AAON M3 Series Installation Operation & Maintenance
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AAON M3 Series Installation Operation & Maintenance

AAON M3 Series Installation Operation & Maintenance

Modular indoor and outdoor air handling units
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Modular Indoor and Outdoor Air Handling Units
WARNING
QUALIFIED INSTALLER
Improper
installation,
alteration, service or maintenance
can
cause
property
personal injury or loss of life. Startup
and service must be performed by a
Factory Trained Service Technician.
A copy of this IOM should be kept
with the unit.
Installation, Operation
& Maintenance
adjustment,
damage,
M3 Series
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.

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  • Page 1 M3 Series Modular Indoor and Outdoor Air Handling Units Installation, Operation & Maintenance WARNING WARNING QUALIFIED INSTALLER If the information in this manual is not followed exactly, a fire or explosion Improper installation, adjustment, may result causing property damage, alteration, service or maintenance personal injury or loss of life.

  • Page 2: Table Of Contents

    Table of Contents Safety .............................. 7 Unit Orientation ..........................12 Model Number Nomenclature ...................... 13 Base Model Feature Description ....................14 Supply Fan Module Feature Description ..................15 Cooling/Preheat Module Feature Description ................18 Heating Coil Module Description ....................21 Blank Module Feature Description ....................
  • Page 3 Removing Coils ......................... 62 Doors/Panels ..........................63 Outside Opening Door and Panel ....................64 Filters ............................64 Replacement Parts ........................65 M3 Series Startup Form ........................ 68 Maintenance Log .......................... 71 Literature Change History......................72 R57350 · Rev. D · 160822...
  • Page 4 Index of Tables and Figures Tables: Table 1 - Draw-Through Drain Trap Dimensions ................ 47 Table 2 - Blow-Through Drain Trap Dimensions................. 51 Table 3 - Flat Pleated Filters ......................66 Table 4 - Angled Pleated Filters ....................66 Table 5 - Cartridge/Bag Filters ..................... 66 Figures: Figure 1 - Unit Orientation ......................
  • Page 5 Figure 34 - Blower Rotation ......................59 Figure 35 - Coil Removal ......................63 Figure 36 - Access Door/Panel Removal ..................64 Figure 37 - Access Door ....................... 64 Figure 38 - Cartridge/Bag Filter Layout Viewed from Upstream Side........67...
  • Page 6 ® AAON M3 Series Features and Options Introduction Energy Efficiency System Integration  Direct Drive Backward Curved Plenum  Shipping Available as Factory Fans Assembled or Individual Modules  Double Wall Rigid Polyurethane Foam  AAON or Customer Provided Controls Injected Panel R-13Construction ...

  • Page 7: Safety

    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 statements are given to prevent actions that could result in equipment damage, property damage, personal injury or death.
  • Page 8 WARNING CAUTION During installation, testing, servicing Electric motor over-current protection and troubleshooting of the equipment and overload protection may be a it may be necessary to work with live function of the Variable Frequency electrical components. Only Drive to which the motors are wired. qualified licensed electrician...
  • Page 9 CAUTION WARNING Rotation must be checked on all Always use a pressure regulator, MOTORS AND COMPRESSORS of valves gauges control 3 phase units at startup by a qualified incoming pressures when pressure service technician. Scroll testing a system. Excessive pressure compressors are directional and can may cause line ruptures, equipment be damaged if rotated in the wrong...
  • Page 10 WARNING WARNING Risk of injury from hot parts – Some chemical coil cleaning compounds are caustic or toxic. Use Disconnect power, close these substances only in accordance isolation valves and allow equipment with manufacturer’s usage to cool before servicing equipment instructions.
  • Page 11 WARNING HOT PARTS Disconnect power, close isolation valves and allow equipment to cool before servicing equipment to prevent serious injury. Equipment may have multiple power supplies. Electric resistance heating elements and hot water or steam heating coils may have automatic starts. Hot water will circulate even after power is off.

  • Page 12: Unit Orientation

    Unit Orientation Determine left hand or right hand orientation (connections): M3 Series Top View Right Hand Side Supply Air Return Air AIR FLOW Supply Fan Coil Filter Connections & service access on left side for Left Hand Side left hand orientation Consider the air flow to be hitting the back of your head.

  • Page 13: Model Number Nomenclature

    Model Number Nomenclature Base Model Number Individual Module Model Numbers Identifies the main unit features and options. Identifies module configurations, features, and options. MBA-101-0-00-0F0A0-000A0-0-0 FMB-102-0-00-B00C0-00000-0-0 CLA-103-A-00-CNCA0-00000-0-0 M3-0-094-134x119-3-A-A-A-0-A-0 BMA-104-A-00-00000-00000-0-0 SFA-105-0-AA-CPTB0-00000-0-0 DPA-106-0-00-D0000-0000C-M-0 Complete Model Number The complete unit model number consists of air handling unit assembly, increasing in a base model number followed by a series of value from the return/outside air section to...

  • Page 14: Base Model Feature Description

    M3 Series Base Feature String Nomenclature M3 - 0 - 060 - 108 x 099 - 3 - B - A - B - C - B - 0 Base Model Feature Description Assembly BASE MODEL A = Factory Assembled...

  • Page 15: Supply Fan Module Feature Description

    Supply Fan Module Feature String Nomenclature SFA - 000 - 0 - 0 0 - C P H G A - A C B R - B - 0 Supply Fan Module Feature Description Blower Type SUPPLY FAN MODULE 0 = Standard Efficiency Module ID A = Premium Efficiency SFA = Supply Fan...
  • Page 16 Supply Fan Module Feature String Nomenclature SFA - 000 - 0 - 0 0 - C P H G A - A C B R - B - 0 Blower Power Switch 0 = 24” Diameter 0 = No Wiring A = 27”...
  • Page 17 Supply Fan Module Feature String Nomenclature SFA - 000 - 0 - 0 0 - C P H G A - A C B R - B - 0 Module Accessories Type 0 = None 0 = Standard A = Treadplate Floor A = Stainless Steel Interior B = Base Drain B = Stainless Steel Exterior...

  • Page 18: Cooling/Preheat Module Feature Description

    Cooling/Preheat Coil Module Feature String Nomenclature CLD - 000 - A - 0 0 - A A 0 0 A - C A C 0 G - B - 0 Cooling/Preheat Module Feature Description COOLING/PREHEAT MODULE 0 = 8 FPI, 0.0060” Fin Thick, 0.017” Tube Wall Module ID A = 10 FPI, 0.0060”...
  • Page 19 Cooling/Preheat Coil Module Feature String Nomenclature CLD - 000 - A - 0 0 - A A 0 0 A - C A C 0 G - B - 0 Circuiting 0 = Full Serpentine 0 = No Preheat Coil A = 8 FPI, 0.0060”...
  • Page 20 Cooling/Preheat Coil Module Feature String Nomenclature CLD - 000 - A - 0 0 - A A 0 0 A - C A C 0 G - B - 0 Preheat Coil Type Access 0 = No Preheat Coil 0 = Left Door, Left Drain, Left Coil Connections A = Hot Water, Full Serpentine (2 Rows Only) A = Left Door, Left Drain, Right Coil Connections B = Hot Water, Half Serpentine...

  • Page 21: Heating Coil Module Description

    Heating Coil Module Feature String Nomenclature HCD - 000 - A - H E - B B C A A - 0 0 0 0 0 - B - 0 Heating Coil Module Description Staging HEATING COIL MODULE 0 = No Electric Heat Module ID A = 2 Stage HCA = Hot Water Coil, External Connections...
  • Page 22 Heating Coil Module Feature String Nomenclature HCD - 000 - A - H E - B B C A A - 0 0 0 0 0 - B - 0 Coating 0 = No Heating Coil 0 = No Heating Coil A = 8 FPI, 0.0060”...

  • Page 23: Blank Module Feature Description

    Blank Module Feature String Nomenclature BMC - 000 - A - 0 0 - 0 0 0 0 0 - 0 0 0 0 Q - B - 0 Blank Module Feature Description Module Accessories BLANK MODULE 0 = None Module ID A = Treadplate Floor BMA = 2’...

  • Page 24: Filter Module Feature Description

    Filter Module Feature String Nomenclature FMA - 000 - 0 - 0 0 - A B C A 0 - 0 0 0 0 0 - 0 - 0 Filter Module Feature Description Blank FILTER MODULE 0 = Standard Module ID FMA = Flat Filter Bank Blank FMB = Angle Filter Bank...

  • Page 25: Mixing Box/Economizer Module Feature Description

    Mixing Box/Economizer Module Feature String Nomenclature MBA - 000 - 0 - 0 0 - B B C A 0 - A B 0 0 Q - B - 0 Mixing Box/Economizer Module Feature Description Exhaust Air Location MIXING BOX/ECONOMIZER 0 = None MODULE A = End...
  • Page 26 Mixing Box/Economizer Module Feature String Nomenclature MBA - 000 - 0 - 0 0 - B B C A 0 - A B 0 0 Q - B - 0 Module Accessories Type 0 = None 0 = Standard A = Treadplate Floor A = Stainless Steel Interior B = Base Drain B = Stainless Steel Exterior...

  • Page 27: Discharge Module Feature Description

    Discharge Module Feature String Nomenclature DPA - 000 - 0 - A A - B A 0 0 B - 0 0 0 0 Q - B - 0 Discharge Module Feature Description Blank DISCHARGE MODULE 0 = Standard Module ID DPA = Discharge Plenum Power Switch DPB = Discharge Plenum with Control Panel...
  • Page 28 Discharge Module Feature String Nomenclature DPA - 000 - 0 - A A - B A 0 0 B - 0 0 0 0 Q - B - 0 Access Type 0 = Left Door, No Drain 0 = Standard A = Right Door, No Drain A = Stainless Steel Interior B = Both Doors, No Drain...

  • Page 29: Control Panel Module Feature Description

    Control Panel Module Feature String Nomenclature CMB - 000 - 0 - A A - 0 0 0 0 A - 0 0 0 0 Q - B - 0 Control Panel Module Feature Description Blank CONTROL PANEL MODULE 000 = Standard Module ID CMA = 36”...

  • Page 30: Exhaust Fan Module Feature Description

    Exhaust Fan Module Feature String Nomenclature EFA - 000 - A - A B - A B B A A - B B E C R - 0 - 0 Blower Type Exhaust Fan Module Feature Description EXHAUST FAN MODULE 0 = Standard Efficiency Module ID A = Premium Efficiency...
  • Page 31 Exhaust Fan Module Feature String Nomenclature EFA - 000 - A - A B - A B B A A - B B E C R - 0 - 0 Blower Outside Air Location 0 = 24” Diameter 0 = None A = 27”...
  • Page 32 Exhaust Fan Module Feature String Nomenclature EFA - 000 - A - A B - A B B A A - B B E C R - 0 - 0 Damper Actuator Type Access 0 = None 0 = Left Door, No Drain A = Standard Damper A = Right Door, No Drain B = Standard Damper, On/Off Actuator...

  • Page 33: Energy Recovery Module Feature Description

    Energy Recovery Module Feature String Nomenclature HRA - 000 - 0 - A C - 0 0 0 0 0 - G A A A C - D - 0 Energy Recovery Module Feature Description Return Air Opening Location ENERGY RECOVERY MODULE 0 = None Module ID A = Bottom...
  • Page 34 Energy Recovery Module Feature String Nomenclature HRA - 000 - 0 - A C - 0 0 0 0 0 - G A A A C - D - 0 Access Type 0 = Left Door, Left Drain 0 = Standard 1 = Left Door, No Drain A = Stainless Steel Interior 2 = Right Door, No Drain...

  • Page 35: Return Fan Module Feature Description

    Return Fan Module Feature String Nomenclature RFA - 000 - 0 - 0 0 - C P H D A - 0 0 0 A R - B - 0 Return Fan Module Feature Description Blower HP RETURN FAN MODULE 0 = 1 hp, 1170 rpm Module ID A = 2 hp, 1170 rpm...
  • Page 36 Return Fan Module Feature String Nomenclature RFA - 000 - 0 - 0 0 - C P H D A - 0 0 0 A R - B - 0 Blank Access 000 = Standard M = No Door, No Drain N = No Door, Left Drain Connection P = No Door, Right Drain...

  • Page 37: General Description

    General Description CAUTION M3 Series modular air handling units have These units must not be used as a been designed to maximize the versatility “construction heater” anytime and range of applications. This manual is during any phase of construction. intended to be a guide to facilitate the...

  • Page 38: Storage

    6. With permission of freight carrier, order The warranty card must be completed in full parts and/or make repairs. and returned to AAON not more than 3 7. Stay in contact with freight carrier to months after unit is delivered.

  • Page 39: Rigging

    Rigging to prevent excess lateral force on the lifting points. WARNING All shipping covers should be left in place Check the shipping section weights until ductwork is ready to be connected or on the Bill of Lading to be sure they shipping sections are ready to be joined.

  • Page 40: Module Location

    Module Location The numbering begins at the return air side Module location is identified by a three digit of the unit. Module 101 will always be the number which is labeled on the access side bottom module at the return air end of the of the base rail.

  • Page 41: Figure 6 - Moving Module With Pipes

    The modules can be moved by rolling them on pipes. The pipes should be spaced a maximum of one foot apart. See the following figure. Figure 8 - Module Connection 4. Pull the two sections together using a come-along attached to the lifting points on the base rail.

  • Page 42: Figure 10 - Top View Of Module Connection

    The following figure displays a top view of the correctly overlapping module sections with integrated splice. Figure 12 - Aligning the Top of a Unit 5. Secure the two sections together with bolts in the holes surrounding the lifting hole in the base rail. Figure 10 - Top View of Module Be sure to replace the lifting lugs on either Connection...

  • Page 43: Figure 15 - Pulling Sections Together

    7. Pull sections together until exterior skins 9. Attach integrated splice on walls and roof meet. to adjoining section with self-tapping screws (#10 HEX HEAD) Figure 15 - Pulling Sections Together Figure 17 - Attaching Splice 8. After ensuring that the dimensions are correct, fasten sections together with self- 10.

  • Page 44: Module Disassembly

    It is the contractor’s responsibility to seal all field- split sections. Spring Isolator Adjustment AAON M3 Series air handling units are equipped with spring isolators in all blower sections for vibration attenuation. Figure 19 - Attaching Base Splice CAUTION Splice should have 1/8”...

  • Page 45: Blower Wheels

    Blower Wheels The isolators can be adjusted by first AAON units are equipped with a backward loosening the locking bolt located on top of curved blower wheels that is set to deliver the frame. The adjustment bolt located just the air volume specified according to unit below the frame is used to set the spring into size and/or job requirements.

  • Page 46: Condensate Drains

    Figure 22 - Supply Fan Banding cause an un-trapped drain to back up due to Condensate Drains air being pulled up through the condensate WARNING drain piping. Blow-through coils will have a positive static pressure in the drain pan. The Condensate drains that are not condensate piping on these drain pans must properly trapped could cause drain...

  • Page 47: Table 1 - Draw-Through Drain Trap Dimensions

    Draw-Through Coils Table 1 - Draw-Through Drain Trap Dimensions Draw-Through Drain Pan Pressure Trap Dimensions Negative Static (inches of water) (inch) (inch) -0.50 1.50 0.75 -1.00 2.00 1.00 -1.50 2.50 1.25 -2.00 3.00 1.50 -2.50 3.50 1.75 -3.00 4.00 2.00 -3.50 4.50 2.25...

  • Page 48: Draw-Through P-Trap Example

    Draw-Through P-Trap Example Figure 24 – Draw-Through Drain Pan Connection Locations The unit shown above is a draw-through unit In the case below the outside air static with a mixing box, 12” cartridge filters with pressure is -0.75” due to duct loss between 2”...

  • Page 49: Figure 25 - Example Draw-Through Aaonecat32 Rating Sheet

    These values are listed on the Unit Rating Sheet which can be obtained from the AAON sales representative. Figure 25 - Example Draw-Through AAONEcat32 Rating Sheet...
  • Page 50 The following components should be added: 0.28” RA Opening 12” Cartridge Filter 0.35” Pleated Cartridge Filter 0.30” 0.45” Cooling Coil 0.09” Preheat Coil 0.35” Dirt Allowance These values should be added to the absolute value of 1.5” to get a total of 3.32” static pressure.

  • Page 51: Table 2 - Blow-Through Drain Trap Dimensions

    Blow-Through Coils Table 2 - Blow-Through Drain Trap Dimensions Blow-Through Drain Pan Pressure Trap Dimension Positive Static (inches of water) (inch) Figure 26 - Blow-Through Drain Trap The Y dimension of blow-through traps should be at least equal to the value of the positive pressure in the drain pan plus one inch.

  • Page 52: Blow-Through P-Trap Example

    Unit Rating Sheet which can be obtained heating coil. To find the static pressure in from the AAON sales representative. the drain pan, subtract .08” and .15” from...

  • Page 53: Figure 28 - Example Blow-Through Aaonecat32 Rating Sheet

    Figure 28 - Example Blow-Through AAONEcat32 Rating Sheet...

  • Page 54: Base Drains

    The ‘Y’ dimension on the blow-through p- 1. Remove the external control panel from trap should be at least 3.77”, or one inch the shipping position in the supply fan plus the calculated static pressure in the module. drain pan. The total p-trap height will need to be 3.77”...

  • Page 55: Electrical

    not be run in the same conduit as power wiring. Protect the branch circuit in accordance with code requirements. The unit must be electrically grounded in accordance with the National Electric Code, ANSI / NFPA No. 70. In Canada use current C.S.A.

  • Page 56: Dampers And Actuators

    Use the following procedure to AAON damper blades are connected with cut a round hole in a foam panel. interlocking gears. A coupling is attached to one of the gears for connection to the 1. Locate the placement of the hole. Be sure actuator.

  • Page 57: Duct System

    Duct System Remove duct shipping covers immediately prior to duct connection. A 1 inch tall duct flange is provided around each duct opening. Piping CAUTION All piping design and installation should be performed by qualified professionals. All applicable codes and industry standards should be adhered to.

  • Page 58: Operation

    drains. Remove the two bolts by each coil Operation connection. When replacing the cover, take care not to over-tighten the bolts as this could cause the rivet-nut to come loose. WARNING Vents and drains are sealed with half inch plugs. Improper installation, adjustment,...

  • Page 59: Procedures

    • Check for compliance of all codes and special provisions. • Attach all access panels, close all doors. • Ensure that ductwork dampers are open. CAUTION Improper startup procedures could damage unit possibly void manufacturer’s warranties. Procedures Figure 34 - Blower Rotation Install any gauges, voltmeter, and ammeter before startup.

  • Page 60: Water Balancing

    • Winterize coils if necessary. • Inspect and if necessary clean unit interior. Controls M3 Series air handlers can be shipped from the factory with no controls and no wiring, Yearly: • Clean coils, drain pan and drain line.

  • Page 61: E-Coated Coil Cleaning

    will help prevent dirty coils; however, coils surfaces can be easily damaged (fin edges should still be cleaned at least annually by bent over) if the tool is applied across the an HVAC professional. fins. The coils should be cleaned using low- Use of a water stream, such as a garden pressure water, low-pressure air, or a non- hose, against a surface loaded coil will drive...

  • Page 62: Winterizing Coils

    prior to application of this product. As in all CAUTION surface preparation, the best work yields the best results. Harsh chemicals, household bleach, or acid cleaners should not be used Apply CHLOR*RID DTS - Apply directly to clean outdoor or indoor e-coated onto the substrate.

  • Page 63: Doors/Panels

    removed independently from either side of the unit. To remove a coil, first disconnect the water piping from the coil. Remove the coil access panel on the side from which the coil is to be removed. Remove the screws connecting coil end panel to the coil.

  • Page 64: Outside Opening Door And Panel

    WARNING Shut off power to unit and wait for fans to stop turning before removing an access panel. To make sure the unit is not pressurized, open door opposite the access panel. Serious injury can result from removing a panel under positive pressure. To remove an access panel, remove bolts from the perimeter.

  • Page 65: Replacement Parts

    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: 918-583-2266 Fax: 918-382-6364 www.aaon.com...

  • Page 66: Table 3 - Flat Pleated Filters

    Table 3 - Flat Pleated Filters Unit Size Filter Size Qty Wide Qty High Total Qty Face Area 20” x 16” 35.56 ft 20” x 16” 44.44 ft 20” x 16” 44.44 ft 20” x 16” 55.56 ft 20” x 16” 66.67 ft 20”...

  • Page 67: Figure 38 - Cartridge/Bag Filter Layout Viewed From Upstream Side

    Figure 38 - Cartridge/Bag Filter Layout Viewed from Upstream Side. Filters Face Load Into Type 8 Holding Frame.

  • Page 68: M3 Series Startup Form

    M3 Series Startup Form Job Name:_______________________________________________ Date:______________ Address:______________________________________________________________________ ______________________________________________________________________________ Model Number:_________________________________________________________________ Serial Number:_____________________________________________ Tag:_______________ Startup Contractor:______________________________________________________________ Address:______________________________________________________________________ _______________________________________________________ Phone:______________ Pre Startup Checklist Installing contractor should verify the following items. 1. Is there any visible shipping damage? 2. Is the unit level? 3.
  • Page 69 Supply Fan Assembly Alignment Check Rotation Nameplate Amps________ Number Band Size_____________________ VAV Controls_________________ VFD Frequency________________ Springs Operating Correctly Energy Recovery Wheel Assembly Wheels Spin Freely Check Rotation FLA ________ Number Power Exhaust Fan Assembly Alignment Check Rotation Nameplate Amps________ Number Band Size_____________________ VFD Frequency________________ Springs Operating Correctly...
  • Page 70 Outside Air/Economizer Dampers OA Operation Check Damper Wiring Check Gears Check RA Operation Check Damper Wiring Check Gears Check EA Operation Check Damper Wiring Check Gears Check Damper Actuator Type:__________________________________________________________ Economizer Changeover Type and Operation:_______________________________________ Electric Heating Stages__________ Limit Lockout Aux.

  • Page 71: 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.

  • Page 72: Literature Change History

    Literature Change History June 2010 Update of the IOM adding PVC and CPVC piping Caution and revising the Module Assembly section. April 2012 Update of the IOM changing the 2” pleated 30% efficient filter from MERV 7 to MERV 8, correcting the Unit Lifting Drawing to show a 60 degree minimum strap angle, adding the electronic startup form, adding the index of tables and figures, and updating the table of contents.

  • Page 76: R57350 · Rev. D · 160822

    Maintenance R57350 · Rev. D · 160822 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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