must be allowed to stabilize typically 10 15 minutes before making any other adjustments The type of unit and opt...

Page 46: ...nser Air Source Heat Pump Sub Cooling 12 18 F Sub Cooling with Hot Gas Reheat 15 22 F Superheat 8 15 F Water Cooled Condenser Water Source Heat Pump Sub Cooling 4 8 F Sub Cooling with Hot Gas Reheat 4 8 F Superheat 8 15 F Adjusting Sub Cooling and Superheat Temperatures The system is overcharged if the sub cooling temperature is too high and the evaporator is fully loaded low loads on the evaporat...

Page 47: ...6 87 261 4 114 384 6 141 547 0 34 105 0 61 172 5 88 265 4 115 389 9 142 553 9 35 107 1 62 175 4 89 269 4 116 395 2 143 560 9 36 109 2 63 178 4 90 273 5 117 400 5 144 567 9 37 111 4 64 181 5 91 277 6 118 405 9 145 575 1 38 113 6 65 184 5 92 281 7 119 411 4 146 582 3 39 115 8 66 187 6 93 285 9 120 416 9 147 589 6 40 118 1 67 190 7 94 290 1 121 422 5 148 596 9 41 120 3 68 193 9 95 294 4 122 428 2 149...

Page 48: ... charge See Startup section for information on air flow adjustment and refrigerant charge adjustment DX Cooling Set unit controls to cooling mode of operation with supply fans on Check the fans for correct operating direction amperage and voltage Check compressor operation rotation amperage and voltage to the unit nameplate check the amperage on the load side of the compressor contactor Condensate...

Page 49: ...f an e coated coil and is required to maintain coating warranty coverage Coil cleaning shall be part of the unit s regularly scheduled maintenance procedures Failure to clean an e coated coil will void the warranty and may result in reduced efficiency and durability For routine quarterly cleaning first clean the coil with the below approved coil cleaner After cleaning the coils with the approved c...

Page 50: ...mended that a hose be used as a pressure washer will damage the fins The water to be used for the rinse is recommended to be of potable quality though a lesser quality of water may be used if a small amount of CHLOR RID DTS is added Check with CHLOR RID International Inc for recommendations on lesser quality rinse water Supply Fans Lubrication All original blower motors and bearings are furnished ...

Page 51: ...r the restart time delay All settings and the last 4 faults are retained even if there is a complete loss of power DPM Setup Procedure With the supply voltage active to the module you can setup all of the DPM s settings without the line voltage connected To change the setpoint parameters use the right arrow key to advance forward through the setpoint parameters and the left arrow to backup if need...

Page 52: ...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 53: ... Table 11 45 70 tons Pre Filters Feature 6A Quantity Size Type 0 No Pre Filters A 18 20 x 20 x 2 Pleated 30 Eff MERV 8 Table 12 23 35 tons Unit Filters Feature 6B Quantity Size Type 0 9 20 x 20 x 2 Pleated 30 Eff MERV 8 A 9 20 x 20 x 4 Pleated 30 Eff MERV 8 B 9 20 x 20 x 4 Pleated 65 Eff MERV 11 C 9 20 x 20 x 4 Pleated 85 Eff MERV 13 D 9 20 x 20 x 4 Pleated 95 Eff MERV 14 Table 13 45 70 tons Unit ...

Page 54: ... number and part number when ordering parts AAON Warranty Service and Parts Department 2424 S Yukon Ave Tulsa OK 74107 Ph 918 382 6400 Fax 918 382 6364 www aaon com Note Before calling technician should have model and serial number of the unit available for the service department to help answer questions regarding the unit ...

Page 55: ...orrosion problems may occur especially when more factors are valued 0 Use is not recommended Water Containing Concentration mg l or ppm Time Limits Analyze Before AISI 316 SMO 254 Copper Alloy Nickel Alloy Alkalinity HCO3 70 Within 24 Hours 0 70 300 300 0 Sulfate SO4 2 70 No Limit 70 300 0 300 0 0 HCO3 SO4 2 1 0 No Limit 1 0 0 Electrical Conductivity 10µS cm No Limit 0 10 500 µS cm 500 µS cm 0 pH ...

Page 56: ...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 57: ...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 Yes No 8 On 208 230V units has transformer tap b...

Page 58: ...ssure PSIG Suction Pressure PSIG 1 2 3 4 Refrigeration System 1 Cooling Mode Pressure Saturated Temperature Line Temperature Sub cooling Superheat Discharge N A N A Suction N A Liquid N A Refrigeration System 2 Cooling Mode Pressure Saturated Temperature Line Temperature Sub cooling Superheat Discharge N A N A Suction N A Liquid N A Refrigeration System 3 Cooling Mode Pressure Saturated Temperatur...

Page 59: ... A Liquid N A Refrigeration System 2 Heating Mode Heat Pump Only Pressure Saturated Temperature Line Temperature Sub cooling Superheat Discharge N A N A Suction N A Liquid N A Refrigeration System 3 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 4 Heating Mode Heat Pump Only Pressure Sa...

Page 60: ...No 2 Has the entire system been filled with fluid Yes No 3 Has air been bled from the heat exchangers and piping Yes No 4 Is the glycol the proper type and concentration N A if water Yes No 5 Is there a minimum load of 50 of the design load Yes No 6 Has the water piping been insulated Yes No 7 What is the freeze point of the glycol N A if water ______________________________ Air Cooled Condenser F...

Page 61: ...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 62: ...M adding the brazed plate heat exchanger cleaning instructions November 2012 Update of the IOM adding information about compressor cycling July 2013 Updated qualified installed warning and removed warranty card verbiage November 2013 Updated water pipe connections May 2015 Updated Refrigerant to Water Heat Exchanger section to state that a screen strainer is factory provided ahead of the condenser...

Page 63: ...63 ...

Page 64: ... Technical Support 918 382 6400 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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