AAON CL Series Installation Operation & Maintenance
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AAON CL Series Installation Operation & Maintenance

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CL SERIES
Condensing Units
Installation, Operation
& Maintenance

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Summary of Contents for AAON CL Series

  • Page 1 CL SERIES Condensing Units Installation, Operation & Maintenance...

  • Page 2: Table Of Contents

    Table of Contents Safety ................................6 CL Series Feature String Nomenclature ...................... 11 GENERAL DESCRIPTION ........................14 Unpacking: ............................... 14 OWNER'S INFORMATION ........................14 Warning: ..............................14 Wiring Diagrams: ............................. 15 General Maintenance: ..........................15 INSTALLATION ............................15 Lifting and Handling: ..........................15 Condenser Placement: ..........................
  • Page 3 Mechanical Cleaning: ..........................36 Parts: ................................ 36 AIR-COOLED CONDENSER ........................36 E-Coated Coil Cleaning ........................... 36 REFRIGERANT PIPING FOR THE CL SERIES ..................39 General: ..............................39 Determining Refrigerant Line size: ......................39 Equivalent Line Length: .......................... 39 Liquid line sizing: ............................ 40 Liquid Line Routing:..........................
  • Page 4 Hot Gas Reheat Line Guidelines: ......................43 Literature Change History........................58 Index of Tables and Figures Tables: Table 1 - Service Clearances ........................15 Table 2 - Acceptable Refrigerant Circuit Values ..................19 Table 3 - % Charge to Flood Condenser Coil for Ambient Below 70°F ............. 20 Table 4 - Nameplate Voltage Markings &...
  • Page 5 ® AAON CL Series Features and Options Introduction Energy Efficiency  Air-Cooled or Energy Saving Evaporative Installation and Maintenance Access Doors with Hinges, Lockable Handles  Condenser and Rain Gutters  Direct Expansion Systems Walk-In Weatherproof Compressor   Tandem Scroll Compressors Compartment ...

  • Page 6: Safety

    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.
  • Page 7 WARNING WARNING GROUNDING REQUIRED FIRE, EXPLOSION OR CARBON MONOXIDE POISONING HAZARD All field installed wiring must be Failure to replace proper controls completed by qualified personnel. Field installed wiring must comply with could result in fire, explosion or NEC/CEC, local and state electrical carbon monoxide poisoning.
  • Page 8 CAUTION CAUTION VARIABLE FREQUENCY DRIVES DOOR LATCHES Door compartments containing Electric motor over-current protection hazardous voltage or rotating parts and overload protection may be a are equipped with door latches that function of the Variable Frequency allow locks. Door latches are shipped Drive to which the motors are wired.
  • Page 9 CAUTION CAUTION COMPRESSOR LUBRICANT COIL CLEANING Polyolester (POE) and Polyvinylether Do not clean DX refrigerant coils with (PVE) oils are two types of lubricants hot water or steam. The use of hot used in hydrofluorocarbon (HFC) water or steam on refrigerant coils will refrigeration systems.
  • Page 10 WARNING COMPRESSOR CYCLING 3 MINUTE MINIMUM OFF TIME prevent motor overheating compressors must cycle off for a minimum of 3 minutes. 5 MINUTE MINIMUM ON TIME To maintain the proper oil level compressors must cycle on for a minimum of 5 minutes. The cycle rate must not exceed 7 starts per hour.

  • Page 11: Cl Series Feature String Nomenclature

    CL Series Feature String Nomenclature Model Options Feature Options B E 0 4 0 0 0 0 0 0 0 0 0 0 - 0 0 0 - 0 0 0 - J A F 0 0 B H - 0 0 -...
  • Page 12 CL Series Feature String Nomenclature Model Options Feature Options CL - 125 - 3 - 0 - B E 0 4 - 0 0 0 : 0 0 0 0 - 0 0 0 - 0 0 0 - 0 0 0 - J A F 0 0 B H -...
  • Page 13 CL Series Feature String Nomenclature Model Options Feature Options CL - 125 - 3 - 0 - B E 0 4 - 0 0 0 : 0 0 0 0 - 0 0 0 - 0 0 0 - 0 0 0 - J A F 0 0 B H -...

  • Page 14: General Description

    GENERAL DESCRIPTION Before unit operation, the main power switch must be turned on for at least twenty four hours All AAON CL Series condensers are factory for units with compressor crankcase heaters. This assembled, wired, and shipped with a 100 psi will give the crankcase heater time to clear any nitrogen holding charge.

  • Page 15: Wiring Diagrams

    Wiring Diagrams: Condenser Placement: A complete set of unit specific wiring diagrams in The AAON condenser is designed for outdoor both ladder and point-to-point form are laminated applications and mounting at ground level or on a in plastic and located inside the control rooftop.

  • Page 16: Mounting Isolation

    8. The minimum micron level required by 3. Four valve manifold gauge sets are more AAON is 350 microns for systems using POE effective than standard manifold gauge sets oils. due to the extra hose port in combination with a 3/8’’...

  • Page 17: Low Ambient & Modulating Reheat System Evacuation Instructions

    Low Ambient & Modulating Reheat System Evacuation Instructions: Proper system evacuation is critical to remove moisture and non-condensables from the system before charging the system with refrigerant. Systems with low ambient flooded condenser option require the following procedure to ensure the entire system is pulled into a good vacuum.

  • Page 18: Charging Refrigerant

    10-15 minutes, before making any other adjustments. 11. The minimum micron level required by AAON is 350 microns for systems using POE The type of unit and options determine the ranges oils. for liquid sub-cooling and evaporator superheat.

  • Page 19: Checking Liquid Sub-Cooling

    Table 2 - Acceptable Refrigerant Circuit Values Checking Liquid Sub-cooling: 1. Measure the temperature of the liquid line Sub- Sub-cooling Superheat as it leaves the condenser coil. cooling W/Hot Gas (°F) (°F) Reheat (°F) 2. Read the gauge pressure reading of the Air Cooled 8-15* 8-15**...

  • Page 20: Special Low Ambient Charging Instructions

    If the ambient temperature is 0°F, no more charge is required. If the The AAON low ambient system maintains normal ambient temperature is between 0°F and head pressure during periods of low ambient by 70°F, multiply the charge amount needed at...

  • Page 21: Lac Valve

    gas around the condenser. The discharge gas LAC Valve: The LAC valve is a non-adjustable three way warms the liquid in the receiver and raises the valve that modulates to maintain receiver pressure to the valve setting. The following pressure. As the receiver pressure drops below the schematic shows an example system using the valve setting (180 psig for R-22 and 295 psig for LAC valve.

  • Page 22: Electrical

    Electrical The single point electrical power connections are made in the electrical control compartment. Verify the unit nameplate agrees with the power supply. Connect power and control field wiring as shown on the unit wiring diagram provided with the unit. Table 4 - Nameplate Voltage Markings &...
  • Page 23 Three phase voltage imbalance will cause motor CAUTION overheating and premature failure. The maximum allowable imbalance is 2%. 3-PHASE ROTATION Voltage imbalance is defined as 100 times the Rotation must be checked on all maximum deviation from the average voltage MOTORS AND COMPRESSORS of divided by the average voltage.

  • Page 24: Refrigerant Piping Connections

    Refrigerant Piping Connections: Evaporative Condenser Field Piping condensing unit refrigerant piping Connections: connections are located in the upper corner of the There are two field water connections that must be service vestibule side of the unit (opposite the made for the evaporative condenser. There is a ¾”...

  • Page 25: Figure 6 - Evaporative Condenser Section Water Treatment Components

    Figure 6 - Evaporative Condenser Section Water Treatment Components...

  • Page 26: Startup

    STARTUP CAUTION Pre-Startup: COMPRESSOR ROTATION After the installation and immediately before the startup of the condenser be sure that these items Scroll compressors are directional and have been checked. will be damaged by operation in the wrong direction. Low pressure switches 1.

  • Page 27: Axial Flow Fans

    • Using diagrams in step 5, determine if the pin Axial Flow Fans: was in the hub (HUB) or retainer side (RET) Multi-Wing Z Series Aluminum Fan Blade of fan. Pitch Angle Setting Instructions: • Using table in step 4, find the possible blade Before You Begin, to maintain balance of fan: pitch.

  • Page 28: Insert Blades

    Step 5. Final Assembly Multi-Wing W Series Black Glass Reinforced Definition of HUB and RET for purposes of Polypropylene Fan Blade Pitch Angle Setting instructions. For 2-piece hubset: Instructions: Step 1. Note original position of retaining plates, center boss and all hardware including additional hardware used for balancing.

  • Page 29: Servicing And Maintenance

    SERVICING AND MAINTENANCE Suction Filter Removal Instructions 1. Shut down operation of the unit 2. Close both shut-off valves to isolate the General: suction filter Qualified technicians must perform routine service checks and maintenance. This includes reading and recording the condensing and suction pressures and checking for normal sub-cooling and superheat (see Charging Refrigerant:).

  • Page 30: Refrigerant Liquid Line Filter Driers

    Non-compliance could result in injury or Replacement Parts: violation of EPA regulations. Parts for AAON equipment may be obtained from your local AAON representative. When ordering parts reference the unit serial number and part WARNING number.

  • Page 31: Severe Service

    EVAPORATIVE CONDENSER - GENERAL Evaporative cooling equipment rejects heat by evaporating a portion of the recirculated water spray and discharging it from the unit with the hot, saturated air. As the spray water evaporates, it leaves behind the mineral content and impurities of the supply water.

  • Page 32: Performance

    CL evaporative cooled The coil is leak tested at 450 psig before shipment. condensing units. AAON will not be responsible for loss of refrigerant. It is the responsibility of the installer Cleanliness: to verify that the system is sealed before charging Dirt and debris may accumulate in the sump with refrigerant.

  • Page 33: Condenser Fan Motors

    (if ordered and the ambient Condenser Fan Motors: temperature is below 40°F) to operate. The make- The direct-drive condenser motors on AAON up water solenoid will remain activated until evaporative condensers are 1200-rpm premium water gets to the high water level.

  • Page 34: Water Treatment System

    Water Treatment System: Sequence of Operation: AAON evaporative condensers come On a call for cooling, the condenser pump is equipped with a water treatment system that must activated. A pressure switch in the pump be maintained by a local water treatment...

  • Page 35: Evaporative Condenser - Maintenance Requirements

    nameplate manufacture’s EVAPORATIVE CONDENSER - recommendations. MAINTENANCE REQUIREMENTS 6. Inspect axial fans eliminators Pump Maintenance: removing any debris which may have Cleaning - Remove oil, dust, water, and chemicals accumulated during operation. from exterior of motor and pump. Keep motor air inlet and outlet open.

  • Page 36: Evaporative Condenser - Water Quality

    (fin edges bent over) if the tool is procedures. applied across the fins. Parts: Use of a water stream, such as a garden hose, Contact your local AAON Representative for against a surface loaded coil will drive the fibers factory authorized parts. Orders must include the...
  • Page 37 GulfClean ™ Coil Cleaner ; AAON PN: G074480 Quarterly cleaning is essential to extend the life of an e-coated coil and is required to maintain Recommended Chloride Remover coating warranty coverage.
  • Page 38 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.

  • Page 39: Refrigerant Piping For The Cl Series

    However, as pipe diameters narrow, unit. AAON, Inc. is not responsible for pressure-reducing frictional forces increase. interconnecting refrigerant piping. Consult ASHRAE Handbook – Refrigeration and Excessive suction line pressure drop causes loss ASME Standards.

  • Page 40: Liquid Line Sizing

    Liquid line sizing: Liquid Line Insulation: When sizing the liquid line, it is important to When the liquid line is routed through regions minimize the refrigerant charge to reduce where temperature losses are expected, no installation costs and improve system reliability. insulation is required, as this may provide This can be achieved by minimizing the liquid line additional sub-cooling to the refrigerant.

  • Page 41: Suction Line Traps

    length) to maintain oil flow towards the Suction Line Traps: compressor, and keep it from flooding back into Include a trap immediately after the evaporator the evaporator. coil outlet to protect the TXV bulb from liquid refrigerant. Crankcase heaters are provided to keep any condensed refrigerant that collects in the Include traps every 20 feet in vertical riser compressor from causing damage or wear.

  • Page 42: Suction Line Accessories

    When installing vertical hot gas bypass lines, an Hot Gas Reheat Line: oil drip line must be provided at the lowest point The AAON modulating hot gas reheat system in the system. The oil drip line must be vertical, diverts hot discharge gas from the condenser to its diameter must be the same as the diameter of the riser, and a maximum of 10”...

  • Page 43: Hot Gas Reheat Line Guidelines

    Discharge lines must be sized to ensure adequate to the suction line. Connect the oil return line velocity of refrigerant to ensure oil return, avoid below the sight glass and 1 inch above the bottom excessive noise associated with velocities that are of the oil drip line.

  • Page 44: Figure 10 - Hot Gas Bypass Piping Diagram With Air Handler Above Condenser

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

  • Page 45: Figure 11 - Hot Gas Bypass Piping Diagram With Air Handler Below Condenser

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

  • Page 46: Figure 12 - Hot Gas Reheat Piping Diagram With Air Handler Above Condenser

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

  • Page 47: Figure 13 - Hot Gas Reheat Piping Diagram With Air Handler Below Condenser

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

  • Page 48: Figure 14 - Hot Gas Reheat Piping Diagram With Air Handler Above Condenser And Field Installed Suction

    TO BE INSTALLED IN FIELD Note: Components shown within air handler and condensing unit are factory installed; all other components are field installed. Figure 14 - Hot Gas Reheat Piping Diagram with air handler above condenser and field installed suction line accumulator...

  • Page 49: Figure 15 - Hot Gas Reheat Piping Diagram With Air Handler Above Condenser And Field Installed Suction

    Note: Components shown within air handler and condensing unit are factory installed; all other components are field TO BE INSTALLED IN FIELD installed. Figure 15 - Hot Gas Reheat Piping Diagram with air handler above condenser and field installed suction line accumulator...

  • Page 50: Figure 16 - Reheat/Hot Gas Bypass Piping Diagram With Air Handler Above Condenser

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

  • Page 51: Figure 17 - Reheat/Hot Gas Bypass Piping Diagram With Air Handler Below Condenser

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

  • Page 52: Figure 18 - Reheat/Hot Gas Bypass Piping Diagram With Air Handler Evaporator Above Condenser And Field

    TO BE INSTALLED IN FIELD TO BE INSTALLED IN FIELD Note: Components shown within air handler and condensing unit are factory installed; all other components are field installed. Figure 18 - Reheat/Hot Gas Bypass Piping Diagram with air handler evaporator above condenser and field installed suction line accumulator...

  • Page 53: Figure 19 - Reheat/Hot Gas Bypass Piping Diagram With Air Handler Below Condenser And Field Installed

    Note: Components shown within air handler and condensing unit are factory installed; all other components are field installed. TO BE INSTALLED IN FIELD Figure 19 - Reheat/Hot Gas Bypass Piping Diagram with air handler below condenser and field installed suction line accumulator...
  • Page 54 CL STARTUP FORM PAGE 1 of 2 DATE:___________________ JOB NAME:_________________________________________________________________________________________ ADDRESS:_________________________________________________________________ MODEL No:______________ CITY, STATE:______________________________________________________________ SERIAL No:______________ START-UP CONTRACTOR:___________________________________________________ TAG:____________________ PRE START-UP CHECKLIST Installing contractor shall verify the following items (cross out items that do not apply). 1. Is there any visible shipping damage?__________________________________________________ Yes 2.
  • Page 55 CL STARTUP FORM PAGE 2 of 2 REFRIGERATION SYSTEM #1 SATURATED LINE PRESSURE SUB-COOLING SUPERHEAT TEMPERATURE TEMPERATURE DISCHARGE SUCTION LIQUID REFRIGERATION SYSTEM #2 SATURATED LINE PRESSURE SUB-COOLING SUPERHEAT TEMPERATURE TEMPERATURE DISCHARGE SUCTION LIQUID REFRIGERATION SYSTEM #3 SATURATED LINE PRESSURE SUB-COOLING SUPERHEAT TEMPERATURE TEMPERATURE...
  • Page 56 NOTES:...
  • Page 57 AAON E-Coated Coil Maintenance Record...

  • Page 58: Literature Change History

    Revised wording for oil return line. Updated the Nameplate Voltage Markings and Tolerance table. Added 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.
  • Page 60 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.

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