AAON SA-023 Installation operation & maintenance - Sa Series Startup Form

Manual is about: SA SERIES Vertical Self - Contained Units and Indoor Air Handling Units

Summary of SA-023

  • Page 1

    Sa series vertical self-contained units and indoor air handling units installation, operation & maintenance if the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life. For your safety do not store or use gasoline...

  • Page 3

    3 table of contents safety .............................................................................................................................................. 6 sa series feature string nomenclature ....................................................................................... 11...

  • Page 4

    Recommended chloride remover ......................................................................................... 50 supply fans ............................................................................................................................... 50 phase and brownout protection modul...

  • Page 5

    5 index of tables and figures tables: table 1 - sa series models .......................................................................................................... 18 table 2 - glycol freezing points ...............................................................................................

  • Page 6: Safety

    6 safety attention should 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 ...

  • Page 7: Warning

    7 variable frequency drives do not leave vfds unattended in hand mode or manual bypass. Damage to personnel or equipment can occur if left unattended. When in hand mode or manual bypass mode vfds will not respond to controls or alarms. Warning grounding required all field installed wiring must be co...

  • Page 8: Caution

    8 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. Water pressure prior to connection of condensing water supply, verify water pressure is less than maximum pressure s...

  • Page 9: Warning

    9 some chemical coil cleaning compounds are caustic or toxic. Use these substances only in accordance with the manufacturer ’s usage instructions. Failure to follow instructions may result in equipment damage, injury or death. Warning door compartments containing hazardous voltage or rotating parts ...

  • Page 10: Warning

    10 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. Every unit has a unique equipment nameplate with electrical, operational, and unit clearance specifications. Always r...

  • Page 11

    Sa series feature string nomenclature gen s iz e v l t c on fig a1 a2 a3 a4 b1 b2 b3 1a 1b 1c 1d 2 3 4 5a 5b 5c 6a 6b 6c 7 8 9 10 11 12 13 14a 14b 15 sa - 035 - 3 - a - e r 0 9 - 0 0 0 : a c 0 0 - 0 0 0 - e b f - a b 0 - 0 0 0 0 0 0 0 - h a - 0 0 0 0 0 0 0 0 b 16 17 18 19 20 21 22 23 11 sa series fe...

  • Page 12

    Sa series feature string nomenclature gen s iz e v l t c on fig a1 a2 a3 a4 b1 b2 b3 1a 1b 1c 1d 2 3 4 5a 5b 5c 6a 6b 6c 7 8 9 10 11 12 13 14a 14b 15 sa - 035 - 3 - a - e r 0 9 - 0 0 0 : a c 0 0 - 0 0 0 - e b f - a b 0 - 0 0 0 0 0 0 0 - h a - 0 0 0 0 0 0 0 0 b 16 17 18 19 20 21 22 23 12 b1: heating ...

  • Page 13

    Sa series feature string nomenclature gen s iz e v l t c on fig a1 a2 a3 a4 b1 b2 b3 1a 1b 1c 1d 2 3 4 5a 5b 5c 6a 6b 6c 7 8 9 10 11 12 13 14a 14b 15 sa - 035 - 3 - a - e r 0 9 - 0 0 0 : a c 0 0 - 0 0 0 - e b f - a b 0 - 0 0 0 0 0 0 0 - h a - 0 0 0 0 0 0 0 0 b 16 17 18 19 20 21 22 23 13 5a: supply a...

  • Page 14

    Sa series feature string nomenclature gen s iz e v l t c on fig a1 a2 a3 a4 b1 b2 b3 1a 1b 1c 1d 2 3 4 5a 5b 5c 6a 6b 6c 7 8 9 10 11 12 13 14a 14b 15 sa - 035 - 3 - a - e r 0 9 - 0 0 0 : a c 0 0 - 0 0 0 - e b f - a b 0 - 0 0 0 0 0 0 0 - h a - 0 0 0 0 0 0 0 0 b 16 17 18 19 20 21 22 23 14 13: special ...

  • Page 15

    Sa series feature string nomenclature gen s iz e v l t c on fig a1 a2 a3 a4 b1 b2 b3 1a 1b 1c 1d 2 3 4 5a 5b 5c 6a 6b 6c 7 8 9 10 11 12 13 14a 14b 15 sa - 035 - 3 - a - e r 0 9 - 0 0 0 : a c 0 0 - 0 0 0 - e b f - a b 0 - 0 0 0 0 0 0 0 - h a - 0 0 0 0 0 0 0 0 b 16 17 18 19 20 21 22 23 15 14b: watersi...

  • Page 16: General Information

    16 general information sa series self contained units and indoor air handling units have been designed for indoor installation only. Sa series units can contain spring isolated direct drive backward curved plenum fans, shell and tube or brazed plate water-cooled condensers, r-410a scroll compressors...

  • Page 17: Caution

    17 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. Direct expansion (dx) system...

  • Page 18: Caution

    18 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. Wiring diagrams unit specific wiring diagrams are laminated and affixed inside the controls compartment do...

  • Page 19: Installation

    19 installation 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 or foundation can s...

  • Page 20

    20 figure 2 - one piece single unit lifting details.

  • Page 21

    21 figure 3 - two piece single unit coil section lifting details.

  • Page 22

    22 figure 4 - two piece single unit fan section lifting details.

  • Page 23

    23 figure 5 - one piece dual unit lifting details.

  • Page 24

    24 figure 6 - two piece dual unit coil section lifting details.

  • Page 25

    25 figure 7 - two piece dual unit fan section lifting details.

  • Page 26

    26 split unit assembly units may be split into modules for shipping. Fan and coil modules must be bolted together and factory provided splices must be installed before operation of the unit. Split units will also require electrical connection between the modules and individual units after assembly. ...

  • Page 27

    27 figure 8 - dual unit without splices and before being bolted together. Figure 9 - dual unit assembly details.

  • Page 28

    28 figure 10 - dual unit with splices after being bolted together..

  • Page 29: Warning

    29 refrigerant-to-water heat exchanger condenser water pump, condenser water piping, cooling tower, pressure gauges, strainers, piping insulation and all components of the waterside piping must be field installed. Open loop applications this product contains one or more refrigerant-to-water heat exc...

  • Page 30: Warning

    30 at 32°f. When water freezes in a heat exchanger significant forces are exerted on the components of the heat exchanger where the water is confined. Failure of the condenser due to freezing will allow water to enter the refrigerant circuit and will cause extensive damage to the refrigerant circuit...

  • Page 31: Caution

    31 table 3 - condenser water connections model (sa-) supply and return connection size 023, 045 1 1/2” mpt 028, 030, 035, 050, 055, 058, 060, 065, 070 2” mpt only use approved water pipe material. Avoid using galvanized material for water lines/fittings as the material is corrosive and may cause fou...

  • Page 32: Caution

    32 note: ball valves should be installed in the condenser water supply and return lines for unit isolation and water flow balancing. All manual flow valves should be of the ball valve design. Globe or gate valves should not be used due to high pressure drops and poor throttling characteristics. Pres...

  • Page 33: Caution

    33 piping systems should not exceed 10 ft/sec fluid velocity to ensure tube wall integrity and reduce noise. Brazed plate heat exchanger cleaning because of a normally high degree of turbulence in brazed plate heat exchangers, for many applications the heat exchanger channels are self cleaning. For ...

  • Page 34: Caution

    34 note: locations for field cut electrical entries are marked on the unit. Field cut openings must be a minimum of 6 inches away from all components and wiring to prevent damage due to drilling or cutting. To pass wires through the wall or roof of the unit, a hole should be cut and conduit passed t...

  • Page 35: Caution

    35 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 pr...

  • Page 36: Caution

    36 example: a total of 8 wires must be pulled 75ft to a control the unit. What size wire should be used? According to the table 5, 16 awg allows for 63ft (500 ft/8 wires) and 14 awg allows for 94ft (750 ft/8 wires). Thus, 14 awg should be used. Duct connection return air enters the either the left, ...

  • Page 37

    37 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 losi...

  • Page 38: Caution

    38 waterside economizer piping kit figure 12 - sa series unit with waterside economizer piping for single cabinet units connect the three factory provided piping assemblies. For dual cabinet units connect both sets of factory provided piping assemblies. Connect the piping assembly to the unit. Conne...

  • Page 39

    39 figure 13 - air conditioner waterside economizer piping kit figure 14 - air conditioner waterside economizer back view right intake piping kit left intake piping kit assembly 6 assembly 1 assembly 2 assembly 3 assembly 4 assembly 5 waterside economizer valve waterside economizer bypass valve head...

  • Page 40

    40 figure 15 - water-source heat pump waterside economizer piping kit figure 16 - water-source heat pump waterside economizer back view right intake piping kit left intake piping kit assembly 6 assembly 1 assembly 2 assembly 3 assembly 4 assembly 5 waterside economizer valve waterside economizer byp...

  • Page 41: Startup

    41 hot water coil factory installed one or two row hot water heating coils can be factory mounted. These coils are supplied from a hot water source through separate piping from the condenser water source. All controls for heating operation are field supplied and field installed. Always connect the s...

  • Page 42

    42 fan assemblies are equipped with spring isolators in the fan section for vibration attenuation. Prior to shipment the isolators are set in the lock down position to protect the unit during transit. Once the unit is set into place it is important that all of the isolators are adjusted out of the s...

  • Page 43: Warning

    43 supply fan removal 1. Disconnect all electrical power sources to the unit. 2. Disconnect the supply fans using the quick connect electrical harness located in the control compartment. 3. Remove the three screws on the hold down bracket on the front side of the fan assembly frame. 4. Remove the ba...

  • Page 44

    44 required, the band can be removed from the wheel. Use fan program in aaonecat32 to determine the new band size for the required cfm and static pressure. The following photos of a wheel are provided for practical guidelines only in order to identify the air band location in the wheel. Actual field...

  • Page 45: Caution

    45 figure 23 - securing the band filters do not operate the unit without filters in place. Unit should be checked for correct filter placement during startup. Operation of the equipment without filters will result in a clogged evaporator coil. Adjusting refrigerant charge adjusting the charge of a s...

  • Page 46: Caution

    46 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...

  • Page 47

    47 table 9 - r-410a refrigerant temperature-pressure chart °f psig °f psig °f psig °f psig °f psig 20 78.3 47 134.7 74 213.7 101 321.0 128 463.2 21 80.0 48 137.2 75 217.1 102 325.6 129 469.3 22 81.8 49 139.7 76 220.6 103 330.2 130 475.4 23 83.6 50 142.2 77 224.1 104 334.9 131 481.6 24 85.4 51 144.8 ...

  • Page 48: Operation

    48 operation unit operations should be controlled with thermostat or unit controller, never at the main power supply, except for emergency or complete shutdown of the unit. Steam or hot water preheating operation valve control for steam and hot water heating coils are by others. Heating is accomplis...

  • Page 49: Warning

    49 e-coated coil cleaning documented routine cleaning of e-coated coils is required to maintain coating warranty coverage. Surface loaded fibers or dirt should 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 enterin...

  • Page 50: Caution

    50 recommended chloride remover chlor*rid dts™ should be used to remove soluble salts from the e-coated coil, but the directions must be followed closely. This product is not intended for use as a degreaser. Any grease or oil film should first be removed with the approved cleaning agent. Remove barr...

  • Page 51

    51 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 3ɸ. The dpm is 50/60 hz self-sensing. Dpm should be wired according to unit specific wiring diagram include in the control compartment when the dpm is...

  • Page 52

    52 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, 3Ø 200, 1Ø; 20...

  • Page 53: Warning

    53 filter replacement monthly filter inspection is required to maintain optimum unit efficiency. It is strongly recommended that filter media be replaced monthly. Filters are located upstream of the evaporator coil. Open access panel and pull filters straight out to inspect all of the filters. Repla...

  • Page 54

    54 replacement parts parts for aaon equipment may be obtained from your local aaon representative. Reference the unit serial number and part number when ordering parts. Aaon warranty, service, and parts department 2424 s. Yukon ave. Tulsa, ok 74107 ph: 918-382-6400 fax: 918-382-6364 www.Aaon.Com not...

  • Page 55

    55 appendix a - heat exchanger corrosion resistance corrosion resistance of copper and stainless steel in brazed plate heat exchangers - points to measure and check in a water analysis the resistance guide below provides the corrosion resistance of stainless steel type aisi 316 and pure copper (99.9...

  • Page 56

    56 water containing concentration (mg/l or ppm) time limits - analyze before aisi 316 smo 254 copper alloy nickel alloy total hardness (°dh) 4.0-8.5 no limit + + + + nitrate (no 3 ) no limit + + + + > 100 + + 0 + iron (fe) no limit + + + + > 0.2 + + 0 + aluminum (al) no limit + + + + > 0.2 + + 0 + m...

  • Page 57: Sa Series Startup Form

    57 sa series startup form job name:_______________________________________________ date:______________ address:______________________________________________________________________ ______________________________________________________________________________ model number:__________________________...

  • Page 58

    58 supply fan assembly alignment check rotation nameplate amps________ number hp l1 l2 l3 1 2 3 4 band size_____________________ vav controls_________________ vfd frequency________________ springs operating correctly compressors/dx cooling check rotation number l1 l2 l3 head pressure psig suction pr...

  • Page 59

    59 refrigeration system 4 - cooling mode pressure saturated temperature line temperature sub-cooling superheat discharge n/a n/a suction n/a liquid n/a refrigeration system 1 - heating mode (heat pump only) pressure saturated temperature line temperature sub-cooling superheat discharge n/a n/a sucti...

  • Page 60

    60 unit configuration water-cooled condenser air-cooled condenser no water leaks condenser safety check water flow ________ gpm water inlet temperature ________°f water outlet temperature ________°f water/glycol system 1. Has the entire system been flushed and pressure checked? Yes no 2. Has the ent...

  • Page 61

    61 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 replacemen...

  • Page 62

    62 literature change history june 2010 revision of the iom adding pvc and cpvc piping caution. February 2011 revision of the iom correcting the information about head pressure control, adding information about adjusting a heat pump unit’s refrigerant charge and adding information about assembling sp...

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    63.

  • Page 64

    Copyright © aaon, all rights reserved throughout the world. Aaon ® and aaonaire ® are registered trademarks of aaon, inc., tulsa, ok. Aaon 2425 south yukon ave. Tulsa, ok 74107-2728 www.Aaon.Com sa series installation, operation & maintenance r74130 · rev. E · 170925 factory technical support: 918-3...