AAON V3-E vertical indoor air handling unit Installation, Operation & Maintenance Manual
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V3 Series
Vertical Indoor Air Handling Units
Installation, Operation
& Maintenance
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 must be kept with the unit.
WARNING
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.
WARNING
FOR YOUR SAFETY
Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.
Table of Contents
2
3
Index of Tables and Figures
Tables:
Figures:
Figure 2 - Minimum Clearance Required for Access to Unit (V3 Series plan view) ...................20
Figure 7 - V3 Schematic with (1) Exhaust Fan, (2) Energy Recovery, (3) Air Handler ..............23
4
Figure 24 - Hot Gas Purge Circuit ...........................................................................................39
G014420 · Rev. D · 211025
(ACP J01398)
5
Safety
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 that may result in equipment damage, property damage, or personal injury.
WARNING - Warning statements are given to prevent actions that could result in equipment damage, property damage, personal injury or death.
DANGER - Danger statements are given to prevent actions that will result in equipment damage, property damage, severe personal injury or death.
WARNING
CAUTION
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, serious injury, death or property damage.
Installation and service must be performed by a qualified installer, service agency or the gas supplier.
Before servicing, disconnect all
WHAT TO DO IF YOU SMELL GAS
Do not try to light any appliance.
Shut off main gas supply.
Do not touch any electrical switch.
Do not use any phone in the building.
Leave the building immediately.
Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.
If you cannot reach your gas supplier, call the fire department.
WARNING 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.
Electric shock hazard. Before servicing, disconnect all electrical power to the unit, including remote disconnects, to avoid shock hazard or injury from rotating parts. Follow proper Lockout-Tagout procedures.
6
WARNING
FIRE, EXPLOSION 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
CARBON-MONOXIDE POISONING
HAZARD
Failure to follow instructions could result in severe personal injury or death due to carbon-monoxide poisoning, if combustion products infiltrate into the building.
Check that all openings in the outside wall around the vent (and air intake) pipe(s) are sealed to prevent infiltration of combustion products into the building.
Check that furnace vent (and air intake) terminal(s) are not obstructed in any way during all seasons.
CAUTION
Unit power supply wire must be only copper or aluminum.
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 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
GROUNDING REQUIRED
All field installed wiring must be completed by qualified personnel.
Field installed wiring must comply with
NEC/CEC, local and state electrical code requirements. Failure to follow code requirements could result in serious injury or death. Provide proper unit ground in accordance with these code requirements.
7
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 unit damage, injury or death.
CAUTION
Failure to properly drain and vent coils when not in use during freezing temperature may result in coil and equipment damage.
CAUTION
Rotation must be checked on all
MOTORS of 3 phase units at startup by a qualified service technician.
Check fan motor rotation for proper operation. Alterations must only be made at the unit power connection.
WARNING
Do not use oxygen, acetylene or air in place of refrigerant and dry nitrogen for leak testing. A violent explosion may result causing injury or death.
8
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 must be field supplied on system water piping.
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.
CAUTION
To prevent damage to the unit, do not use acidic chemical coil cleaners. Do not use alkaline chemical coil cleaners with a pH value greater than 8.5, after mixing, without first using an aluminum corrosion inhibitor in the cleaning solution.
WARNING
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.
CAUTION
Do not clean DX refrigerant coils with hot water or steam. The use of hot water or steam on refrigerant coils will cause high pressure inside the coil tubing and damage to the coil.
Door compartments containing hazardous voltage or rotating parts are equipped with door latches to allow locks. Door latch are shipped with nut and bolts requiring tooled access. If you do not replace the shipping hardware with a pad lock always re-install the nut & bolt after closing the door.
CAUTION
WARNING
Do not work in a closed area where refrigerant or nitrogen gases may be leaking. A sufficient quantity of vapors may be present and cause injury or death .
WARNING
Never attempt to open an access door or remove a panel while the unit is running. Pressure in the unit can cause excessive force against the panel.
WARNING
Do not weld or cut foam panel with plasma cutters or a cutting torch –
When burnt the foam produces dangerous fumes.
WARNING
Ensure that sufficient dampers will be open to provide air path before fan is allowed to run.
CAUTION
PVC (Polyvinyl Chloride) and CPVC
(Chlorinated Polyvinyl Chloride) are vulnerable to attack by certain chemicals. Polyolester (POE) oils used with R-410A and other refrigerants, even in trace amounts, in a PVC or CPVC piping system will result in stress cracking of the piping and fittings and complete piping system failure.
9
1.
Startup and service must be performed by a Factory Trained Service Technician.
2.
The unit is for indoor use only. See
General Information section for more unit information.
3.
Use only with type of the gas approved for the furnace. Refer to the furnace rating plate.
4.
Install this furnace only in a location and position as specified in the Installation section of this manual.
5.
Provide adequate combustion ventilatio n air to the furnace. If a vent duct extension is used, a class IV approved vent is
required. See the General Venting section
of this manual.
6.
Combustion products must be discharged to the outdoors. Connect the furnace to an approved vent system. See the
General Venting section of this manual.
7.
Condensate is produced in the furnace and requires a condensate drain system.
See the Condensate Drain Piping section
of this manual.
8.
Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections.
9.
Always install and operate furnace within the intended airflow range, temperature rise range, and duct system external static pressure (ESP) as specified on the unit nameplate.
10.
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.
11.
These units must not be used for heating or cooling at any time during any phase of construction. Very low return air temperatures, harmful vapors, and misplacement of the filters will damage the unit and its efficiency.
12.
Clean furnace, duct and components upon completion of the construction setup. Verify furnace operating conditions including input rate, temperature rise and ESP.
13.
Every unit has a unique equipment nameplate with electrical, operational, and unit clearance specifications. Always refer to the unit nameplate for specific ratings unique to the model you have purchased.
14.
READ THE ENTIRE INSTALLATION,
OPERATION AND MAINTENANCE
MANUAL. OTHER IMPORTANT
SAFETY PRECAUTIONS ARE
PROVIDED THROUGHOUT THIS
MANUAL.
15.
Keep this manual and all literature safeguarded near or on the unit.
10
V3 Series Feature String Nomenclature
Model Options : Unit Feature Options
V3 - B R B - 2 - 0 - 2 6 H A - E E A : A B C H - 0 E A - F F B - 0 C 0 - A 0 0 0 0 0 0 0 0
0 0 0 0 0 B 0 0 0
V3 Bas e Model Des cription
BASE MODEL
SERIES AND GENERATION
V3 = Horizontal - Back Intake, Front Discharge
UNIT SIZE
A = Up to 1,200 cfm
B = Up to 2,000 cfm
C = Up to 4,000 cfm
D = Up to 6,000 cfm
E = Up to 10,000 cfm
UNIT ORIENTATION
R = Right Hand Connections
L = Left Hand Connections
REVISION
B = Second Revision
VOLTAGE
1 = 230V/1Φ/60Hz
2 = 230V/3Φ/60Hz
3 = 460V/3Φ/60Hz
4 = 575V/3Φ/60Hz
8 = 208V/3Φ/60Hz
9 = 208V/1Φ/60Hz
CORROSION PROTECTION
0 = None
A = Interior Corrosion Protection
Model Option A: COOLING
A1: COOLING TYPE
0 = No Cooling
1 = R-410A DX Cooling
2 = Chilled Water Cooling
A2: COOILNG ROWS
0 = No Cooling
4 = 4 Row Coil
6 = 6 Row Coil
8 = 8 Row Coil
A3: COOLING STAGES
0 = No Cooling
1 = Single Circuit
2 = Two Circuits - Interlaced Coil
D = Double Serpentine
F = Single Serpentine
H = Half Serpentine
Q = Quarter Serpentine
A4: COOLING FPI
0 = No Cooling
A = 10 fpi
B = 8 fpi
C = 12 fpi
D = 14 fpi
11
V3 Series Feature String Nomenclature
Model Options : Unit Feature Options
V3 - B R B - 2 - 0 - 2 6 H A - E E A : A B C H - 0 E A - F F B - 0 C 0 - A 0 0 0 0 0 0 0 0
0 0 0 0 0 B 0 0 0
Model Option B: HEATING
B1: HEATING TYPE
0 = No Heating
1 = Hot Water
3 = Electric Heating
4 = Steam Distributing
5 = Electric Heat (UL 60335-2-40 Compliant)
A = Open Combustion Natural Gas Heat
B = Separated Combustion Natural Gas Heat
C = Open Combustion LP Gas Heat
D = Separated Combustion LP Gas Heat
E = Open Combustion Natural Gas Heat - High
Altitude
F = Separated Combustion Natural Gas Heat - High
Altitude
G = Open Combustion LP Gas Heat - High Altitude
H = Separated Combustion LP Gas Heat - High
Altitude
B2: HEATING DESIGNATION
0 = No Heating
1 = 1 Row Coil
2 = 2 Row Coil
A = 7 kW (5.3 kW @ 208V)
B = 14 kW (10.5 kW @ 208V)
C = 21 kW (15.8 kW @ 208V) OR 45MBH input
D = 28 kW (21.0 kW @ 208V) OR 60MBH input
E = 35 kW (26.3 kW @ 208V) OR 72MBH input
F = 42 kW (31.5 kW @ 208V) OR 80MBH input
G = 49 kW (37.0 kW @ 208V)
H = 56 kW (42.0 kW @ 208V) OR 108MBH input
J = 63 kW (47.3 kW @ 208V) OR 120MBH input
K = 70 kW (52.5 kW @ 208V)
L = 77 kW (57.8 kW @ 208V) OR 160MBH input
M = 84 kW (63.0 kW @ 208V)
N = 7.5 kW (5.6 kW @ 208V)
P = 10 kW (7.5 kW @ 208V)
Q = 15 kW (11.3 kW @ 208V)
R = 20 kW (15 kW @ 208V)
S = 22.5 kW (16.9 kW @ 208V)
T = 30 kW (22.5 kW @ 208V)
U = 40 kW (30 kW @ 208V)
V = 50 kW (37.6 kW @ 208V)
W = 60 kW (45.1 kW @ 208V)
B3: HEATING STAGES
0 = No Heating
1 = 1 Stage
2 = 2 Stage
3 = 3 Stage
4 = 4 Stage
5 = 5 Stage
6 = 6 Stage
A = Modulating 3:1 96% Efficient Counter-Flow
D = 2 Stage 96% Efficient Counter-Flow
G = 4 Stage 96% Efficient Counter-Flow
S = Modulating/SCR Electric
F = Single Serpentine 12 fpi
H = Half Serpentine 12 fpi
Q = Quarter Serpentine 12 fpi
K = Single Serpentine 8 fpi
L = Half Serpentine 8 fpi
M = Quarter Serpentine 8 fpi
N = Single Serpentine 10 fpi
P = Half Serpentine 10 fpi
R = Quarter Serpentine 10 fpi
Feature 1: SUPPLY FAN
1A: SUPPLY AIR BLOWER CONFIGURATION
A = 1 Blower + 1 High Efficiency EC Motor
B = 2 Blowers + 2 High Efficiency EC Motors
C = Option A + Piezo Ring
D = Option B + Piezo Ring
1B: SUPPLY AIR BLOWER
A = 310 mm Direct Drive BC Plenum Fan
B = 355 mm Direct Drive BC Plenum Fan
C = 450 mm Direct Drive BC Plenum Fan
D = 250 mm Direct Drive BC Plenum Fan
1C: SUPPLY AIR BLOWER MOTOR
A = 500 W (0.67 hp)
B = 1.0 kW (1.34 hp)
C = 1.7 kW (2.28 hp)
D = 3.0 kW (4.02 hp)
E = 6.0 kW (8.00 hp)
F = 800 W (1.07 hp)
12
V3 Series Feature String Nomenclature
Model Options : Unit Feature Options
V3 - B R B - 2 - 0 - 2 6 H A - E E A : A B C H
-
0 E A - F F B - 0 C 0 - A 0 0 0 0 0 0 0 0
0 0 0 0 0 B 0 0 0
1D: SUPPLY BLOWER CONTROL/CONTROL
VENDORS
C = Field Installed Controls by Others
D= Field Installed Controls by Others + Isolation
Relays
E = VCC-X Orion Controls System
H = AAON Touchscreen Controller
Feature 2: REFRIGERATION OPTIONS
0 = Standard - None
A = Single Circuit External Hot Gas Bypass
B = Dual Circuit External Hot Gas Bypass
C = Heat Pump
D = Option B + H
F = Options C + H
H = Modulating Hot Gas Reheat
P = Option H (Circuit 1) + Option A (Circuit 2)
R = Option C + A
S = Option C + B
T = Option C + H + A
U = Option C + H + B
Feature 3: SPECIAL CONTROLS
0 = Standard - None
A = Constant Volume Controller - CV Cool + CV
Heat
C = VAV Controller - VAV Cool + CV Heat
E = Make Up Air Controller - CV Cool + CV Heat
Feature 4: ADDITIONAL CONTROLS
0 = Standard - None
A = Phase and Brownout Protection
B = Return and Supply Air Firestat
C = Return Air Smoke Detector
D = Options A + B
E = Options A + C
F = Options B + C
G = Options A + B + C
H = Remote Safety Shutdown Terminals
J = Energy Recovery Wheel Rotation Detection
K = Options A + H
L = Options A + J
M = Options B + H
N = Options B + J
Feature 4: ADDITIONAL CONTROLS
Continued
P = Options C + H
Q = Options C + J
R = Options H + J
S = Options A + B + H
T = Options A + B + J
U = Options A + C + H
V = Options A + C + J
W = Options A + H + J
Y = Options B + C + H
Z = Options B + C + J
1 = Options B + H + J
2 = Options C + H + J
3 = Options A + B + C + H
4 = Options A + B + C + J
5 = Options A + B + H + J
6 = Options A + C + H + J
7 = Options B + C + H + J
8 = Options A + B + C + H + J
Feature 5: MIXING BOX
5A: RETURN AIR DAMPER POSITION
0 = Standard - None
F = Front
L = Left Hand (Front OA Damper Required)
R = Right Hand (Front OA Damper Required)
T = Top (Front OA Damper Required)
5B: OUTSIDE AIR DAMPER POSITION
0 = Standard - None
F = Front
L = Left Hand (Front RA Damper Required)
R = Right Hand (Front RA Damper Required)
T = Top (Front RA Damper Required)
5C: MIXING BOX DAMPER CONTROL
0 = Standard - None
A = 2 Position Actuators (24V)
B = Fully Modulating Actuators (DDC)
C = Fixed Position Dampers
D = Fully Modulating Actuator - Enthalpy Limit
E = Fully Modulating Actuator - Sensible Limit
13
V3 Series Feature String Nomenclature
Model Options : Unit Feature Options
V3 - B R B - 2 - 0 - 2 6 H A - 1 1 H : A A B H - 0 A A - F F B - 0 A 0 - 0 0 0 0 0 0 0 0 0
0 0 0 0 0 B 0 0 0
Feature 6: FILTER BOX
6A: PRE FILTER BOX
0 = Standard - None
A = 2” Pleated - MERV 8
B = 4” Pleated - MERV 8
C = 4” Pleated - MERV 11
D = 4” Pleated - MERV 13
E = 4” Pleated - MERV 14
F = 2” Pleated - MERV 8 + 4” Pleated - MERV 8
G = 2” Pleated - MERV 8 + 4” Pleated - MERV 11
H = 2” Pleated - MERV 8 + 4” Pleated - MERV 13
J = 2” Pleated - MERV 8 + 4” Pleated - MERV 14
6B: UNIT FILTER
0 = Standard - None
A = 2” Pleated - MERV 8
B = 4” Pleated - MERV 8
C = 4” Pleated - MERV 11
D = 4” Pleated - MERV 13
E = 4” Pleated - MERV 14
F = 2” Pleated - MERV 8 + 4” Pleated - MERV 8
G = 2” Pleated - MERV 8 + 4” Pleated - MERV 11
H = 2” Pleated - MERV 8 + 4” Pleated - MERV 13
J = 2” Pleated - MERV 8 + 4” Pleated - MERV 14
6C: FINAL FILTER BOX
0 = Standard - None
H = 4” Pleated - MERV 8
J = 4” Pleated - MERV 11
K = 4” Pleated - MERV 13
L = 4” Pleated - MERV 14
Feature 7: FILTER OPTIONS
0 = Standard - None
A = Magnehelic Gauge
B = Clogged Filter Switch
C = Options A + B
D = Magnehelic Gauge - Unit Filter + ERW Filter
F = Clogged Filter Switch - Unit Filter + ERW Filter
G = Options D + F
Feature 8: COIL COATING
0 = Standard - None
A = E-coated Cooling and Heating Coils
B = Copper Finned Coils + Stainless Steel Coil
Casing
D = Stainless Steel Coil Casing
E = Options A + D
Feature 9: EXPANSION VALVE
0 = None
A = Thermal Expansion Valves
Feature 10: EXPANSION VALVE
CONTROLS
0 = None
A = Standard Control
Feature 11: EXTERNAL PAINT
0 = Standard - None
A = AAON Gray Paint
B = Special Paint
14
V3 Series Feature String Nomenclature
Model Options : Unit Feature Options
V3 - B R B - 2 - 0 - 2 6 H A - E E A : A B C H - 0 E A - F F B - 0 C 0 - A 0 0 0 0 0 0 0 0
0 0 0 0 0 B 0 0 0
Feature 12: TONNAGE
0 = Standard - None
A = 2 ton Capacity
B = 3 ton Capacity
C = 4 ton Capacity
D = 5 ton Capacity
E = 6 ton Capacity
F = 7 ton Capacity
G = 8 ton Capacity
U = 9 ton Capacity
H = 10 ton Capacity
V = 11 ton Capacity
W = 13 ton Capacity
J = 14 ton Capacity
Y = 15 ton Capacity
Z = 16 ton Capacity
K = 17 ton Capacity
1 = 18 ton Capacity
2 = 20 ton Capacity
L = 22 ton Capacity
M = 25 ton Capacity
3 = 26 ton Capacity
N = 30 ton Capacity
P = 31 ton Capacity
Q = 34 ton Capacity
R = 40-45 ton Capacity
S = 50-55 ton Capacity
4 = 60 ton Capacity
T = 63 ton Capacity
5 = 70 ton Capacity
Feature 13: ENERGY RECOVERY
TYPE
0 = Standard - None
A = Energy Recovery Wheel - Total + High CFM,
Polymer
C = Energy Recovery Wheel - Total + High CFM,
1% Purge, Polymer
E = Energy Recovery Wheel - Sensible + High CFM,
Polymer
G = Energy Recovery Wheel - Sensible + High CFM,
1% Purge, Polymer
13: ENERGY RECOVERY TYPE Continued
J = Energy Recovery Wheel - Total + High CFM,
Aluminum
L = Energy Recovery Wheel - Total + High CFM,
1% Purge, Aluminum
N = Energy Recovery Wheel - Sensible + High CFM,
Aluminum
Q = Energy Recovery Wheel - Sensible + High CFM,
1% Purge, Aluminum
Feature 14: POWER
14A: POWER OPTIONS
0 = Standard - Power Block
14B: ELECTRICAL RATING
0 = Standard - 5kAIC
J = 10 kAIC
Feature 15: CONTROL PANEL
0 = Internal Control Panel (Front Supply Blower
Access Required)
A = Small Control Panel - 16” x 16”
B = Medium Control Panel - 25” x 22”
C = Large Control Panel - 48” x 22”
D = Removable Internal Control Panel (Single Side
Access)
Feature 16: SHIPPING SPLITS
0 = Standard - None
A = 1 Shipping Split (2 pallets)
B = 2 Shipping Splits (3 pallets)
C = 3 Shipping Splits (4 pallets)
D = 4 Shipping Splits (5 pallets)
E = 5 Shipping Splits (6 pallets)
H = Special Shipping Split (SPA Required)
15
V3 Series Feature String Nomenclature
Model Options : Unit Feature Options
V3 - B R B - 2 - 0 - 2 6 H A - E E A : A B C H - 0 E A - F F B - 0 C 0 - A 0 0 0 0 0 0 0 0
0 0 0 0 0 B 0 0 0
Feature 17: ENERGY RECOVERY
CABINET
0 = Standard - None
A = Top RA + Back EA + Back OA Connections
G = OA + EA Dampers - Top RA + Back EA + Back
OA Connections
N = OA + Economizer Dampers - Top RA + Back
EA + Back Connections
U = OA + EA + Economizer Dampers - Top RA +
Back EA + Back OA Connections
Feature 18: BLANK
0 = Standard - None
Feature 19: EXHAUST FAN
0 = Standard - None
A = 250 mm Exhaust Fan, 800 W EC Motor
B = 310 mm Exhaust Fan, 1.0 kW EC Motor
C = 310 mm Exhaust Fan, 1.7 kW EC Motor
D = 355 mm Exhaust Fan, 1.7 kW EC Motor
E = 450 mm Exhaust Fan, 3.0 kW EC Motor
F = 450 mm Exhaust Fan, 6.0 kW EC Motor
G = Dual 310 mm Exhaust Fan, 1.0 kW EC Motor
H = Dual 310 mm Exhaust Fan, 1.7 kW EC Motor
J = Dual 355 mm Exhaust Fan, 1.7 kW EC Motor
K = Dual 450 mm Exhaust Fan, 3.0 kW EC Motor
L = Dual 450 mm Exhaust Fan, 6.0 kW EC Motor
M = Option A + Piezo Rings
N = Option B + Piezo Rings
P = Option C + Piezo Rings
Q = Option D + Piezo Rings
R = Option E + Piezo Rings
S = Option F + Piezo Rings
T = Option G + Piezo Rings
U = Option H + Piezo Rings
V = Option J + Piezo Rings
W = Option K + Piezo Rings
Y = Option L + Piezo Rings
Feature 20: CRATING
0 = Standard - None
A = Export Crating
B = Forkliftable Base - 5” Base
C = Options A + E
D = Options A + B
E = Shipping Shrink Wrap
F = Options B + E
G = Options A + B + E
Feature 21: ADDITIONAL CONTROLS 2
0 = Standard - None
D = High Condensate Level Switch
Feature 22: WARRANTY
0 = Standard - 1 Year Parts
A = 2 Year Parts Only Warranty (Begins at Date of
Shipment)
B = 3 Year Parts Only Warranty (Begins at Date of
Shipment)
C = 4 Year Parts Only Warranty (Begins at Date of
Shipment)
D = 5 Year Parts Only Warranty (Begins at Date of
Shipment)
Feature 23: TYPE
0 = Standard
X = Special Pricing Authorization
16
General Information
AAON ® V3 Series indoor air handling units have been designed for indoor installation only. Units are assembled, wired, charged with dry nitrogen and run-tested at the factory. V3 Series units are not intended for residential use. Startup and service must be performed by a Factory Trained Service
Technician.
WARNING
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 must be kept with the unit.
CAUTION
These units must not be used for heating or cooling at any time during any phase of construction. Very low return air temperatures, harmful vapors, and misplacement of the filters will damage the unit and its efficiency.
Certification of Gas Heat Models a.
Certified as a Category IV forced air furnace with or without cooling. b.
Certified for indoor installation.
Certification of Steam or Hot Water Heat
Models a.
Certified as a forced air heating system with or without cooling. b.
Certified for indoor installation only.
CAUTION
This equipment is protected by a standard limited warranty under the condition that initial installation, service, startup and maintenance is performed according to the instructions set forth in this manual.
This manual must be read in its entirety prior to installation and before performing any service or maintenance work.
Equipment described in this manual is available with many optional accessories. If you have questions after reading this manual in its entirety, consult other factory documentation or contact your AAON
Sales Representative to obtain further information before manipulating this equipment or its optional accessories
Certification of Electric Heat Models a.
Certified as an electric warm air furnace with or without cooling. b.
Certified for indoor installation only.
Certification of Cooling Models a.
Certified as a commercial central air conditioner with or without electrically operated compressors. b.
Certified for indoor installation only. c.
Certified with refrigerant R-410A coils or with chilled water cooling coils.
17
Codes and Ordinances
V3 Series units have been tested and certified, by ETL, in accordance with UL
Safety Standard 1995/CSA C22.2 No. 236,
ANSI Safety Standard Z21.47b-2008/CSA
2.3b-2008, and ANSI Safety Standard Z83.8-
2006/CSA 2.6-2006.
Size the system in accordance with the
American Society of Heating, Refrigeration and Air Conditioning Engineers Handbook.
Installation of V3 Series units must conform to the ICC standards of the International
Mechanical Code, the International Building
Code, Installation of Air Conditioning and
Ventilating Systems Standard, NFPA 90A, and local building, plumbing and waste water 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. Units with gas heaters must conform to the National Fuel Gas Code ANSI Z223.1
(NFPA 54) in the United States and
Can/CGA-B149 Installation Code in Canada.
CAUTION
The Clean Air Act of 1990 bans the intentional venting of refrigerant as of
July 1, 1992. Approved methods of recovery, recycling, or reclaiming must be followed.
WARNING
Coils and sheet metal surfaces present sharp edges and care must be taken when working with equipment.
WARNING
Failure to observe the following instructions will result in premature failure of your system and possible voiding of the warranty.
Receiving Unit
When received, check the unit 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.
Check nameplate to ensure the correct model sizes and voltages have been received to match the job requirements.
If repairs must be made to damaged goods, notify the factory 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 Technical
Support for assistance with handling damaged goods, repairs, and freight claims:
(918) 382-6450.
Note: Upon receipt check shipment for items that ship loose such as remote sensors.
Consult order and shipment documentation to identify potential loose-shipped items.
Loose-shipped items may have been placed inside unit cabinet for security. Secure all doors with locks or nuts and bolts to prevent unauthorized access.
18
Figure 1 - Lockable Handle
Storage
This equipment is not suitable for outdoor use of storage. If installation will not occur immediately following delivery, store equipment in a dry protected area away from construction traffic and in the proper orientation as marked on the packaging with all internal packaging in place. Secure all loose-shipped items.
Wiring Diagrams
Unit specific wiring diagrams are laminated and affixed inside the controls compartment door.
Installation
AAON equipment has been designed for quick and easy installation. Startup and service must be performed by Factory
Trained Service Technician.
The V3 unit can either be shipped assembled or shipped in sections. See the Unit
Assembly section of this document for instructions on assembling the sections.
Locating the Unit
Placement of the unit relative to ductwork, electrical and plumbing must be carefully considered. Return air plenum or duct can be mounted directly to the return air flanges.
Use flexible gasket material to seal the duct to the unit.
Verify floor, foundation or suspension support can support the total unit weight, including accessory weights. Unit must be level in both horizontal axes to support the unit and reduce noise and vibration from the unit.
19
Unit
Size
Table 1 - V3 Series Clearances
Access Side
Opposite Front
Clearance
(dimension X
access side or
Back 3
V3A
V3B
V3C
V3D
36 inches 1
6 inches 2
33 in
33 in
33 in
35 in
V3E 35 in
1.
Additional clearance may be required
to allow for coil removal. See Table 2
2.
May be installed flush depending upon local codes.
3.
For units with internal control panel, the clearance in the table is needed for either front or back, but not both. The clearance is for supply fan removal.
Front access must be at least
18 inches for units with gas heat. If no gas heat, and no internal control panel, front or back clearance is 6 inches with note #2.
Table 2 - Clearances for Coil Pull
Unit Size
V3A
Access Side
32 inches
V3B
V3C
V3D
V3E
32 inches
44 inches
58 inches
58 inches
Back (RA)
Left
Front
Right
X
Figure 2 - Minimum Clearance Required for
Access to Unit (V3 Series plan view)
Internal Control Panel
V3 units with internal control panel have removable access panels on the front and back of the supply fan section. V3 units that have energy recovery only have one removable supply fan access panel on the front of the unit. The supply flanges can be interchanged with the access panels if necessary as the openings have the same dimensions, except on size E.
Figure 3 - V3 internal control panel with rear removable access panel shown
20
Removable Internal Control Panel
V3 units with removable internal control panel have a removable access panel on the access side of the unit. Removing the electrical panel gives access to the supply fan.
To access the supply fan, disconnect the wiring that connects from the unit to the removable control panel. Then remove the four corner bolts and use the handles to remove the electrical panel.
Figure 4 - Removable Internal Control Panel
Figure 5 - Supply Fan Access after removing control panel
Floor Mounted Units
Make sure the unit is level and mounted on a field supplied platform with a minimum height to allow for proper depth of the condensate line p-trap. Other installation provisions may be necessary according to job specifications. V3 Series vertical air handling units are designed for up flow applications only.
Suspended Units
V3 Series vertical air handling units are not equipped for suspended installations.
21
V3 Series
Left Hand Side
“Front”
Supply Air
Top View
Right Hand Side
Return Air
“Back”
Connections and service access on right side for right hand orientation
Consider the air flow to be hitting the back of your head.
Air Flow
Figure 6 - V3 Series Unit Orientation
Note: Access doors may be on the “left” or “right” side as designated by the unit orientation on the configurator string. “Back” will always be the same side as the pre-filter and return air opening.
“Front” will always be the side opposite the pre-filter and return air opening.
Lifting and Handling the Unit
Before lifting unit, be sure that all shipping material has been removed from unit.
Care must be taken if using spreader bars, blocking or other lifting devices to prevent damage to the cabinet, coil or fans.
WARNING
UNIT HANDLING
Incorrect lifting can cause damage to the unit, 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.
Unit Assembly
Although V3 Series units are shipped factory assembled as standard, the unit may be ordered as shipping splits for certain applications such as for assembly in existing structures where modules must be manipulated separately. If the unit was ordered as shipping splits, then they must be assembled in the field.
Locate the schematic in the equipment’s literature packet.
22
1.
Identify and Situate Splits
V3 Units can have the following ship split sections:
1.
Exhaust Fan
2.
Energy Recovery
3.
Air Handler
4.
Electric Heat
5.
Gas Heat
6.
Pre Filter
7.
Mixing Box
1 2 3
Figure 7 - V3 Schematic with (1) Exhaust
Fan, (2) Energy Recovery, (3) Air Handler
2.
Connect Power and Control Wiring between sections
V3 Series units are equipped with low and high voltage quick connects to connect wiring from one section to the next. It might be necessary to increase the hole size in the cabinet in order to get the quick connector through the opening. See the Electrical section for more information.
Figure 8 - Low & High Voltage Quick
Connect
A color-coded wiring diagram is laminated and affixed to the inside of the control compartment access door.
V3 Series units are equipped with a single point power connection. Wire from the unit to external controls and power sources must be provided in the field.
3.
Connect Sections
Remove the access side panels by removing the screws and pulling the panels off. Using the V3 Schematic as an example, section 1 will have a duct flange, and it will connect to section 2 on the side that does not have a flange.
Apply ½” thick, 5/8” wide adhesive gasket around the edges of the box without the flanges.
Push section 1 and 2 together so that the flange from section 1 is inside of section 2.
Flange
Section 2
Figure 9 - Connect Sections
23
Use bar clamps or other non-destructive winching device to pull the tops of the modules together tightly.
Figure 10 - Bar Clamp
At each of the pre-drilled holes in the flange , drill 5/16 hex head self-tapping screws to secure the two sections together.
Figure 11 - Flange Overlap
5/16” Hex Head
Self-Tapping Screw s
Provided w ith Unit
1”
Figure 12 - Self-Tapping Screw
V3 units with a forklift base must be bolted together at the connecting sections. See
Figure 13 - Forklift Base Assembly
4.
Re-attach Access Side Panels
5.
Final Sealing
It is very important to keep air from infiltrating the unit cabinet. Seal all piping penetrations with Armaflex, Permagum or other suitable sealant. Also seal around drain connections, electrical connections and all other inlets where air may enter the cabinet.
This is especially important when the unit is installed in an unconditioned area.
CAUTION
Installing Contractor is responsible for proper sealing of the electrical and piping entries into the unit. Failure to seal the entries may result in damage to the unit and property.
24
Control Box
Some V3 units include an external control box that must be mounted in the field. The control box is designed with two mounting holes on the back panel. Make sure the wall fasteners can hold the weight of the control
Figure 14 - Back View External Control
Box
Electrical
Verify the unit nameplate agrees with power supply. Connect power and control field wiring as shown on the unit specific wiring diagram provided laminated and attached to the door in the controls compartment.
Table 3 - Nameplate Voltage Markings & Tolerances
Hz
Nameplate
Voltage
Nominal
System
Voltage
Operating Voltage Range
Min Max
1
Acceptable Performance
Range 2
Min Max
60
50
115
208/230
208
230
265
460
575
230
400
120
208/240
208
240
277
480
600
230
400
104
187
187
208
240
416
520
198
344
127
254
228
254
293
508
635
254
440
108
187
187
216
249
432
540
208
360
Notes:
1.
Operating voltage is the min and max voltage for which the unit can function. Never operate outside of this min and max voltage.
2.
The Acceptable Performance Range is the min and max voltage for which the unit performance is designed and rated to give acceptable performance.
126
252
228
252
291
504
630
254
440
25
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.
WARNING
The foam insulation releases dangerous fumes when it is burnt. Do not cut a foam part with a cutting torch or plasma cutter. Do not weld to a foam filled part.
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 is recommended that the field installed overcurrent protection or disconnect switch not be installed on the unit.
On units with external control box, electrical supply can enter through either side of the controls compartment.
Figure 15 - External control box electrical connections
On units with internal control panel, electrical supply can enter through the return air side (rear) of the V3 unit.
26
Figure 16 - V3 internal control panel electrical connections
A single point connection to a terminal block is provided. High voltage conductors must enter the control panel in a separate opening and separate conduit than low voltage conductors.
WARNING
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 could result in dangerous operation, serious injury, death, or property damage.
To pass wires through the wall or roof of the unit, cut a hole and pass conduit through it.
Use the following procedure to cut a round hole in a foam panel.
Cutting Electrical Openings
1.
Locate the placement of the hole. Be sure that the conduit will not interfere with the operation of any component or prevent access of any door or removable panel. Field cut openings must be a minimum of 6 inches away from all components and wiring to prevent damage due to drilling or cutting.
2.
Drill a pilot hole all the way through the foam panel.
3.
Using a hole saw, cut the hole through the metal on both sides of the foam part.
4.
With a knife cut the foam out of the hole.
5.
After the conduit is installed in the hole caulk the entire perimeter of the hole on both sides with an industrial grade silicone sealant or a duct seal compound.
CAUTION
Installing Contractor is responsible for proper sealing of the electrical and gas entries into the unit. Failure to seal the entries may result in damage to the unit and property.
If a larger cut-out is needed for additional duct connections not provided by the factory, or for any other reason, it is very important that the foam be completely sealed.
Insulation covers must be fabricated from sheet metal to cover the foam at the cut. The edges and corners that are not covered must then be sealed using silicone caulking or a duct seal compound.
If a reciprocating saw is used to make the cutout take care 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 the absence of local codes, the current National Electric Code,
ANSI/NFPA 70 or the current Canadian
Electrical Code CSA C22.1.
Note: Units are factory wired for 208V,
230V, 460V or 575V. In some units, the
208V and 230V options may also be provided in single or three phase configurations. The transformer configuration must be checked by a qualified technician prior to startup.
Wire power leads to the unit’s terminal block or main disconnect. All wiring beyond this point has been completed by AAON and cannot be modified without effecting the unit’s agency/safety certification.
Supply voltage must be within the min/max range shown on the unit nameplate. Available short circuit current must not exceed the short circuit current rating (SCCR) shown on the unit nameplate.
CAUTION
Three phase voltage imbalance will cause motor premature failure. overheating and
Three phase voltage imbalance will cause motor overheating and premature failure.
The maximum allowable imbalance is 2%.
Voltage imbalance is defined as 100 times the maximum deviation from the average voltage divided by the average voltage.
27
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.
CAUTION
Rotation must be checked on all
MOTORS of three phase units.
Supply fan motors must all be checked by a qualified service technician at startup and any wiring alteration must only be made at the unit power connection.
Wire control signals to the unit’s low voltage terminal block located in the controls compartment.
If any factory installed wiring must be replaced, use a minimum 105°C type AWM insulated conductors.
Thermostat Control Wiring
If a thermostat is used for unit control, locate the thermostat on an inside wall 4-5 feet above the floor where it will not be subjected to drafts, sun exposure, or heat from electrical fixtures of appliances. Control wiring must deliver adequate voltage to components to assure proper operation. Control voltage returning from controller circuit must be a minimum of 21 VAC. To assure proper wiring use the following chart to determine the allowable wiring distances.
Wire
Table 4 - Control Wiring
Size
(Stranded) - Copper
Conductors Only
Total Wire Distance
Allowable
20 AWG
18 AWG
16 AWG
14 AWG
12 AWG
200 ft
350 ft
500 ft
750 ft
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 distance allowable for that size wire. The wiring to the unit must not exceed the total wire distance allowable. If the voltage at the connectors is less than 21 VAC, isolation relays must be installed. If under external control 21 VAC must be field verified.
All external devices must be powered via a separate external power supply.
Example:
A total of 8 wires must be pulled 75ft to a control the unit. What size wire must be used?
According to the Table 4, 16 AWG allows for
63ft (500 ft/8 wires) and 14 AWG allows for
94ft (750 ft/8 wires). Thus, 14 AWG must be used.
28
Duct Connection
Attach duct to flanges provided on the unit.
The installer is responsible for sealing ducts to the flanges to prevent water leaks.
See Figure 6 for return and supply air duct
locations. Size ductwork in accordance with the ASHRAE Handbook. Install ductwork in accordance with NFPA Standard 90A.
When attaching duct to the unit, use a flexible/compressible material rated for duct connections. A three inch flexible connector for both return and supply duct connections is recommended.
Condensate Drain Pans
Units require field installed drain p-traps and lines to be connected to the condensate drain pans of the unit.
For condensate drain lines, the line must be the same pipe size or larger than the drain connection, include a p-trap, and pitch downward toward drain. An air break must be used with long runs of condensate lines.
See Installation section of this manual for more information.
CAUTION
Do not operate unit without p-traps.
Failure to install a p-traps may result in overflow of condensate water.
Condensate Drain Piping
A p-trap and drain line must be installed on the drain connection, with the p-trap not to exceed 6” from the drain connection. The lines must be the same pipe size or larger than the drain connection, include a p-trap, and pitch downward toward drain. An air break must be used with long runs of condensate lines.
CAUTION
Use an emergency drain pan for all applications where a risk of water damage to surrounding structure or furnishings. Refer to local codes.
Draw-through cooling coils will have a negative static pressure in the drain pan area.
This will cause an un-trapped drain to back up due to air being pulled up through the condensate drain piping.
Condensate drain trapping and piping must conform to all applicable governing codes.
Figure 17 - Drain Trap
Note: The drain pan connection is a 1” MPT fitting.
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 pan plus one inch. To calculate the static pressure at the drain pan add the pressure drops of all components upstream of the drain pan, including the cooling coil, and add the return
29
duct static pressure. Include the dirt allowance pressure drop for the filters to account for the worst-case scenario.
The height from top of the bottom bend of the trap to the bottom of the leaving pipe must be at least equal to one half of the X dimension.
This ensures that enough water is stored in the trap to prevent losing the drain seal during unit startup
Note: The absolute value of the fan inlet pressure will always be greater than or equal to the absolute value of the static pressure in the drain pan on draw-through units, so the fan inlet pressure is a safe value to use for the drain pan static pressure.
Table 5 - Drain Trap Dimensions
Draw-Through
Drain Pan Pressure Trap Dimensions
Negative Static X X/2
(inches of water) (inch) (inch)
-0.50 1.50 0.75
-1.00
-1.50
-2.00
-2.50
2.00
2.50
3.00
3.50
1.00
1.25
1.50
1.75
-3.00
-3.50
-4.00
4.00
4.50
5.00
2.00
2.25
2.50
Startup
(See back of the manual for startup form)
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 unit.
WARNING copy of this IOM must be kept with the
30
WARNING
Electric shock hazard. Shut off all electrical power to the unit to avoid shock hazard or injury from rotating parts.
During startup, it is necessary to perform routine checks on the performance of the unit.
This includes checking of the air flow, the air filters and refrigerant charge.
Filters
Do not operate the unit without filters in place. Operation of the equipment without filters in place can result in clogged coils.
Units are shipped with the selected filters installed. If filters have been removed during installation, open the filter access door and re-install the correct filters with the airflow indicator arrows pointing in the direction of airflow.
Check filters after a few days of operation after the unit has been started up as dust and debris from construction may cause premature filter loading. Replace the filters if necessary.
Supply Fans
V3 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.
Fan Air Flow Adjustment
A specific air volume is delivered by the fans with Electronically Commutated Motors
(ECM). Field air flow adjustment may be required at startup.
Electrically Commutated Motor Airflow
Adjustment
Figure 18 - Typical wiring diagram with EC motor
If the application is for the motor to run at a constant speed, the potentiometer can be utilized without any change. If the application is to vary the motor speed for changing conditions, remove the jumper indicated on the terminal strip (red wire).
ECat submittal. Typically, this max speed will be the rpm set at the factory.
The fan speed can be modulated using the
0-10 VDC input signal.
To check fan output from the factory, the potentiometer can be dialed to 100%. By sending a 5V signal*, for instance, the rpm can be measured and this reading can be converted to cubic feet of air moved by the fan.
It is advised that a medium range signal* be utilized for this procedure. The highest signal sent by the controller can then be determined by adjustment.
CAUTION
Before completing startup and leaving the unit a complete operating cycle must be observed to verify that all components are functioning properly.
Figure 19 - Shows the jumper that is to be removed (jumped between S1 and S2).
Note, the potentiometer is still active in the
electrical loop. Refer to Figure 18.
Figure 20 - Potentiometer
Set the potentiometer dial for the maximum fan speed for a particular application.
Maximum fan speed is determined by the
31
Operation
Unit operations must be controlled with thermostat or unit controller, never at the main power supply, except for emergency or complete shutdown of the unit.
Thermostat Operation
Heating
Thermostat system switch - "Heat"
Thermostat fan switch - "Auto" or "On"
Thermostat temperature set to desired point.
Cooling
Thermostat system switch - "Cool"
Thermostat fan switch - "Auto" or "On"
Thermostat temperature set to desired point.
Air Circulation
Thermostat system switch - "Off"
Thermostat fan switch - "Auto" or "On"
No change of the thermostat temperature.
With these settings, the supply blower will run continuously but the supply air will not be heated, cooled, or dehumidified.
System Off
Thermostat system switch - "Off"
Thermostat fan switch - "Auto"
No change of the thermostat temperature.
With these settings the system is shut down, with the exception of control system power.
Night and Weekend Unoccupied Operation
To reduce the operating time of the unit when the space is unoccupied, such as nights and weekends, it is recommended that the temperature setting be raised about 5°F while unoccupied during the cooling season and lowered about 10°F during the heating season.
Split System DX Cooling Operation and
Control
When a call for cooling (G and Y1, Y2, etc.) is made the supply blower motors and compressors will energize.
Chilled Water or Non-Compressorized
DX Cooling Operation
Valve controls for chilled water cooling coil and non-compressorized DX coil are by others.
Steam or Hot Water Preheating
Operation
Valve control for steam and hot water heating coils are by others. Heating is accomplished by passing steam or hot water through the steam or hot water coil assembly.
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 amount of resistance heaters which will produce the required heat.
On a fault condition the main limit located in the supply air or the auxiliary limit located downstream the supply blower will remove power from all contactors.
Gas Heater Operation
When heat (G and W1, W2, etc.) is called for the combustion motor starts and the ignition control is energized. See Gas
Heater section for more details.
32
Maintenance
(See back of the manual for maintenance log.)
At least once each year, a qualified service technician must inspect the unit. Inspect supply fans, evaporator coils and air filters monthly.
WARNING
Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Installation and service must be performed by a qualified installer. A copy of this IOM must be kept with the unit.
Periodically during operation, it is necessary to perform routine service checks on the performance of the unit. This includes checking of the air flow, the air filters, condenser water flow and refrigerant 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.
Condensate Drain Pans
Drain pans will have moisture present and require periodic cleaning to prevent 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.
Winterizing Coils
In some cases it may be necessary to winterize water coils to prevent them from freezing.
First completely drain the coils. There is a drain located below the ‘water in’ connection and a vent connection located above the
‘water out’ connection. Auxiliary drain piping can also be added to exterior water piping if yearly winterizing is necessary.
After the coil is drained, fill with an antifreeze solution using a circulating pump.
Then thoroughly drain.
Supply Fans
CAUTION
Blower wheels must be inspected for excessive dust build up periodically and cleaned if required. Excessive dust build up on blower wheels may cause an unbalanced state; leading to vibration and/or component failure.
Damages due to excessive dust build up will not be covered under factory warranty.
WARNING
Electric shock hazard. Shut off all electrical power to the unit to avoid shock hazard or injury from rotating parts.
33
E-Coated Coil Cleaning
Documented routine cleaning of e-coated coils is required to maintain coating warranty coverage for fin and tube and microchannel coils. See the AAON E-Coated Coil
Maintenance Record sheet.
WARNING
Electric shock hazard. Shut off all electrical power to the unit to avoid shock hazard or injury from rotating parts.
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 cleaner. If a vacuum cleaner is not available, a soft non-metallic bristle brush may be used. In either case, the tool must be applied in the direction of the fins. Coil surfaces can be easily damaged (fin edges bent over) if the tool is applied across the fins.
Use of a water stream, such as a garden hose, against a surface loaded coil will drive the fibers and dirt into the coil. This will make cleaning efforts more difficult. Surface loaded fibers must be completely removed prior to using low velocity clean water rinse.
A monthly clean water rinse is recommended for coils that are applied in coastal or industrial environments to help to remove chlorides, dirt, and debris. It is very important when rinsing, that water temperature is less than 130°F and pressure is less than 100 psig to avoid damaging the fin edges. An elevated water temperature
(not to exceed 130°F) will reduce surface tension, increasing the ability to remove chlorides and dirt.
CAUTION
High velocity water from a pressure washer or compressed air must only be used at a very low pressure to prevent fin and/or coil damages. The force of the water or air jet may bend the fin edges and increase airside pressure drop. Reduced unit performance or nuisance unit shutdowns may occur.
Quarterly cleaning is essential to extend the life of 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.
CAUTION
Harsh chemicals, household bleach, or acid cleaners must not be used to clean outdoor or indoor e-coated coils.
These cleaners can be very difficult to rinse out of the coil and can accelerate corrosion and attack the E-coating. If there is dirt below the surface of the coil, use the recommended coil cleaners.
For routine quarterly cleaning, first clean the coil with the below approved coil cleaner.
After cleaning the coils with the approved cleaning agent, use the approved chloride remover to remove soluble salts and revitalize the unit.
34
Recommended Coil Cleaner
The following cleaning agent, when 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:
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 not intended for use as a degreaser. Any grease or oil film must first be removed with GulfClean ™ Coil Cleaner.
Remove Barrier - First ensure the power to the 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 of this product. As in all surface preparation, the best work yields the best results.
Application - Apply GulfClean ™ Coil
Cleaner directly onto the substrate.
Sufficient product must be applied uniformly across the substrate to thoroughly wet out surface, with no areas missed. This may be accomplished by use of a pump-up sprayer or conventional spray gun. Apply 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 on the inside of the unit have been rinsed. Note: Coils must always be cleaned / back flushed, opposite of airflow to prevent impacting the dirt into the coil.
Repeat these steps with GulfClean ™ Salt
Reducer. When finished replace all panels and tops that were removed.
35
Options
Heating Coils
One or two row hot water and steam heating and preheating coils can be factory installed.
These coils are supplied from a building hot water source. All valve controls for heating coil operation are field supplied and field installed. Hot water and steam coil connections are spun copper tube.
Connect the steam heating supply to the top of the coil and the return to the bottom.
Table 7 - Hot Water Coil Sweat Connection
Sizes
Model (V3-)
A
B
Supply and Return
Connection Size (OD)
7/8"
1 1/8"
C
D & E
1 3/8"
1 5/8"
Connect the hot water heating supply to the bottom of the coil and return to the top.
Steam in
Steam out
Figure 21 - Steam Distributing Piping
Table 6 - Steam Distributing Coil Sweat
Connection Sizes
Model (V3-)
Supply and Return
Connection Size (OD)
A-E 2 1/8"
Air handling units with steam heating coils
MUST BE installed high enough to allow for a minimum of 1 foot condensate drop leg off of the steam coil, or as recommended by the steam trap manufacturer. Lines must be insulated with approved insulation and be properly fastened, sloped, and supported according to local code requirements.
36
Figure 22 - Hot & Chilled Water Piping
Water coils must not be subjected to entering air temperatures below 38°F to prevent coil freeze-up. If air temperature across the coil is going to be below this value, use a glycol solution to match the coldest air expected.
Water supply lines must be insulated, properly fastened, drained, and supported according to local code requirements.
Chilled Water Coil
Factory installed four, six or eight row chilled water cooling coils can be factory mounted.
These coils are supplied from a building chilled water source. All valve controls for the cooling coil operation are field supplied and field installed.
Table 8 - Chilled Water Coil Sweat
Connection Sizes
Model (V3-)
A
B
C
D & E
Supply and Return
Connection Size (OD)
1 1/8"
1 3/8"
1 5/8"
2 1/8"
Connect the chilled water supply to the bottom of the coil and return to the top.
Water supply lines must be insulated with closed cell type pipe insulation or insulation that includes a vapor barrier. Lines must be properly fastened, drained and supported according to local code requirements, and job specifications.
WARNING
Piping shall be in accordance with national and local codes. Pressure limiting devices, backflow preventers and all other safety requirements are the sole responsibility of the installing contractor.
CAUTION
Installing Contractor is responsible for proper sealing of the water piping entries into the unit Failure to seal the entries may result in damage to the unit and property.
Direct Expansion (DX) Systems
All DX refrigerant coils are factory charged with a nitrogen holding charge. All DX systems include evaporator coils and thermal expansion valves (TXV).
Never turn off the main power supply to the unit, except for servicing, emergency, or complete shutdown of the unit. When power is cut off from the unit, crankcase heaters cannot prevent refrigerant migration into the split system condensing unit 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.
CAUTION
CRANKCASE HEATER
OPERATION
Some units are equipped with compressor crankcase heaters, which must be energized at least 24 hours prior to cooling operation, to clear any liquid refrigerant compressors. from the
If power to the unit must be off for more than an hour, turn the thermostat 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 main power
37
supply, except for emergency or complete shutdown of the unit.
During the cooling season, if the air flow is reduced due to dirty air filters or any other reason, the cooling coils can get too cold which will cause excessive liquid to return to the compressor. As the liquid concentration builds up, oil is washed out of the compressor, leaving it starved for lubrication.
The compressor life will be seriously shortened by reduced lubrication and the pumping of excessive amounts of liquid oil and refrigerant.
Note: Low Ambie nt Operation
Air-cooled DX units without a low ambient option, such as condenser fan cycling or the
0°F low ambient option, will not operate in the cooling mode of operation properly when the outdoor temperature is below 55°F. Low ambient and/or economizer options are required if cooling operation below 55°F is expected.
Evaporator Coil
The air handling unit coils are pressurized.
The copper caps must be punctured to permit a gradual escape of the pressure prior to un-sweating those caps. Immediately couple the tubing to the indoor unit to avoid exposing the coils to moisture. A properly sized filter drier is furnished in the condenser.
When making solder connections, make sure dry nitrogen flows through the lines, when heating the copper, to prevent oxidization inside of the copper.
Field piping between the condensing unit and the air handler is required. Line sizes must be selected to meet actual installation conditions, not simply based on the connection sizes.
CAUTION
REFRIGERANT PIPING
Line sizes must be selected to meet actual installation conditions, not simply based on the connection sizes at the condensing unit or air handling unit.
Thermal Expansion Valve
Thermal expansion valve bulbs must be mounted with good thermal contact on a horizontal section of the suction line close to the evaporator, but outside the cabinet, and well insulated. On suction lines less than or equal to 7/8” OD, mount in the 12 o’clock position. On suction lines greater than 7/8”
OD, mount in either the 4 o’clock or 8 o’clock position.
Figure 23 - TXV Bulb Position
Hot Gas Reheat
Hot Gas Reheat (HGRH) is available for use with DX systems that need humidity control.
The AAON modulating hot gas reheat system diverts hot discharge gas from the condenser to the air handling unit through the hot gas line. Field piping between the condensing unit and the air handler is required. Line sizes must be selected to meet actual installation conditions, not simply based on the connection sizes.
The line delivers the hot discharge gas to the reheat coil and/or the hot gas bypass valve, so it is sized as a discharge line.
38
Hot Gas Bypass
Hot Gas Bypass is available for use with DX systems that may experience low suction pressure during the operating cycle. This may be due to varying load conditions associated with VAV applications or units supplying a large percentage of outside air. Hot Gas
Bypass is not necessary in units with variable capacity compressors. The system is designed to divert refrigerant from the compressor discharge to the low pressure side of the system in order to keep the evaporator from freezing and to maintain adequate refrigerant velocity for oil return at minimum load.
Hot discharge gas is redirected to the evaporator inlet via an auxiliary side connector (ASC) to false load the evaporator when reduced suction pressure is sensed.
Field piping between the condensing unit and the evaporator is required. Line sizes must be selected to meet actual installation conditions, not simply based on the connection sizes.
Purge Circuit
The purge circuit is required on hot gas reheat or hot gas bypass lines. The purge circuit needs to be field furnished and installed at the lowest point of the line set.
With this installation, oil drains into the drain leg of the hot gas reheat line. Oil accumulates until it reaches the level of the 1/8”OD capillary tubing.
Figure 24 - Hot Gas Purge Circuit
The combination of capillary action and the pressure difference between the hot gas reheat line (high pressure) and the suction line (low pressure) causes the oil to travel through the capillary tube into the suction line of the first circuit to return the oil to the compressor. The capillary tube connection to the suction line of the first circuit must be a minimum of 5 feet from the inlet to the compressor to allow the oil time to dissipate into the suction vapor and not slug the compressor with liquid oil.
Adjusting Refrigerant Charge
Adjusting the charge of a system in the field must be based on determination of liquid subcooling 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 be taken.
CAUTION
The Clean Air Act of 1990 bans the intentional venting of refrigerant
(CFC’s and HCFC’s) as of July 1,
1992. Approved methods of recovery, recycling or reclaiming must be followed. Fines and/or incarceration may be levied for non-compliance.
39
Before Charging
Unit being charged must be at or near full load conditions before adjusting the charge.
Units equipped with hot gas reheat must be charged with the hot gas reheat valves closed while the unit is in cooling mode to get the proper charge. After charging, operate the unit in reheat (dehumidification) mode to check for correct 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 options determine the ranges for liquid sub-cooling and evaporator superheat. Refer to the tables below when determining the proper sub-cooling.
Checking Liquid Sub-Cooling
Measure the temperature of the liquid line as it leaves the condenser.
Read the gauge pressure at the liquid line close to the point where the temperature was taken. Use liquid line pressure as it will vary from discharge pressure due to condenser pressure drop.
Convert the pressure obtained to a saturated temperature using the appropriate refrigerant temperature-pressure chart.
Subtract the measured liquid line temperature from the saturated temperature to determine the liquid sub-cooling.
Compare calculated sub-cooling to the table below for the appropriate unit type and options.
Table 9 - Acceptable Refrigeration Circuit
Values
Cooling
Mode Liquid
Sub-Cooling
Values
8-15°F Cooling Only Unit 4
Cooling Only Unit with Hot
Gas Reheat 1,4
Heat PumpUnit 2,4
5-15°F
2-4°F
Heat Pump Unit with Hot
Gas Reheat 3,4
Cooling Only Unit with
LAC 4
2-6°F
8-15°F
Cooling Only Unit with Hot
Gas Reheat & LAC 4
8-15°F
Notes:
1.
Must be charged with the hot gas valve closed.
After charging, operate the unit in reheat
(dehumidification) mode to check for correct operation.
2.
The sub-cooling value in this table is for the unit running in cooling mode of operation. After charging, operate the unit in heating mode to check for correct operation.
3.
The sub-cooling value in this table is for the unit running in cooling mode of operation and the hot gas valve closed. After charging, operate the unit in reheat (dehumidification) mode to check for correct operation and then in heating mode to check for correct operation.
4.
Sub-cooling must be increased by 1°F per 10 feet of vertical liquid line rise for R-410A (AHU above CU). For example, a cooling only unit with hot gas reheat and a vertical liquid drop can charge to a sub-cooling value of 5-15°F, but a cooling only unit with hot gas reheat and a vertical liquid rise of 30 ft must charge to a sub-cooling value of at least 8-15°F. DO NOT
OVERCHARGE. Refrigerant overcharging leads to excess refrigerant in the condenser coils resulting in elevated compressor discharge pressure.
40
Checking Evaporator Superheat
Measure the temperature of the suction line close to the evaporator.
Read gauge pressure at the suction line close to the evaporator.
Convert the pressure obtained to a saturated temperature using the appropriate refrigerant temperature-pressure chart.
Subtract the saturated temperature from the measured suction line temperature to determine the evaporator superheat.
Compare calculated superheat to the acceptable cooling mode superheat values of
8-15°F for all system types. Superheat will increase with long suction line runs.
For refrigeration systems with tandem compressors, it is critical that the suction superheat setpoint on the TXV is set with one compressor running. The suction superheat must be 10-13°F with one compressor running. The suction superheat will increase with both compressors in a tandem running.
Inadequate suction superheat can allow liquid refrigerant to return to the compressors which will wash the oil out of the compressor. Lack of oil lubrication will destroy a compressor.
Measure liquid sub-cooling with both compressors in a refrigeration system running.
CAUTION
Thermal expansion valve must be adjust to approximately 8-15°F of suction superheat. Failure to have sufficient superheat will damage the compressor and void the warranty.
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 evaporator result in increased sub-cooling) and the evaporator superheat is within the temperature range as shown in the table above (high superheat results in increased sub-cooling).
Correct an overcharged system by reducing the amount of refrigerant in the system to lower the sub-cooling.
CAUTION
DO NOT OVERCHARGE!
Refrigerant overcharging leads to excess refrigerant in the condenser coils resulting in elevated compressor discharge pressure.
The system is undercharged if the superheat is too high and the sub-cooling is too low
Correct an undercharged system by adding refrigerant to the system to reduce superheat and raise sub-cooling.
If the sub-cooling is correct and the superheat is too high, the TXV may need adjustment to correct the superheat. Before adjusting the
TXV, verify the sensing bulb is in the correct
position according to Figure 23 and follows
the guidelines below.
1. The suction line is clean where the sensing bulb is attached.
2. The entire length of the sensing bulb is in contact with the suction line.
41
30
31
32
33
34
35
36
37
°F
20
21
22
23
24
25
26
27
28
29
38
39
40
41
42
43
44
45
46
3. Place the sensing bulb several inches downstream of the equalizer line.
4. The sensing bulb is fully insulated.
5. If the sensing bulb is installed on a vertical portion of the suction line, place the sensing bulb upstream of suction line trap.
96.8
98.8
100.9
102.9
105.0
107.1
109.2
111.4
113.6
115.8
118.1
120.3
PSIG
78.3
80.0
81.8
83.6
85.4
87.2
89.1
91.0
92.9
94.9
122.7
125.0
127.4
129.8
132.2
Table 10 - R-410A Refrigerant Temperature-Pressure Chart
°F
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
PSIG
134.7
137.2
139.7
142.2
144.8
147.4
°F
74
75
76
77
78
79
PSIG °F PSIG °F PSIG
213.7 101 321.0 128 463.2
217.1 102 325.6 129 469.3
220.6 103 330.2 130 475.4
224.1 104 334.9 131 481.6
227.7 105 339.6 132 487.8
231.3 106 344.4 133 494.1
150.1
152.8
155.5
158.2
161.0
163.8
166.7
169.6
172.5
175.4
178.4
181.5
80
81
82
83
84
85
86
87
88
89
90
91
234.9 107 349.3 134 500.5
238.6 108 354.2 135 506.9
242.3 109 359.1 136 513.4
246.0 110 364.1 137 520.0
249.8 111 369.1 138 526.6
253.7 112 374.2 139 533.3
257.5 113 379.4 140 540.1
261.4 114 384.6 141 547.0
265.4 115 389.9 142 553.9
269.4 116 395.2 143 560.9
273.5 117 400.5 144 567.9
277.6 118 405.9 145 575.1
281.7 119 411.4 146 582.3
285.9 120 416.9 147 589.6
184.5
187.6
92
93
190.7
193.9
197.1
200.4
203.6
94
95
96
97
98
290.1 121 422.5 148 596.9
294.4 122 428.2 149 604.4
298.7 123 433.9 150 611.9
303.0
307.5
124
125
439.6
445.4
207.0 99 311.9 126 451.3
210.3 100 316.4 127 457.3
42
Energy Recovery Units
Some V3 units have been equipped with an energy recovery wheel. AAON provides options for either an aluminum energy recovery wheel or a polymer energy recovery wheel. Follow the instructions for the specific type of energy recovery wheel in your installed equipment.
Aluminum Energy Recovery Wheel
This section is provided to assure the energy recovery feature will be properly setup to perform in accordance with the job specifications for your particular application.
Figure 25 - Aluminum Energy Recovery Wheel
1.
Monolith energy recovery wheel
2.
Purge Sector
3.
Profile
4.
Motor
5.
Brush Plate
6.
Rotor Hub
7.
Casing
Aluminum Wheel Check Purge Location
The purge sector is an optional element so it may not be installed on some units. Ensure the purge sector is mounted in the correct location. Purge sector must be located on the fresh supply air side. Based on the airflow and the wheel rotation in the following illustrations, notice the correct locations for the purge sector.
Figure 26 - Aluminum ERW Purge
Sector Location
Aluminum Wheel Cleaning
See general energy recovering cleaning section for how often to clean.
To clean, gain access to the aluminum energy recovery wheel then use the following methods:
Use a brush or vacuum cleaner to remove small foreign materials.
Use compressed air at a distance of at least 2 ft from the wheel. Too much
43
pressure can easily damage the aluminum media.
First remove the energy recovery wheel from the unit. Then use water at a distance of at least 2 ft from the wheel.
Do not use detergents. Keep temperature below 77
F. Tightly cover all electric parts and bearings while used pressurized water. Remove excess water before reinstalling the wheel.
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 seals are damaged, please contact our technical support immediately. A damaged seal may cause efficiency deterioration, mixing of an air flows and unwanted leakages in the system, especially in environments with hygienic requirements.
Aluminum Wheel Brush Plate
Brushes are located on both upper sides of the profiles. Inspect their condition and whether they adhere to the surface of the wheel matrix. Over time, the brushes may lose their cleaning properties and it will be necessary to replace them or simply change their position on the profile. In order to adjust their position unscrew them and place properly.
Aluminum Wheel Purge Sector
Purge sectors are maintenance-free but their condition, rigidness and cleanliness must be checked every year. Pay attention to the distance of the sector against the recovery wheel matrix. Use compressed air to clean, if required.
Aluminum Wheel Drive Components
Drive belt requires periodic inspections. Due to material property, belt may stretch, therefore it may require user to increase the tension, upon inspection.
Belt tension must be checked after the first 24 hours of operation and at least once per year.
44
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 visual condition of the belt all along the wheel. Be sure that belt does not show signs of mechanical damage. Check the convergence on the wheel pulley. The belt must pass freely without encountering any obstacles inside the housing. Due to the segmented design of the belt, replacing individual segments is enough to restore functionality. Please follow the instructions below, presenting proper way of replacing segments or increasing belt tension.
1.
Unclip the belt using pliers. Grab the protruding tongue of the segment to remove and twist it to release the segment from the chain. Disconnect the belt in that place.
4.
Grab the second tongue and similarly insert it through the second hole – this time use the pliers to drag the segment tongue easier and twist it back to the starting position.
5.
Your belt is now shortened and the tension of the belt is increased.
Polymer Energy Recovery Wheel
This section is provided to assure the energy recovery feature will be properly setup to perform in accordance with the job specifications for your particular application.
2.
Remove the necessary amount of segments to increase the belt tension.
3.
Connect the shortened belt ends by inserting the protruding tongue through the hole of the other half of the belt.
Figure 27 - Polymer Energy Recovery Wheel
1.
Removable Segment
2.
Permanent Tension Belt
3.
Pulley
4.
Embedded Segment Stiffeners
5.
Segment Retaining Latches
45
6.
Bearing Beam and Bearing Access
Cover Plate (Diameter Seals are behind
Bearing Beam on both sides)
7.
Adjustable Purge
8.
Motor
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 recovery wheel is very important to maintain proper operation efficiency and building occupant comfort.
Normal maintenance requires periodic inspection of filters, the cassette wheel, drive belts, air seals, wheel drive motor, and its electrical connections.
Wiring diagrams are provided with each motor. When wired according to wiring diagram, energy recovery wheel rotates clockwise when viewed from the shaft/pulley side.
By carefully reviewing the information within this section and following the instructions, the risk of improper operation and/or component damage will be minimized.
It is important that periodic maintenance be performed to help assure trouble free operation.
Polymer Wheel Set Purge Angle
When installed, the purge angle is factory set to 5 degrees. If a different angle is required, complete the following steps to adjust the purge:
1.
Loosen the three purge adjusting screws.
2.
Adjust purge sector to the specified angle.
3.
Tighten the purge adjusting screws.
4.
Turn the wheel by hand clockwise
(when viewed from pulley side) to check for interference.
Polymer Wheel Check Purge Seal
If a purge is installed, check for a slight interference fit between the seal and the face of the wheel by sliding a piece of paper
(“feeler gauge”) between the seal and the media a multiple locations along the purge seal as you rotate the wheel slowly by hand
(clockwise when viewed from the pulley side). Verify that the media slightly grabs the paper during rotation.
46
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 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 or in other than the factory orientation can change seal clearances. Tight seals will prevent rotation.
Polymer Wheel to Air Seal Clearance
To check wheel to seal clearance; first disconnect power to the unit, in some units the energy recovery wheel assembly can be pulled out from the cabinet to view the air seals. On larger units, the energy recovery wheel may be accessible inside the walk-in cabinet.
A business card or two pieces of paper can be used as a feller gauge, (typically each .004” thick) by placing it between the face of the wheel and pile seal.
Using the paper, determine if a loose slip fit exist between the pile seal and wheel when the wheel is rotated by hand.
To adjust air seal clearance, loosen all seal plate retaining screws holding the separate seal retaining plates to the bearing support channels and slide the seals plates away from the wheel. Using the paper feeler gauge, readjust and retighten one seal plate at a time to provide slip fit clearance when the wheel is rotated by hand.
Confirm that the wheel rotates freely. Apply power to the unit and confirm rotation.
Visually inspect the belt and ensure the belt is tracking near the center of the rim. Verify the wheel speed is approximately 45-50
RPM. Confirm there is no excessive noise such as scraping, brushing, or banging.
Polymer Wheel Orientation & Support
The Energy Recovery Cassette may be mounted in any orientation. However, Care must be taken to make certain that the cassette frame remains flat and the bearing beams are not racked.
47
Frame
A
Wheel
Bearing beams shown racked
Bearing beams
(2)
C
Flat surf ace
B
Avoid Racking of Cassette Frame
To verify, make certain that the distance between wheel rim and bearing beam is the same at each end of the bearing beam, to within 1/4 of an inch (dimension A & B).
This amount of racking 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.
Polymer Wheel Startup
Open the access door and determine that the energy recovery wheel rotates freely when turned by hand with no interference noise.
Apply power and observe that the wheel rotates. If the wheel does not rotate when power is applied, it may be necessary to readjust the “diameter air seals”.
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 wheel segments are fully engaged in wheel frame and segment retainers are completely fastened. (See
Segment Installation Diagram).
3.
With hands and objects away from moving parts, activate unit and confirm wheel rotation. Wheel rotates clockwise (as viewed from the pulley side).
4.
If wheel has difficulty starting, turn power off and inspect for excessive interference between the wheel surface and each of the four (4) diameter seals.
To correct, loosen diameter seal adjusting screws and back adjustable diameter seals away from surface of wheel, apply power to confirm wheel is free to rotate, then re-adjust and tighten hub and diameter seals, as shown in hub seal adjustment diagram.
5.
Start and stop wheel several times to confirm seal adjustment and to confirm belt is tracking properly on wheel rim
(approximately 1/4” from outer edge of rim).
Diameter Seal Adjustment
48
Hub Seal Adjustment
WARNING
Do not alter factory wiring. Deviation from the supplied wiring diagram will void all warranties, and may result in equipment damage or personal injury.
Contact the factory with wiring discrepancies.
Polymer Energy Recovery Cleaning
To clean, gain access to the polymer energy recovery wheel, remove the segments, then use the following methods:
Soak in the solution until grease and tar deposits are loosened (Note: some staining of the desiccant may remain and is not harmful to performance).
Before removing, rapidly run finger across surface of segment to separate polymer strips for better cleaning action.
Rinse dirty solution from segment and remove excess water before reinstalling in wheel.
CAUTION
Do not use acid based cleaners, aromatic solvents, steam or temperatures in excess of 170°F; damage to the wheel may occur!
Polymer Wheel Segment Installation &
Replacement
An uneven number of segments in the wheel will cause the wheel to accelerate in rotation.
Minimize wheel imbalance and unwanted rotation during service by installing or removing opposing segments for even weight distribution. Failure to maintain control of the wheel rotation while removing or installing all segments could cause severe injury to fingers or hands. Always close and secure segment retaining latches before rotating wheel.
Figure 28 - Wheel Segment Removal Pattern
Wheel segments are secured to the wheel frame by a Segment Retainer which pivots on the wheel rim and is held in place by Segment
Retaining Latches.
49
Segment Retainer
To install wheel segments, follow the steps below. Reverse procedure for segment removal.
Disconnect power from the wheel.
Gain access to the wheel and slide wheel frame out of cabinet.
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.
3.
Holding segment by the two outer corners, press the segment towards the center of the wheel and inwards against the spoke flanges. If hand pressure does not fully seat the segment, insert the 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 installed. Rotate the wheel 180º again to install the fourth segment opposite the third. Repeat this sequence with the remaining four segments.
Polymer 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 surface. Rotate wheel clockwise until two opposing spokes are hidden behind the bearing support beam. Using a folded piece of paper as a feeler gauge, position paper between the wheel surface and diameter seals.
Adjust seals towards wheel surface until a slight friction on the feeler gauge (paper) is detected when gauge is moved along the length of the spoke. Retighten adjusting screws and recheck clearance with “feeler” gauge.
Segment Installation
50
Polymer Wheel Drive Components
The wheel drive motor bearings are prelubricated and no further lubrication is necessary.
The wheel drive pulley is secured to the drive motor shaft by a combination of either a key or D slot and set screw.
The set screw is secured with removable locktite to prevent loosening. Annually confirm set screw is secure. The wheel drive 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 startup.
Polymer Wheel Drive Motor and Pulley
Replacement
1.
Disconnect power to wheel drive motor.
2.
Remove belt from pulley and position temporarily around wheel rim.
3.
Loosen set screw in wheel drive pulley using a hex head wrench and remove pulley from motor drive shaft.
4.
While supporting weight of drive motor in one hand, 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.
Polymer Wheel Belt Replacement
1.
Obtain access to the pulley side bearing access plate if bearing access plates are provided. Remove two bearing access plate retaining screws and the access plate.
2.
Using hexagonal wrench, loosen set screw in bearing locking collar. Using light hammer and drift (in drift pin hole) tap collar in the direction of wheel rotation to unlock collar. Remove collar.
3.
Using socket wrench with extension, remove two nuts which secure bearing housing to the bearing support beam.
Slide bearing from shaft. If not removable by hand, use bearing puller.
4.
Form a small loop of belt and pass it through the hole in the bearing support beam. Grasp the belt at the wheel hub and pull 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.
CAUTION
Protect hands and belt from possible sharp edges of hole in Bearing
Support Beam.
5.
Loop the trailing end of the belt over the shaft (belt is partially through the opening).
6.
Reinstall the bearing onto the wheel shaft, being careful to engage the two locating pins into the holes in the bearing support beam. Secure the bearing with two self-locking nuts.
7.
Install the belts around the wheel and pulley according to the instructions provided with the belt.
8.
Reinstall diameter seals or hub seal and tighten retaining screws. Rotate wheel in clockwise direction to determine that wheel rotates freely with slight drag on seals.
51
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 Bearing Access Cover.
12.
Apply power to wheel and ensure that the wheel rotates freely without interference.
Belt Replacement
Energy Recovery Wheel General Cleaning
Routine maintenance of the Energy Recovery
Wheel includes periodic cleaning of the
Energy Recovery Wheel as well as inspection of the Air Seals and Wheel Drive
Components.
CAUTION
Disconnect electrical power before servicing energy recovery cassette.
Always keep hands away from bearing support beam when installing or removing segments. Failure to do so could result in severe injury to fingers or hand.
Cleaning the energy transfer media will help maintain optimal performance. The frequency of cleaning is largely dependent on the application and air quality. Use
ASHRAE’s Classes of Air categories, to create a routine cleaning schedule.
Class 1 air has low contaminant concentration with inoffensive odor and sensory irritation intensity.
Class 2 air has moderate contaminant concentration, with mildly offensive odors or sensory-irritation intensity.
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.
52
Class of Air
Class 1
Clean Air
Class 2
Moderately Clean
Air
Class 3
Dirty Air
Class 4
Contaminated Air
Examples
Offices
Classrooms
Assembly rooms
Churches
Restrooms
Swimming pools
Dining rooms
Locker rooms
Warehouse
Dorms
Kitchens
Dry cleaners
Beauty salons
Laboratories
Pet shops
Paint spray booths
Laboratory fume exhaust
Kitchen grease exhaust
The energy recovery wheel is “self-cleaning” with respect to dry particles due to its laminar flow characteristics. Smaller particles pass through; larger particles land on the surface and are blown clear as the flow direction is reversed. Any material that builds up on the face of the wheel can be removed with a brush or vacuum. The primary need for cleaning is to remove oil based aerosols that have condensed on energy transfer surfaces.
A characteristic of all dry desiccants, such films can close off micron sized pores at the surface of the desiccant material, reducing the efficiency by which the desiccant can adsorb and desorb moisture and also build up so as to reduce airflow.
In a reasonably clean indoor environment such as a school or office building , measurable reductions of airflow or loss of sensible (temperature) effectiveness may not occur for several years. Measurable changes in latent energy (water vapor) transfer can occur in shorter periods of time in
Cleaning Frequency
Every 8-10 years
Every 4-6 years
Every 1-2 years
Do not use in this application applications such as moderate occupant smoking or cooking facilities. In applications experiencing unusually high levels of occupant smoking or oil based aerosols such as industrial 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.
53
Gas or Electric Heating
The unit is designed to heat a given amount of air while operating. If this amount of air is greatly reduced, approximately 1/3 during the heating season, the gas heat exchanger or electric heating coil may overheat, and may cut the burner or heater off entirely by action
Should overheating occur with a gas heat exchanger, or the gas supply fail to shut off, shut off the manual gas valve to the furnace before shutting off the electrical supply.
Prolonged overheating of the heat exchanger will shorten its life. of the safety high temperature limit devices which are factory mounted at the heat exchanger and supply fan areas.
Adjust airflow after installation to obtain an air temperature rise within the range specified on the unit rating plate at the required external static pressure.
A = Heat A
Table 11 - Electric and Gas Heating Capacities
Electric Heat Capacity Gas Heat Input
Capacity kW (230V, 460V)
7.0
The maximum supply air temperature from the gas heater is 140 ° F and the minimum allowable entering air temperature is 40 ° F.
The maximum temperature rise for the gas heater is 100 ° F. kW (208V)
5.3
MBH
Gas Heat Output
Capacity
MBH
B = Heat B
C = Heat C
D = Heat D
E = Heat E
F = Heat F
G = Heat G
H = Heat H
J = Heat J
K = Heat K
L = Heat L
M = Heat M
N = Heat N
14.0
21.0
28.0
35.0
42.0
49.0
56.0
63.0
70.0
77.0
84.0
7.5
10.5
15.8
21.0
26.3
31.5
37.0
42.0
47.3
52.5
57.8
63.0
5.6
45 MBH
60 MBH
72 MBH
80 MBH
108 MBH
120 MBH
160 MBH
43.2 MBH
57.6 MBH
69.1 MBH
76.8 MBH
103.7 MBH
115.2 MBH
153.6 MBH
P = Heat P
Q = Heat Q
R = Heat R
S = Heat S
T = Heat T
U = Heat U
V = Heat V
W = Heat W
10.0
15.0
20.0
22.5
30.0
40.0
50.0
60.0
7.5
11.3
15.0
16.9
22.5
30.0
37.6
45.1
54
Gas Heating
WARNING
FOR YOUR SAFETY
Read the entire gas heating installation section of this manual before beginning installation of the gas heating section.
If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury, or loss of life.
Unit Location and Clearances
Gas fired unit combustion air inlets and flue vent gas discharges are located on the front of
the unit. See Figure 29. There must be
18 inches of clearance between the front of the V3 and building walls or equipment. If equipment is for replacement and required clearances are not available, contact AAON for recommendations.
Figure 29 - High Efficiency Gas Heater
WARNING
Flue discharge vents must be located at least 120 inches away from any opening through which combustion products could enter the building.
WARNING
Distances from adjacent public walkways, adjacent buildings , operable windows and building openings, shall conform to local codes and/or the National Fuel Gas Code,
ANSI Z223.1/NFPA 54, or the
National Gas & Propane Code, CSA
B149.1
For gas fired unit, do not position flue opening to discharge into a fresh air intake of any other piece of equipment. Install the unit so that the flow of combustion intake air is not obstructed from reaching the furnace.
Flue gas is dangerously hot and contains containments. The user is responsible for determining if flue vent gases may degrade building materials.
The National Gas and Propane Installation
Code, B149.1 specifies a 6 ft. horizontal flue vent terminal clearance to gas and electric meters and relief devices.
Local codes may supersede or further place restrictions on flue vent termination locations.
Allow adequate space for piping access and panel removal. To ensure proper access for field service, maintain minimum clearances for field piping and other
obstructions as indicated by Table 1 and
Consult local building codes for additional service clearance requirements.
Condensate drain connection for the coils is located on the access side of the unit. The high efficiency gas heater condensate drain
55
connection is located on the front side of the
unit. See Figure 2 for orientation.
1. Be sure unit is located with respect to building construction and other equipment to provide ready access and clearance to access panels or doors that must be opened to permit adjustment and servicing of the heating module.
2. The heating unit provided is listed for installation on the positive side of the circulating air blower only.
3. Locate unit to insure an adequate supply of fresh air to replace air used in the combustion and ventilation process.
4. Do not install exhaust vent where flue products can be drawn into adjacent building openings such as windows, doors, or fresh air intakes. Minimize the number of elbows or turns in flue vent pipe.
5. Do not install unit where it may exposed to potentially explosive or flammable vapors.
6 . Do not locate unit in areas where corrosive vapors (such as chlorinated, halogenated, or acidic) are present in the atmosphere or can be mixed with combustion air entering heater.
Duct Connection
On units with gas heat or electric heat, duct at least 6” of straight duct on the supply side of the V3 unit before turning.
On units with gas heaters, a supply air temperature sensor must be mounted in the supply air duct at least 5 feet but less than
20 feet downstream of the furnace discharge to limit the maximum discharge air temperature. If possible, locate the sensor after a turn in the duct for better air mixing.
Condensate Drain Piping
Unit may be equipped with a high efficiency gas heater which requires a condensate drain system.
The condensate drain system includes a factory installed condensate trap for proper system performance. The ¾” PVC condensate connection is located on the front
of the unit. See Figure 6 for unit orientation.
Figure 30 - Gas Heat Condensate Trap
All connecting joints must be watertight to prevent leakage. Glue the necessary PVC pipe and fittings to connect condensate piping to a suitable drain. Be sure to apply sealant to threads to prevent leakage.
Installation of a union ahead of the trap is preferred to permit maintenance of drains and accommodate servicing of the heater.
Never connect condensate drain directly into a sewer line . If connection to a sewer is permitted by code, drain line must terminate in an open sewer tap (separated by an air gap).
Where condensate drains are located outside a heated space or in a space where temperatures may fall below freezing, the drain line must be freeze protected .
The drains must be extended through the heater base and into the heated space below to prevent freezing of condensate in the drain
56
piping. Trap must be located in a heated space or protected to avoid freezing.
Where condensate drains are located outside a heated space or in a space where temperatures may fall below freezing, the drain line must be protected. Use a 2.5 to 5 watt per foot (0.003 to 0.005 kW per meter) at 115 VAC, 40 ° F (4.4 ° C) self-regulating, shielded and waterproof heat tape. Wrap the drain trap and drain line with heat tape and secure with ties.
For installations where the building drain lines are above the level of the furnace drain system, a condensate pump is required.
Condensate Neutralization
Some municipalities require that the acidic condensate produced be neutralized before being discharged into a sewer or drain.
A field provided and installed condensate neutralizer kit may be necessary. Where condensate drains and/or neutralization kit(s) are located outside a heated space or in a space where temperatures may fall below freezing, all components and drain lines must be freeze protected.
Figure 31 - Condensate Neutralizer Kit
An overflow bypass drain line must be installed.
When connecting drain line(s) to building drain, an air gap must be present for proper operation of the condensate disposal system.
Inspect and monitor effectiveness of neutralization media within cartridge.
Replace or refill as necessary.
General Venting
Safe operation of indirect-fired gas furnaces requires a properly operating flue vent system which exhausts all the products of combustion (flue gases) to the outside atmosphere.
Venting must be in accordance with local codes and section 5.3 of the National Fuel
Gas Code NFPA54 / ANSI Z223.1 in the
United States or sections 7.2, 7.3, or 7.4 of
CAN/CSA B149.1 Natural and Propane
Installation Code in Canada. Local requirements typically supersede national requirements.
WARNING
FURNACE VENTING
Failure to provide proper venting affects furnace performance and may result in a health hazard which could cause serious personal injury or death.
V3 furnaces are listed as IV heaters. Category
IV furnaces operate with a positive vent pressure and flue vent gas temperatures typically less than 150 ° F. The venting system must be gas tight and water tight.
Proper installation of the vent system must also assure drainage of condensate to prevent deterioration of the vent system.
The vent piping must be exclusive to a single furnace. Do not use dampers in vent pipes.
All pipe openings external to building must have a protective screen installed.
57
Exhaust flue vent ducting must NOT be joined (no common flue).
Flue vent pipe used for this furnace may be
Schedule 40 PVC pipe or vent pipe listed to
UL 1738 or ULC S636. All field installed vent pipe and fittings must be from the same manufacturer. DO NOT intermix vent system parts from different vent manufacturers. All furnaces include a vent connector/ couplings for attachments of the vent pipe. Minimum length before any turns in pipe is 12”. In
Canada, the PVC vent pipe must be approved to ULC S636.
To ensure that piping is leak free after installation, PVC sections must be solvent welded (glued) consistent with industry standards and applicable local codes. Primer and cement for joints must conform to applicable ASTM standards.
The flue vent and combustion air piping must be properly supported. A 10ft. long section of schedule 40 PVC pipe weighs approximately
14 lbs for 3 in. diameter and 20 lbs. for 4 in. diameter. Horizontal sections must be installed with an upward pitch of not less than
¼ in./ft. (21 mm/m) and securely supported every 3ft. For suspended support, use cradle type hangers to allow for expansion and contraction.
When flue vent pipe is run through unheated spaces where temperatures may be below freezing, insulate pipe using ½ inch
(22.7mm) thick Armaflex-type insulation or heat with a thermostatically controlled heat tape.
Gas furnaces feature high efficiency operation and produce condensate during operation. In locations where the outside air temperature is below freezing, icicles may form on vent terminations from the condensate formed in the vent system.
WARNING
VENT TERMINATION
In locations where the outside temperature falls below freezing, icicles may form on vent terminations due to condensate in the vent system.
Locate vent termination where a falling icicle would not be a hazard.
WARNING
VENT TERMINATION
Vent terminals must be positioned and located away from fresh air intakes, doors, and windows to minimize the possibility of products of combustion from entering occupied space.
Open Combustion Venting
An open combustion gas heater draws combustion air from the space surrounding the heating unit. Louvered combustion air openings are provided in the access panel to the burner vestibule area. Installation must be in an unconfined space with sufficient volume for all appliances located in the space.
A single, properly sized pipe from the exhaust vent connector to the outdoors must be provided. The exhaust vent connection from the unit is a 2” x 4” rubber coupling for connection to 4”PVC. If 2” or 3” PVC is used instead, remove the provided coupling and replace it with the necessary rubber coupling.
Vent pipe diameter and maximum vent length are determined by furnace input rating
58
as shown in Table 12. Flue gases must be
directed downward.
Table 12 - Open Combustion Venting
Model
Size
Input
(MBtu
/hr)
Maximum Vent Length
2”
PVC
(ft)
3”
PVC
4”
PVC
V3-A
V3-B
V3-C
45
60
72
108
90
60
40
15
80
120
30
10
160 N/A
100
100
100
100
100
90
50
100
100
100
100
100
100
100
Notes:
1.
Maximum flue vent length is the equivalent linear length of the pipe
and fittings. See Table 13 for
equivalent lengths for fittings.
2.
Use DWV pipe and fittings instead of
SCH 40 pressure pipe and fittings to reduce overall vent pressure drop.
3.
For separated combustion systems, the maximum vent length is a combination of the combustion air intake and flue vent exhaust pipes.
For example a 60MBtu/hr heater using 3”PVC can have a 50 ft combustion air intake run and a 50 ft flue vent exhaust run.
Table 13 - Equivalent DWV Fittings Length
Equivalent DWV Fittings Length
90° Elbow
45° Elbow
Tee 90° Turn
5 ft
2.5 ft
7.5 ft
Tee Pass Through 2.5 ft
Terminate vertical flue vents as shown in
Figure 32. Maintain proper spacing between
adjacent buildings and walls. The flue vent shall not terminate over public walkways, near soffit vents or crawl space vents or other areas where condensate vapor could create a nuisance or hazard or cause property damage; or where condensate vapor could cause damage or could be detrimental to the operation of regulators, relief valves, or other equipment.
Figure 32 - Open Combustion Venting
Separated Combustion Venting
A separated combustion gas heater requires a two (2) pipe separated combustion vent system with separate air intake and flue vent.
Combustion air is supplied from outdoors into the furnace burner compartment through a single properly sized pipe attached to the air intake collar. These furnaces are Category IV vented appliances. Flue vent piping must be gas tight and water tight. Both the furnace and vent system must be connected to a condensate removal system.
59
The heating unit must include the following:
1.) For flue vent pipe and fittings conveying flue gases, use only Category IV vent materials listed to UL1738 / ULC S636 from same vent manufacturer. DO NOT intermix vent system parts from different vent manufacturers. Follow instruction provided with approved venting materials used.
2.) For combustion air piping, use PVC and glue joints.
3.) Flue vent pipe and air inlet pipe size depends on input rating of the furnace.
Minimum vent length is 5 ft.
4.) The inlet and outlet terminals must be located in the same pressure zone to provide for safe appliance operation.
The venting and combustion air supply must be exclusive to a single furnace. The gas heater is not approved for concentric venting.
Separated combustion systems may not be common vented. Do not use dampers in flue vent or combustion air pipes.
The exhaust vent connection from the unit is a 2” x 4” rubber coupling for connection to
4”PVC. If 2” or 3” PVC is used instead, remove the provided coupling and replace it with the necessary rubber coupling.
The combustion air connection from the unit is a 3” rubber coupling. If 2” or 4” PVC is used instead, remove the provided coupling and replace it with the necessary rubber coupling.
Figure 33 - Separated Combustion Venting
Minimum length before any turns in pipe is
12”.
Flue vent pipe runs through unheated spaces must be insulated.
The flue vent and combustion air piping must be properly supported. Horizontal sections must be installed with an upward pitch of not less than ¼ in./ft. (21 mm/m) toward the termination and securely supported every 3ft.
The vent drip leg must use reducers from the outlet to the drain connection to meet requirements for Canadian installations
(OLC S636). This method is also acceptable in the US.
60
Gas Supply, Piping and Connections
DANGER
The gas pipe in the unit must be checked for leaks before startup.
Leak checking is the responsibility of the installing contractor. All connections must be checked for leaks annually. Failure to leak check could result in fire, explosion, or other hazardous situations.
Gas piping must be installed in accordance with local codes, or in the absence of local code, installation must conform to the current
(United States) National Fuel Gas Code
ANSI-Z223.1/NFPA 54 or the current
(Canada) National Fuel & Propane
Installation Code CSA B149.1 or B149.2.
Gas piping must be sized for the total Btu input of all units (heaters) serviced by a single
supply. See Table 14 or Table 15 to help size
the gas piping. The gas connection size from the unit is ½”NPT.
Pipe Size
1/2”
3/4”
1”
1-1/4”
1-1/2”
2”
2-1/2”
Table 14 - Natural Gas (ft 3 /hr) Maximum Piping Capacities
Specific Gravity = 0.6, Supply Pressure ≤ 0.5 psi, Pressure Drop = 0.5”wc
Length of Pipe
20 ft
120
250
465
50 ft.
73
151
285
100 ft.
50
103
195
150 ft.
40
84
160
950
1460
2750
4350
580
900
1680
2650
400
620
1150
1850
325
500
950
1500
200 ft.
35
72
135
280
430
800
1280
Pipe Size
1/2”
3/4”
1”
1-1/4”
1-1/2”
2”
Table 15 - Propane (kBtu/hr) Maximum Piping Capacities
Specific Gravity = 1.52, Supply Pressure = 11”wc., Pressure Drop, 0.5”wc
Length of Pipe
20 ft
189
393
732
1496
2299
4331
50 ft.
114
237
448
913
1417
2646
After verifying gas inlet pressure and manifold pressure the service technician must time the gas flow rate through the gas meter
100 ft.
78
162
307
630
976
1811
150 ft.
63
132
252
511
787
1496
200 ft.
55
112
213
440
675
1260 with a stopwatch to verify the gas input rate.
Table 16 - Gas Inlet Pressure
Gas Inlet
Pressures (“wc)
Minimum
Maximum
Natural Propane
Gas Gas (LP)
6.0”wc 11.0”wc
10.5”wc 13.0”wc
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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.
A factory installed pressure tap on the outlet end of the gas valve can be used to verify the manifold pressure.
Table 17 - Manifold Pressure
Natural
Unit Size (V3-)
Gas
A
Propane
Gas (LP)
10.5”wc
B
C
3.5”wc
10.0”wc
Do not use gas piping smaller than unit gas connections. Natural gas pipe runs longer than 20 feet and propane gas pipe runs longer than 50 feet may require a larger supply pipe than the unit connection size. Some utility companies may also require pipe sizes larger than the minimum sizes listed.
Piping Sizing Examples
A 100 ft pipe run is needed for a 1080 MBH natural gas heater. The natural gas has a rating of 1000 Btu/ft 3 and a specific gravity of 0.6 (Obtain these values from the local gas supplier.)
1080 MBH
1000 ft
3
BTU
1080 ft 3 /hr
From the natural gas maximum capacities table, at 100 ft and 1080 ft 3 /hr the required minimum pipe size is 2”.
A 100 ft pipe run is needed for a 270 MBH propane gas heater.
270 MBH = 270 kBtu/hr
From the propane gas maximum capacities table, at 100 ft 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”wc and maximum inlet gas pressure to the unit is 10.5”wc. For propane units, the minimum inlet gas pressure to the unit is 11”wc and the maximum inlet gas pressure to the unit is
13”wc.
A field provided 1/8” NPT pressure tap is required to be installed in the piping just upstream of the shutoff valve for test gage connection to allow checking of the gas supply pressure at the unit.
A factory installed pressure tap on the outlet end of the gas valve can be used to verify a manifold pressure of 3.5”wc for natural gas, or 10.5”wc for propane V3-A & V3-B
(10.0”wc on size V3-C).
CAUTION
Heater must be disconnected from the gas supply piping during pressure testing of the supply piping system with pressures in excess of ½ psi. Gas valves can be damaged if subjected to more than ½ psi.
Gas Pressure Regulator & Overpressure
Protection Device
A gas pressure regulator must be installed if natural gas supply pressure to the unit is greater than 10.5”wc and less than 2 psi
(55.4”wc). Regulators must comply with the latest edition of the Standard for Line
Pressure Regulators, ANSI Z21.80/CSA
6.22.
Both a gas pressure regulator and overpressure protection device (OPD) must be installed if gas supply pressure to the unit is greater than 2 psi (55.4”wc) and less than
5 psi (138.4”wc), in compliance with ANSI
62
Z21.80/CSA 6.22. For proper heater operation, pressure to the regulator MUST
NOT be greater than 5 psi (138.4”wc).
Piping Supports
Gas supply piping must be supported directly at the connection to the unit and at intervals listed in the following table with metal straps, blocks, or hooks. Piping must not be strained or bent.
Table 18 - Gas Piping Supports
Pipe Size
1/2” to 3/4”
3/4” to 1”
1-3/4” or Larger
Support Intervals
Every 6 ft
Every 8 ft
Every 10 ft
(Horizontal)
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 must be labeled. Install a drip leg near the unit connection to trap sediment and condensate. Pipe joint compounds used on all gas piping connections must be resistant to liquid petroleum gases. If flexible gas piping to the unit, or in the unit, must be replaced connectors cannot be reused, only new connectors may be used.
Figure 34 - Sediment Trap for Gas Heat
A 1/8” NPT tap is provided on the inlet side of the gas valve to the heater. Connect a fitting suitable for connection to a pressure gauge capable of measuring gas pressure to each heater serviced by a single regulator so that gas pressure at each heater can be measured with all heaters in operation.
Use a back up wrench on the gas valve when connecting field supply gas piping to avoid loosening pre-piped furnace gas connections during installation.
Heat exchanger comes equipped with a condensate drain which must 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 heat exchanger condensate drain connection from the unit is a 3/4” PVC connection.
Leak Testing
WARNING
FIRE OR EXPLOSION HAZARD
Failure to follow the safety warnings exactly could result in serious injury, death or property damage.
Never test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections. A fire or explosion may result causing property damage, personal injury or loss of life.
63
All components of gas supply system, including manual shut off valves and the piping in the interior of the unit, must be leak tested with a soap solution before operating the appliance and at least on an annual basis thereafter.
DANGER
LEAK CHECK GAS PIPE
The gas pipe in the unit must be checked for leaks before startup. Leak checking is the responsibility of the installing contractor. All connections must be checked for leaks annually after installation. Failure to leak check could result in fire, explosion, or other hazardous situations.
Some soaps used for leak detection can be corrosive to certain metals.
Rinse piping thoroughly after leak test has been completed.
CAUTION
WARNING
Gas pressure to appliance controls must never exceed 14 ”wc (1/2 psi)
1. When pressure testing at 1/2 psi or less, close the manual shutoff valve on the appliance before testing.
2. When pressure testing gas supply line at 1/2 psi or higher, close manual gas valve and disconnect heater from supply line to be tested. Cap or plug the supply line.
64
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 other living animals which may be sensitive to the residual odors or gases, must NOT be present in the conditioned space during the startup. In all cases, including the initial factory firing and testing, any of the gases will be under the acceptable level of concentration for human occupancy.
WARNING
Those sensitive to odors or gases from trace amounts of residual oils must NOT be present in the conditioned space during the startup of a gas fired installation.
Input
The correct heat capacity of the furnace is controlled by the burner orifices and the gas manifold pressure. The manifold pressure is factory set but must be checked at the time of start-up.
Gas Heater Startup
1. Turn thermostat or temperature controller to its lowest setting.
2. Turn off gas supply at the manual shut-off valve (supplied by others).
3. Turn off power to the unit at the disconnect switch.
4. This appliance is equipped with an ignition device which automatically lights the burner.
Do NOT try to light the burner by hand.
5. Open door to unit module housing the gas heater.
6. Move gas control switch to “OFF” position.
Figure 35 - Gas Control Switch
7. Install a tapped fitting for attachment to a manometer or other gauge suitable for
14.0”wc in the inlet pressure tap. Install a tapped fitting for attachment to a manometer or other gauge suitable for 10.0”wc in the manifold pressure tap.
8. Wait 5 minutes for any gas to clear out. If you smell gas, turn off gas supply at the manual shut-off valve (field installed). If you don’t smell gas or have corrected any leaks, go to the next step.
9. Turn gas control switch to “ON” position.
10. Close door to unit module housing the gas heater.
11. Open all manual gas valves (supplied by others).
12. Turn power on at disconnect switch.
13. Set thermostat or controller to its highest position to initiate call for heat and maintain operation of unit.
14. Draft inducer will run for a 5 second prepurge period.
15. The control energizes the spark and main gas valve for a 20 second ignition period.
16. The control shuts spark off and waits for a 30 second heat blower on delay period and then energizes the indoor blower heat speed.
17. Control inputs are continuously monitored to ensure limit and pressure switches are closed, flame is established, and the thermostat call for heat remains.
18. Inlet gas pressure must be between 6.0” and 14.0”wc on Natural Gas (11.0” to
13.0”wc on Propane). Adjust supply regulator if necessary or contact utility if unable to obtain proper inlet pressure.
19. At burner ignition, manifold pressure will be 1.7”wc. Furnace will continue at this input rating for 90 seconds.
20. All control systems require a manifold pressure of 3.50”wc at maximum input (high fire) on Natural Gas, and 10.5”wc on Propane
Gas V3-A & V3-B (10.0”wc for V3-C).
21. Systems with modulating gas heat require a manifold pressure of 0.40”wc at 33% turndown on Natural Gas.
Failure to Ignite
1. For the initial start-up, or after unit has been off long periods of time, the first ignition trial may be unsuccessful due to need to purge air from manifold at start-up.
2. If ignition does not occur on the first trial, the gas and spark are shut-off by the ignition control and the control enters an inter-purge period of 45 seconds, during which the draft inducer continues to run.
3. At the end of the inter-purge period, another trial for ignition will be initiated.
4. Control will initiate up to three ignition trials on a call for heat before lockout of control occurs.
65
5. Control can be brought out of lockout by either removing power from the control for more than 1 second or setting the thermostat to its lowest position and waiting 5 seconds and then turning back up to call for heat.
Some controls provided will automatically reset after one hour and initiate a call for heat.
Burner Flames
Prior to completing the start-up, check the appearance of the main burner flame for flame characteristics of properly adjusted natural gas systems.
1. The burner flame must be predominately blue in color and well defined and centered at the tube entry. Distorted flame or yellow tipping of natural gas flame, may be caused by lint and dirt accumulation inside burner or at burner ports, at air inlet between burner and manifold pipe, or debris in the main burner orifice. Soft brush or vacuum clean affected areas after performing Shutdown procedure.
2. Poorly defined, substantially yellow flames, or flames that appear lazy, indicate poor air supply to burners or excessive burner input. Verify gas supply type and manifold pressure with rating plate.
3. Poor air supply can be caused by obstructions or blockage in heat exchanger tubes or flue vent discharge pipe. Inspect and clean as necessary by to eliminate blockage.
Vacuum any dirt or loose debris found in the tubes or vents. Clean heat exchanger tubes with stiff brush after performing Shutdown procedure. Poor flame characteristics can also be caused by undersized combustion air openings or flue gas recirculation into combustion air supply. Increase air opening size or re-direct flue products to prevent recirculation.
4. Reduced air delivery can also be the result of fan blade slippage, dirt accumulation the fan blade or low voltage to draft inducer motor. Inspect draft fan assembly and be sure fan blade is secure to motor shaft. Check line voltage to heater.
WARNING
Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.
Figure 36 - Natural Gas Flame
Yellow Color is
ONLY allowed at the tip of the flame
Figure 37 - Propane Gas Flame
66
Figure 38 - Gas Heater Instructions
67
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 valve and high voltage to the igniter. If a burner flame has been detected within 10 seconds, the spark is extinguished and the flame continues. If a flame has not been detected after 10 seconds, the gas valve closes, the spark ceases and the induced draft blower continues to purge the heat exchanger. After 45 seconds of purge, the ignition system will attempt to light the burners again. Should no flame be detected after 3 tries, the ignition control will lock out the system. Power to the ignition control must be cycled 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 sensing the temperature after the supply fan.
Table 19 - Gas Heat Ignition Times
Time
Pre-Purge
Inter-Purge
Post Purge
Ignition Trial
Blower On Delay
Blower Off Delay
Lockout Recovery
5 sec
45 sec
5 sec
10 sec
30 sec
120 sec
60 min
Gas Heater Operating and Safety
Instructions
1. This furnace does not have a pilot. It is equipped with a direct spark ignition device that automatically lights the gas burner. DO
NOT try to light burners by hand.
2. BEFORE OPERATING, leak test all gas piping up to heater gas valve. Smell around the unit area for gas. DO NOT attempt to place heater in operation until source of gas leak is identified and corrected.
3. Use only hand force to push and turn the gas control switch to the “ON” position.
NEVER use tools. If switch does not operate by hand, replace gas valve prior to staring the unit. Forcing or attempting to repair the gas valve may result in fire or explosion.
4. Do not attempt to operate unit if there is indication that any part or control has been under water. Any control or component that has been under water must be replaced prior to trying to start the unit.
WARNING
Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.
Shutdown
1. Set thermostat or controller to lowest setting.
2. Turn off electrical supply to unit at disconnect switch.
3. Turn off manual gas supply (supplied by others).
4. Disconnect manifold and inlet pressure taps and re-install pipe plugs.
5. Close module door.
Normal Operation
1. Turn on electrical supply to unit at disconnect switch.
2. Turn on manual gas supply (supplied by others).
3. Set Thermostat or Temperature controller to desired temperature.
68
Event
Heat call – 24V at W
Table 20 - Ignition Control Sequence of Operation
Action
Control verifies limit switches are closed
Fault
Flashes “4” if limit is open
Control verifies the pressure switch is open
Soft lock-out and flashes
“3” if switch is closed
Flashes “2” if switch is
Energize inducer fan
Control verifies the pressure switch is closed within 10 sec open after 10 sec
Pre-purge No flame and pressure switch closed
Soft lock-out if flame is present, flashes “5”
Soft lock-out, flashes “1”
Ignition trial
Blower on delay
3 trials with 45 sec inter-purge period if it doesn’t light in 10 sec
Blower delay after ignition proof alarm
Steady state Normal operation
Limit or pressure switch faults
Post purge
Blower off delay
Ignition re-cycle
Limit switch operation
Lockout - soft
Lockout - hard
Inducer fan runs after heat call is removed
Time starts after heat call is removed
Soft lock-out if no
Re-tries 4 times if flame is lost iginition, flashes “1”
Flashes “4” if limit is
Only sensed when heat call is present open
Can be reset by removing heat call “W” or power to control.
Soft lock-out, flashes “1” alarm
Soft lock-out may be caused by failed ignition or too many flame losses.
Controller issue, reset by removing power to the control only.
Hard lock-out may be caused by internal
Hard lock-out, status
LED de-energized
RAM or ROM corruption, faults in flame sense circuit, or faults in gas valve drive circuits.
Service Checks
Flame current is the current which passes through the flame from the sensor to ground.
The minimum flame current necessary to keep the system from lockout is
0.5microamps. To measure flame current, connect an analog DC microammeter to the
FC- and FC+ terminals per Figure 39. Meter
must read 0.5 uA or higher. If the meter reads below “0” on scale, meter leads are reversed.
Disconnect power and reconnect meter leads for proper polarity.
Figure 39 - Flame Sensor Current Check
69
Ignition Control Module
The integrated direct spark ignition control provides control of all furnace functions including control of the induced draft fan, gas valve, pre-purge timing, ignition, flame sensing and monitoring of the safety circuit at all times, and post purge at the completion of a heating cycle. The board includes an LED diagnostic light to monitor control status.
A
Figure 40 - Ignition Control Module
Air Pressure & Blocked Drain Switch
An air pressure switch is provided as part of the control system to verify airflow through draft inducer by monitoring the difference in pressure between the draft inducer and the
atmosphere. (See “C” in Figure 41). If
sufficient negative pressure is not present, indicating lack of proper air movement through heat exchanger, the switch opens shutting off gas supply through the ignition control module. Also, if the drain becomes blocked, the water will back up into the line and the switch will sense no pressure in the line and again the switch opens shutting off gas supply through the ignition control module.
B C
Figure 41 - Safety Switches
Blocked Flue Switch
Another air pressure switch is provided as part of the control system to serve as a
blocked flue switch (See “B” in Figure 41).
When the heater is running, there is a negative pressure reading in this line that is more negative than the switch setting of -
0.18”wc. If the flue were to become blocked, the pressure would become less negative until it reaches the switch setting pressure and shuts the heater off.
Rollout Switch (Manual Reset)
The furnace is equipped with manual reset rollout switch in the event of burner
overheating (see “A” in Figure 41). The
switch will open on temperature rise and shut-off gas supply through the ignition control module. Flame rollout can be caused by insufficient airflow for the burner firing rate (high gas pressure), blockage of the vent system or in the heat exchanger. Do not place the furnace back in operation until the cause of overheating is identified. The rollout switch can be reset by pressing the button on the top of the switch.
Figure 42 - Rollout Switch
70
High Limit Switch
Two high limit switches are provided on all furnace configurations.
One limit control is mounted in the air stream and will shut-off the gas supply in the event of overheating due to reduced airflow over the heat exchanger. This limit is an automatic reset type and will cycle the burners back on when the temperature drops below the preset differential. The furnace will continue to cycle on limit until the cause of the reduced air flow is corrected.
The other limit control is mounted on the induced draft fan housing and will shut-off the gas supply in the event of excessive flue gas temperatures. This switch is an automatic reset type.
Figure 43 - High Limit Switch in Air Stream
Figure 44 - High Limit Switch on Fan
Housing
Table 21 - Gas Heater LED Diagnostics
LED
Code
Stead on
1 flash
2 flash
3 flash
4 flash
5 flash
Description
Indicates power is applied
Control in 1 hour lockout
Pressure switch open with inducer on
Pressure switch closed with inducer off
Limit switch is open
False flame 1 hour lockout
71
Symptom
Table 22 - Gas Heater Troubleshooting Guide
Possible Causes
Control does not power up A.
Faulty 24VAC or 120VAC wiring
B.
Thermostat or transformer
C.
Bad control module
Module LED blinks red
Spark no occurring during trial for ignition
Burner does not light during trial for ignition
Burner lights but valve turns off after trial for ignition
A.
Determine error code and refer to
A.
Faulty spark electrode wiring
B.
Spark gap too wide
C.
Bad control module
A.
Faulty valve wiring
B.
Bad valve
C.
Control module not sparking
A.
Poor flame
B.
Flame not in contact with spark electrode or sensor
C.
Dirty contaminated flame sensor
D.
Faulty flame sensor wiring
E.
Poor ground at burner
Gas Heater Maintenance
WARNING
Once a year, before the unit is in operation for the heating season, a qualified service technician must inspect all flue product carrying areas of the furnace and main burners for continued safe operation.
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.
On the call for heating, the combustion ventilation motor will operate. The control will automatically supply energy to the igniter and the gas valve after the heating call is made.
The flame sensing probe detects the presence of the flame. Should no flame be detected in
DANGER
LEAK CHECK GAS PIPE
The gas pipe in the unit must be checked for leaks before startup. Leak checking is the responsibility of the installing contractor. All connections must be checked for leaks annually after installation. Failure to leak check could result in fire, explosion, or other hazardous situations.
10 seconds, the ignition system will recycle.
If no flame is detected after 3 tries, ignition system will lockout.
Remove the call for heating. The main gas valves must be extinguished.
The supply fans are controlled by the ignition system. In the fan “Auto” mode the fan comes on 45 seconds after the flame is proved and goes off 120 seconds after the heating call is removed.
72
Furnace combustion ventilation air and flue openings must be checked annually for debris and obstructions. If flue vent extensions are used they must meet category IV requirements.
This appliance contains a wire screen at the flue vent outlet. Each heating season, prior to placing the appliance in heat mode maintenance check that no debris or foreign matter has accumulated in the flue vent outlet. A good practice is to check for debris each time the air filters are changed.
In the event the flue 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 flue vent was blocked a qualified technician or service agency must monitor the unit prior to re-starting.
The gas burner and heat exchanger should never require cleaning. If cleaning is necessary, this indicates faulty operation of the unit. Cleaning must only be done by a qualified service agency and only after consultation 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.
WARNING
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 must be kept with the unit.
WARNING
Disconnect all electrical power sources before servicing the unit.
More than one power source may be provided. Failure to do so may result in injury or death from electrical shock or entanglement in moving parts.
CAUTION
If any original wiring needs to be replaced it must be replaced with wiring materials suitable for 105ºC.
Label all wires prior to disconnection when servicing unit. Wiring errors can cause improper or dangerous operation. Verify proper operation after servicing.
Condensate Drainage System Inspection
1. Inspect condensate drain lines to be sure they are free of debris and free flowing.
2. Inspect all condensate lines for freezing and verify operation of freeze protection
(heat trace tape). The factory installed section of the condensate line includes a heat trace. All field installed condensate lines must also include heat trace.
3. Inspect and clean out all waterless p-traps of condensate/ mildew buildup.
4. Inspect and replace the condensate neutralizer cartridge if necessary.
Furnace Exhaust Vent Termination
1. Inspect all flue exhaust vent terminations/outlets. Remove any ice accumulation. Ice accumulation can affect performance and operation of the furnace.
73
2. Inspect the roof floor in front and/or below any flue exhaust termination and furnace access door. Remove any ice accumulation.
Furnace Inspection
Turn off all electrical power to the unit before inspection and servicing.
1. The furnace must be inspected annually by a qualified service agency. The condition of the burners, heat exchanger, draft inducer, vent system, operating controls and wiring must be determined. Check for obvious signs of deterioration, accumulation of dirt and debris and any heat or water related damage.
Replace any damaged or deteriorated parts before the unit is put back into service.
2. Clean draft inducer and vent ducts with a soft brush or vacuum.
3. Check Heat Exchanger for cracks. If any are present, replace heat exchanger before putting unit back into service.
4. Check the attachment point of the furnace to the cabinet or ducts to verify that they are air tight.
5. Check the automatic gas valve to insure that the gas valve seat is not leaking.
6. Inspect and clean condensate drain trap(s).
7. If condensate neutralizer tube is installed, recharge per instructions.
8. Inspect and clean secondary coil fins.
9. Check wiring connections to be sure they are secure and inspect wiring for any deterioration.
10. Label all wires prior to disconnection when servicing unit. Wiring errors can cause improper or dangerous operation. Verify proper operation after servicing.
74
Furnace Operation Check
1. Turn on power to the unit and set thermostat or heat controller to call for heat, allowing furnace to operate.
2. Check for proper start-up and ignition as outlined in Start-Up section.
3. Check the appearance of the burner flame.
4. Check that the circulating air fan is operating and verify the proper airflow through furnace.
5. Verify proper flow of condensate from drain system.
6. Return thermostat or heat controller to normal setting.
Phase and Brownout Protection Module
The DPM is a Digital Phase Monitor that monitors line voltages from 200VAC to
240VAC 1 ɸ and 200VAC to 600VAC 3 ɸ .
The DPM is 50/60 Hz self-sensing. DPM must be wired according to unit specific wiring diagram included in the control compartment
When the DPM is connected to the line voltage, it will monitor the line and if everything is within the setup parameters, the output contacts will be activated. If the line voltages fall outside the setup parameters, the output relay will be de-energized after the trip delay.
Once the line voltages 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 Se tup 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 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.
Default Set-up
Line Voltage 460VAC, 3Ø
Over & Undervoltage ±10%
Trip Time Delay 5 Seconds
Re-Start Time Delay 2 Minutes
Phase Imbalance 5%
75
Screens
Manufacturer’s Screen
R-K Electronics
DPM v0.0.00
Average Voltage Screen
VAvg Imb Hz
460 0 60 off
Default – the default screen shows the real time voltage detected in each of the 3 phases:
A-B B-C C-A
460 459 461 ON
Voltage Selection Screen (Vertical Format) Default = 460V, 3 Ø
200, 1Ø; 208, 1Ø; 220, 1Ø; 230, 1Ø; 240, 1Ø;
200, 3Ø; 208, 3Ø; 220, 3Ø; 230, 3Ø; 240, 3Ø; 380, 3Ø; 415, 3Ø; 440, 3Ø;
460, 3Ø; 480 3Ø; 575, 3Ø; 600, 3Ø;
Over/Under voltage Percentage Screen (Vertical Format) Default = 10%
7% 8% 9% 10% 11% 12% 13% 14% & 15%
Trip Time Delay Screen (Vertical Format) Default = 5 sec
2S, 3S, 4S, 5S, 6S, 27S, 8S, 9S & 10S
Re -Start Time 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 selected Undervoltage Percentage)
“Voltage High” (Average line voltage is more than selected Overvoltage Percentage)
“Imbalance”
(One phase is lower than the average voltage by more than the Imbalance percentage)
“Phase Loss
(One phase is more than 30% below the Line Voltage selection)
“Bad Rotation”
(The phase rotation sequence is reversed)
“Bad Freq”
(Line frequency out of allowable range of 45 to 65 Hz)
76
Filter Replacement
Monthly filter inspection is required to maintain optimum unit efficiency.
WARNING
Electric shock hazard. Shut off all electrical power to the unit to avoid shock hazard or injury from rotating parts.
Replace filter media monthly. Filters are located upstream of the evaporator coil. Open access panel and pull filters straight out to inspect all of the filters. Replace filters with the size indicated on each filter. Arrow on the replacement filters must point towards the blower.
Replacement Parts
Parts for AAON equipment may be obtained from your local representative https://www.aaon.com/RepSearch . When ordering parts, reference the unit serial number and part number.
AAON Technical Support
203 Gum Springs Rd.
Longview, TX 75602
Ph: (918) 382-6450 [email protected] www.AAON.com
Note: Before calling, technician must have model and serial number of the unit available for the service department to help answer questions regarding the unit.
77
Feature 6A
0
A
B
C
D
E
F
G
H
J
Filter Information
Table 23 - V3 Series E Cabinet Pre-Filters
(Quantity) Size
No Pre Filters
(6) 18” x 24” x 2"
Type
Pleated MERV 8
Pleated MERV 8
(6) 18” x 24” x 4" Pleated MERV 11
Pleated MERV 13
Pleated MERV 14
(6) 18” x 24” x 2" and
(6) 18” x 24” x 4"
Pleated MERV 8 and
Pleated MERV 8
Pleated MERV 8 and
Pleated MERV 11
Pleated MERV 8 and
Pleated MERV 13
Pleated MERV 8 and
Pleated MERV 14
78
Feature 6B
0
A
B
C
D
E
F
G
H
J
Feature 6B
0
A
B
C
D
E
F
G
H
J
Table 24 - V3 Series A Cabinet Unit Filters
(Quantity) Size
No Pre Filters
(1) 16” x 25” x 2”
Type
Pleated MERV 8
Pleated MERV 8
(1) 16” x 25” x 4”
Pleated MERV 11
Pleated MERV 13
Pleated MERV 14
Pleated MERV 8 and
Pleated MERV 8
(1) 16” x 25” x 2” and
(1) 16” x 25” x 4”
Pleated MERV 8 and
Pleated MERV 11
Pleated MERV 8 and
Pleated MERV 13
Pleated MERV 8 and
Pleated MERV 14
Table 25 - V3 Series B Cabinet Unit Filters
(Quantity) Size
No Pre Filters
(1) 24” x 24” x 2”
Type
Pleated MERV 8
(1) 24” x 24” x 4”
(1) 24” x 24” x 2” and
(1) 24” x 24” x 4”
Pleated MERV 8
Pleated MERV 11
Pleated MERV 13
Pleated MERV 14
Pleated MERV 8 and
Pleated MERV 8
Pleated MERV 8 and
Pleated MERV 11
Pleated MERV 8 and
Pleated MERV 13
Pleated MERV 8 and
Pleated MERV 14
79
Feature 6B
0
A
B
C
D
E
F
G
H
J
Feature 6B
0
A
B
C
D
E
F
G
H
J
Table 26 - V3 Series C Cabinet Unit Filters
(Quantity) Size
No Pre Filters
(4) 16” x 20” x 2”
Type
Pleated MERV 8
(4) 16” x 20” x 4”
Pleated MERV 8
Pleated MERV 11
(4) 16” x 20” x 2” and
(4) 16” x 20” x 4”
Pleated MERV 13
Pleated MERV 14
Pleated MERV 8 and
Pleated MERV 8
Pleated MERV 8 and
Pleated MERV 11
Pleated MERV 8 and
Pleated MERV 13
Pleated MERV 8 and
Pleated MERV 14
Table 27 - V3 Series D Cabinet Unit Filters
(Quantity) Size Type
No Pre Filters
(4) 18” x 24” x 2" Pleated MERV 8
Pleated MERV 8
(4) 18” x 24” x 4"
Pleated MERV 11
Pleated MERV 13
Pleated MERV 14
(4) 18” x 24” x 2" and
(4) 18” x 24” x 4"
Pleated MERV 8 and
Pleated MERV 8
Pleated MERV 8 and
Pleated MERV 11
Pleated MERV 8 and
Pleated MERV 13
Pleated MERV 8 and
Pleated MERV 14
80
Table 28 - V3 Series Energy Recovery OA Filters (Feature 13 = A-V)
Unit Size
A
B
C
D
E
(Quantity) Size
(1) 16” x 25” x 2”
(1) 24” x 24” x 2”
(4) 16” x 20” x 2”
(4) 18” x 24” x 2”
(8) 16” x 20” x 2”
Type
Pleated MERV 8
Pleated MERV 8
Pleated MERV 8
Pleated MERV 8
Pleated MERV 8
Refrigerant Piping Diagrams
See the matching Condensing Unit IOM for Piping Diagrams
81
V3 Series Startup Form
Job Name:_____________________________________________ Date:____________
Address:____________________________________________________________________
____________________________________________________________________________
Model Number:_______________________________________________________________
Serial Number:___________________________________________ Tag:______________
Startup Contractor:____________________________________________________________
Address:____________________________________________________________________
______________________________________________________ Phone:_____________
Pre Startup Checklist
Installing contractor must verify the following 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? Yes No
8.
On 208/230V units, has transformer tap been checked? Yes No
9.
Has overcurrent protection been installed to match the unit nameplate requirement?
Yes No
10.
Have all set screws on the fans been tightened? Yes No
11.
Do all fans rotate freely? Yes No
12.
Does the field water piping to the unit appear to be correct per design parameters?
Yes No
13.
Is all copper tubing isolated so that it does not rub? Yes No
14.
Have the damper assemblies been inspected? Yes No
15.
Are air filters installed with proper orientation? Yes No
16.
Have condensate drain and p-trap been connected? Yes No
17.
Is the TXV sensing bulb in the correct location? Yes No
18.
Does the TXV sensing bulb have proper thermal contact and is properly insulated?
Yes No
82
Ambient Temperature
Ambient Dry Bulb Temperature ________°F
Voltage
L1-L2 L2-L3
Supply Fan Assembly
Alignment
L1-L3
Ambient Wet Bulb Temperature ________°F
L1-Ground
Check Rotation
L2-Ground L3-Ground
Nameplate Amps________
Number hp L1 L2 L3
1
2
VFD Frequency________________ VAV Controls_________________
Power Exhaust Fan Assembly
Alignment Check Rotation
Number hp L1
1
2
VFD Frequency________________
Nameplate Amps________
L3 L2
VAV Controls_________________
Energy Recovery Wheel Assembly
Wheels Spin Freely Check Rotation
Number hp L1 L2
FLA ________
L3
1
2
Dampers
OA Operation Check
RA Operation Check
EA Operation Check
Damper Wiring Check
Damper Wiring Check
Damper Wiring Check
Gears Check
Gears Check
Gears Check
Damper Actuator Type:__________________________________________________________
Economizer Changeover Type and Operation:_______________________________________
83
Refrigeration System 1 - Cooling Mode
Saturated
Pressure
Temperature
Discharge
Suction
Liquid
Refrigeration System 2 - Cooling Mode
Saturated
Pressure
Temperature
Discharge
Suction
Liquid
Refrigeration System 3 - Cooling Mode
Pressure
Saturated
Temperature
Discharge
Suction
Liquid
Refrigeration System 4 - Cooling Mode
Saturated
Pressure
Temperature
Discharge
Suction
Liquid
Compressors/DX Cooling
Check Rotation
Line
Temperature
Line
Temperature
Line
Temperature
Line
Temperature
Number
1
2
3
4
L1 L2 L3
Head
Pressure
PSIG
Sub-cooling
N/A
N/A
Sub-cooling
N/A
N/A
Sub-cooling
N/A
N/A
Sub-cooling
N/A
N/A
Suction
Pressure
PSIG
Superheat
N/A
N/A
Superheat
N/A
N/A
Superheat
N/A
N/A
Superheat
N/A
N/A
Crankcase
Heater
Amps
84
Air-Cooled Condenser Fans
Alignment
Number
1
2 hp L1
Check Rotation
L2
3
4
Refrigeration System 1 - Heating Mode (Heat Pump Only)
Pressure
Saturated
Temperature
Line
Temperature
Discharge
Suction
Liquid
Refrigeration System 2 - Heating Mode (Heat Pump Only)
Pressure
Saturated
Temperature
Line
Temperature
Discharge
Suction
Liquid
Refrigeration System 3 - Heating Mode (Heat Pump Only)
Pressure
Saturated
Temperature
Line
Temperature
Discharge
Suction
Liquid
Refrigeration System 4 - Heating Mode (Heat Pump Only)
Pressure
Saturated
Temperature
Line
Temperature
Discharge
Suction
Liquid
Nameplate Amps________
L3
Sub-cooling
N/A
N/A
Sub-cooling
N/A
N/A
Sub-cooling
N/A
N/A
Sub-cooling
N/A
N/A
Superheat
N/A
N/A
Superheat
N/A
N/A
Superheat
N/A
N/A
Superheat
N/A
N/A
85
Water/Glycol System
1.
Has the entire system been flushed and pressure checked?
2.
Has the entire system been filled with fluid?
3.
Has air been bled from the heat exchangers and piping?
4.
Is the glycol the proper type and concentration (N/A if water)?
5.
Is there a minimum load of 50% of the design load?
6.
Has the water piping been insulated?
7.
What is the freeze point of the glycol (N/A if water)?
______________________________
Electric Heating
Stages__________ Limit Lockout
Yes No
Yes No
Yes No
Yes No
Yes No
Yes No
Aux. Limit Lockout
Stage
1
2
3
4
Amps Stage
5
6
7
8
Gas Heating
Natural Gas
Stage
1
Propane Purge Air from Lines
Manifold Pressure (“wc) Stage
3
2 4
Gas Heating
1.
Have all gas lines & connections been checked for leaks?
2.
Is there adequate combustion air?
3.
Have condensate drain lines been installed?
4.
Has air been purged from the lines?
5.
Has pilot spark been verified?
Amps
Verify Pilot Spark
Manifold Pressure (“wc)
Yes No
Yes No
Yes No
Yes No
Yes No
86
Modulating Gas Heat
Type of Gas
Analog Input VDC
Gas Pressure @ Train Inlet
“w.c.
Gas Pressure @ Burner
Manifold
“w.c.
CO2 in Flue Gas % %
CO2 in Flue Gas ppm
Flue Gas Temp @
Discharge
Temperature Rise ppm
°F
°F
Natural Gas (5:1)
Low Fire @ 0 VDC
Propane (3:1)
High Fire @ 10 VDC
87
Maintenance Log
This log must be kept with the unit. It is the responsibility of the owner and/or maintenance/service contractor to document any service, repair or adjustments. AAON Service and Warranty
Departments are available to advise and provide phone help for proper operation and replacement parts. The responsibility for proper startup, maintenance and servicing of the equipment falls to the owner and qualified licensed technician.
Action Taken Name/Tel. Entry
Date
Maintenance Log (E-Coated Coil)
Literature Change History
July 2018
Initial Version – See Obsolete H3/V3 IOM (J00188) for obsolete features not found in this version.
H3 Series and V3 Series each have their own IOM due to the different gas heaters.
April 2019
Added Model B1 Heating Type 5 = Electric Heat (UL 60335-2-40 Compliant) and Heating
Designations N (7.5kW) through W (60kW). Added a table for clearances for coil pull. Added information on forklift base assembly. Change the condensate drain figure. Changed some terminology to flue vent for clarification on gas heat flue venting. Added the exhaust and combustion air connection sizes for the gas heater. Updated Gas Heating tables on the start-up form. Change filters from MERV 10 to MERV 8 and removed ASHRAE efficiency values from filters.
May 2019
Added the minimum/maximum voltage range table in the Electrical section.
June 2019
Updated Table 1 - Electric and Gas Heating Capacities with new electric heat options.
September 2019
Added options 5 and 6 in Model Option B3 Heating Stages. Added D = Stainless Steel Coil Casing and E = E-coated Coil + Stainless Steel Coil Casing in Feature 8 Coil Casing.
March 2020
Updated EC motor wiring figures and potentiometer figure.
December 2020
Updated the format of the document to include general information followed by sections that are specific to feature options. Added Final Filter Box options to Feature 6C. Updated the dimensions on the small control panel. Added high condensate level switch option in Feature 21. Updated
EC motor wiring figures and potentiometer figure. Revised measurement of suction line temperature to be taken at the evaporator. Updated the Nameplate Voltage Markings and
Tolerance table. Updated phase imbalance example. Revised the e-coated coil cleaning section.
Added Voltage check to the startup form. Added the AAON E-Coated Coil Maintenance Record.
October 2021
Added piezo ring options to Feature 1A and Feature 19. Added enthalpy limit and sensible limit options to Feature 5C. Added 10 kAIC option to Feature 14B. Added parts only warranty options to Feature 22. Added a section on removable internal control panel for accessing the supply fan.
AAON
203 Gum Springs Rd.
Longview, TX 75602-1721 www.AAON.com
V3 Series
Installation, Operation &
Maintenance
G014420· Rev. D 211025
(ACP J01398)
Factory 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 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.

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