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AAON M2 Series Installation Operation & Maintenance

Modular indoor air handling units & self-contained units
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Modular Indoor Air Handling Units
Installation, Operation
WARNING
FIRE OR EXPLOSION HAZARD
Failure to follow safety warnings
exactly could result in serious injury,
death or property damage.
Be sure to read and understand the
installation, operation and service
instructions in this manual.
Improper
installation,
alteration, service or maintenance
can cause serious injury, death or
property damage.
A copy of this IOM should be kept
with the unit.
& Self-Contained Units
& Maintenance
adjustment,
M2 Series
WARNING
Do not store gasoline or other
flammable vapors and liquids in the
vicinity of this or any other appliance.
WHAT TO DO IF YOU SMELL GAS
 Do not try to light any appliance.
 Do not touch any electrical switch;
do not use any phone in your
building.
 Leave the building immediately.
 Immediately call you gas supplier
from a phone remote from the
building. Follow the gas supplier's
instructions.
 If you cannot reach your gas
supplier call the fire department.
Startup
and
service
performed by a Factory Trained
Service Technician.
must
be

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Summary of Contents for AAON M2 Series

  • Page 1 M2 Series Modular Indoor Air Handling Units & Self-Contained Units Installation, Operation & Maintenance WARNING WARNING FIRE OR EXPLOSION HAZARD Do not store gasoline or other flammable vapors and liquids in the Failure to follow safety warnings vicinity of this or any other appliance.

  • Page 3: Table Of Contents

    Table of Contents Safety .............................. 9 Feature String Nomenclature ......................15 M2 Series Base Feature String Nomenclature ................16 Fan Module Description ......................17 Filter Module Description ......................18 Mixing Module Description ...................... 19 Heat Module Description ......................20 Blank Module Description ......................22 Coil Module Description ......................
  • Page 4 Condensate Drain Pans ......................89 Duct Furnace ..........................89 Lubrication ..........................89 Replacement Parts ........................90 AAON-Longview Product Support ................... 90 Phase and Brownout Protection Module ................... 91 Filter Replacement ........................93 Appendix A - Heat Exchanger Corrosion Resistance ..............96...
  • Page 5 Split System Piping Diagrams ...................... 98 M2 Series Startup Form ......................115 Maintenance Log ........................121...
  • Page 6 Index of Tables and Figures Tables: Table 1 – Electric and Gas Heating Capacities ................35 Table 2 - Minimum Clearances ..................... 37 Table 3 - Glycol Freezing Points ....................49 Table 4 - Standard Water-Source Connections ................50 Table 5 - Freezing Points ......................51 Table 6 –...
  • Page 7 Figure 5 - M2 Series Unit Four Point Lifting ................38 Figure 6 - M2 Series Unit Eight Point Lifting ................39 Figure 7 - M2 Series Individual Module Bottom Tier Lifting ............40 Figure 8 - M2 Series Individual Module Top Tier Lifting ............40 Figure 9 - Unit Suspension ......................
  • Page 8 Figure 46 - Segment Retainer ....................... 76 Figure 47 - Segment Installation ....................76 Figure 48 - Belt Replacement ....................... 77 Figure 49 - Angular Misalignment ....................86 Figure 50 - Parallel Misalignment ....................86 Figure 51 - Belt Deflection ......................86 Figure 52 - Filter Layout .......................

  • Page 9: 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 10 WARNING WARNING Electric shock hazard. Before ROTATING COMPONENTS servicing, shut off all electrical power unit, including remote Unit contains fans with moving parts disconnects, to avoid shock hazard that can cause serious injury. Do not or injury from rotating parts. Follow open door containing fans until the proper Lockout-Tagout procedures.
  • Page 11 CAUTION CAUTION Electric motor over-current protection Failure to properly drain and vent and overload protection may be a coils when not in use during freezing function of the Variable Frequency temperature may result in coil and Drive to which the motors are wired. equipment damage.
  • Page 12 Failure follow instructions may result in equipment Failure of the condenser as a result damage, injury or death. of chemical corrosion is excluded from coverage under AAON Inc. warranties and the heat exchanger CAUTION manufacturer’s warranties. Door compartments containing...
  • Page 13 WARNING WARNING HOT PARTS Never attempt to open an access Disconnect power, close door or remove a panel while the unit isolation valves and allow equipment is running. Pressure in the unit can to cool before servicing equipment to cause excessive force against the prevent serious injury.
  • Page 14 1. Startup and service must be performed Factory Trained Service Technician. 8. READ THE ENTIRE INSTALLATION, OPERATION AND MAINTENANCE 2. Use only with type of the gas approved MANUAL. OTHER IMPORTANT for the furnace. Refer to the furnace SAFETY PRECAUTIONS rating plate.

  • Page 15: Feature String Nomenclature

    If 0, is the first module on the second level. the module is on the bottom level, the first number is 1 while the first number in the top Figure 1 - Typical M2 Series Selection...

  • Page 16: M2 Series Base Feature String Nomenclature

    M2 Series Base Feature String Nomenclature Model Options M2 - H - 011 - R - 2 - A - A - 0 - C - 0 M2 Series Base Feature String Nomenclature Assembly BASE MODEL DESCRIPTION A = Factory Assembled...

  • Page 17: Fan Module Description

    Fan Module Feature String Nomenclature SDD - 103 - J - B I - F 00 00 - A 0000 - 0 - 0 Fan Mo dule Descriptio n J = 15” BC Plenum - 50% Width FAN MODULE DESCRIPTION K = 18”...

  • Page 18: Filter Module Description

    Filter Module Feature String Nomenclature FTA - 102 - P - A0 - 0 0000 - 0 00 00 - 0 - 0 Filter Module Descriptio n FILTER MODULE DESCRIPTION Blank Module ID 0000 = Standard FTA = Small Flat Filter FTC = Cartridge Filter Second Filter Type FTE = Medium Flat Filter...

  • Page 19: Mixing Module Description

    Mixing Module Feature String Nomenclature MBH - 101 - A - 00 - 0 0000 - 0 0000 - 0 - 0 Mixin g Mod ule Descriptio n Blank MIXING MODULE DESCRIPTION 0000 = Standard Module ID MBA = Vertical Damper Bypass Opening MBB = Horizontal Top Damper 0 = Standard - None...

  • Page 20: Heat Module Description

    Heat Module Feature String Nomenclature PHA - 104 - H - 00 - 0 00 0 0 - E 02 0 0 - 0 - 0 Heat Module Description HEAT MODULE DESCRIPTION Module ID Coating PHA = Electric Heat 0 = Standard PHB = Hot Water Coil H = Stainless Steel Coil Casing &...
  • Page 21 Heat Module Feature String Nomenclature PHA - 101 - H - 00 - 0 00 0 0 - E 02 0 0 - 0 - 0 Stages Filter Options 00 = Hot Water Heating Coil 0 = Standard 01 = 1 Stage A = Magnehelic Gauge 02 = 2 Stage B = Clogged Filter Switch...

  • Page 22: Blank Module Description

    Blank Module Feature String Nomenclature BBA - 101 - 0 - AR - 0 0000 - 0 0000 - 0 - 0 Blan k M odule Description BLANK MODULE DESCRIPTION Module ID Blank BBA = Small 0000 = Standard BBB = Medium BBC = Large Bypass Opening BBD = XL...

  • Page 23: Coil Module Description

    Cooling Coil Module Feature String Nomenclature CLC - 103 - F - 0 0 - 0 00 0 0 - 6 10 I P - S - 0 Coil Modu le Description COOLING COIL MODULE Stages DESCRIPTION 0 = Standard - None Module ID 1 = 1 Stage CLB = Chilled Water or DX...
  • Page 24 Cooling Coil Module Feature String Nomenclature CLC - 103 - F - 0 0 - 0 00 0 0 - 6 10 I P - S - 0 Circuiting Drain Pan 0 = No Cooling Coil 0 = No Drain Pan D = Double Serpentine S = Stainless Steel F = Single Serpentine...

  • Page 25: Controls Module Description

    Controls Module Feature String Nomenclature TRA - 101 - 0 - 00 - 0 0000 - 00000 - 0 - 0 Controls Mo dule Description Safety Control CONTROLS MODULE DESCRIPTION 0 = Standard Module ID 2 = Firestat TRA = Small TRB = Medium Blank TRC = Large...

  • Page 26: Energy Recovery Module Description

    Energy Recovery Module Feature String Nomenclature HRA - 102 - A - 00 - 00000 - 00000 - 0 - 0 Energy Recovery Module Description Blank ENERGY RECOVERY MODULE 00000 = Standard DESCRIPTION Module ID Blank ® HRA = AAONAIRE Energy Recovery Wheel 00000 = Standard Position...

  • Page 27: Water-Source Heat Pump Module Description

    Water-Source Heat Pump Module Feature String Nomenclature WHP - 204 - A - 25 - D K 000 - D A 0 H 0 - 0 - 0 Water-Source Heat Pump Module Descriptio n WATER-SOURCE HEAT PUMP MODULE DESCRIPTION Staging Module ID G = 1 On/Off Refrigeration System WHP = Water-Source Heat Pump...
  • Page 28 Water-Source Heat Pump Module Feature String Nomenclature WHP - 204 - A - 25 - D K 000 - D A 0 H 0 - 0 - 0 Heat Exchanger Type Special 0 = Standard 0 = None A = SMO 254 Brazed Plate Heat Exchanger X = Special Pricing Authorization B = Cupronickel Coaxial Heat Exchanger Blank...

  • Page 29: Unit Orientation

    Unit Orientation Determine left hand or right hand orientation/connections: M2 Series Top View Right Hand Side Supply Air Return Air AIRFLOW “Front” “Back” Supply Fan Coil Filter Connections & service access on left side for Left Hand Side left hand orientation Consider the airflow to be hitting the back of your head.

  • Page 30: General Information

    General Information CAUTION M2 Series modular indoor air handling units This equipment is protected by a and self-contained units have been designed standard limited warranty under the for indoor installation. Flexible connectors condition that initial installation, are required on all duct connections to service, startup and maintenance is minimize air leaks.

  • Page 31: Codes And Ordinances

    The Clean Air Act of 1990 bans the Codes and Ordinances intentional venting of refrigerant as of M2 Series units have been tested and July 1, 1992. Approved methods of certified, by ETL, in accordance with the recovery, recycling, or reclaiming UL Safety Standard 1995/CSA C22.2 No.

  • Page 32: Storage

    all doors with locks or nuts and bolts to Preparation for Storage prevent unauthorized access. Blower wheels and fans  Depending local climate conditions, condensation may collect on components inside the units. To prevent surface rust discoloration, spray all bare metal parts with rust...
  • Page 33 control panel, and leave the unit off until the main power switch has been turned on again WARNING for at least 24 hours for units with compressor crankcase heaters. This will give COMPRESSOR CYCLING the crankcase heater time to clear any liquid accumulation out of the compressor before it 5 MINUTE OFF TIME is started.

  • Page 34: Gas Or Electric Heating

    If unit has not been selected as a 100% Note: Low Ambient Operation Air-cooled DX units without a low ambient outside air unit (make up air unit) the return option, such as condenser fan cycling, ECM air duct must be sealed to the unit and the driven condenser fans or the 0°F low return air temperature must be maintained ambient option, will not operate in the...

  • Page 35: Table 1 - Electric And Gas Heating Capacities

    Table 1 – Electric and Gas Heating Capacities...

  • Page 36: Installation

    Installation contact AAON for recommendations. The M2 can either be shipped assembled or WARNING shipped in individual modules. See the Module Assembly section of this document When locating gas fired units, it is for instructions on individual modules.

  • Page 37: Lifting The Assembled Unit

    Point Lifting Figure and the M2 Series Unit Eight Point Lifting Figure. Energy Recovery Energy Wheel Recovery Module CAUTION Wheel UNIT HANDLING Coil Module To prevent injury or death lifting equipment capacity shall exceed unit weight by an adequate safety factor.

  • Page 38: Figure 5 - M2 Series Unit Four Point Lifting

    Figure 5 - M2 Series Unit Four Point Lifting...

  • Page 39: Figure 6 - M2 Series Unit Eight Point Lifting

    Figure 6 - M2 Series Unit Eight Point Lifting...

  • Page 40: Lifting The Individual Modules

    The air handling unit must be installed level as the internal drain pan is manufactured with a slope toward the drain. Other installation provisions may be necessary according specifications requirements. Figure 8 - M2 Series Individual Module Top Tier Lifting...

  • Page 41: Module Assembly

    Module Assembly Although M2 Series modular units are Modules are arranged in order with 100 shipped factory assembled as standard, the series modules on the first tier and 200 unit may be ordered as individual modules series modules on the second tier.
  • Page 42 If, for any reason, a module or its position in final assembly is unidentifiable, then consult project engineer, AAON sales representative, or AAON-Longview Product Support. After identifying modules and determining module arrangement, modules can be prepared for final assembly.

  • Page 43: Figure 10 - Module Assembly Schematic

    Base model number CONFIGURATION: M2-H-011-R-2-A-A-0-C-0 FTF-101-P-A0-00000-00000-0-0 HRA-102-A-00-00000-00000-0-0 CLF-103-C-00-210F0-610F0-S-0 SFA-104-K-C0-A0000-00000-0-0 PEC-201-K-BI-A0000-00000-0-0 FTE-203-P-B0-00000-00000-0-0 Configuration Schematic can be found in unit literature packet Module configuration numbers Arrows indicate airflow Table provides required service access clearances for applicable modules Note: Energy recovery wheel module will have a 100 series number, but will span both tiers, also utilizing a 200 series space.

  • Page 44: Figure 11 - Bolted Base Rail

    2. Connect Modules affixed. Self-tapping sheet metal screws are provided to attach the straps to the unit Modules are to be connected with nuts and cabinet. bolts through the base rail and with metal strapping over module joints. Metal straps Leave bar clamps in place until strap is have adhesive backs and are to be secure.

  • Page 45: Figure 14 - Strap Types

    Figure 17 - Strap Installation Strap Strap 4. Run Power and Control Wiring M2 Series units are equipped with an internal wiring chase, located along the inside top of each module. Wire is provided for power and control wiring inside the unit.
  • Page 46 Wire from the unit to external controls and power sources must be provided in the field. A color-coded wiring diagram is laminated and affixed to the inside of the control compartment access door. M2 Series units are equipped with a single point power connection. 5. Final Sealing It is very important to keep air from infiltrating the unit cabinet.

  • Page 47: Evaporator Coils

    Hot Gas Reheat (HGRH) is available for use APPLICATIONS with DX systems that need humidity control. The AAON modulating hot gas reheat Water-source heat pump units using system diverts hot discharge gas from the 100% outside air must have electric...

  • Page 48: Open Loop Applications

    AAON warranties and the of 316 Stainless Steel. 316 Stainless Steel is heat exchanger manufacturer warranties. subject to severe corrosion and failure when exposed to chlorides. Failure of the condenser will allow water to...

  • Page 49: Water Piping

    AAON water flow switch installed at the factory. warranties and the heat exchanger manufacturer warranties. The water connections will differ depending on whether the unit is water-cooled only or Unit is capable of operating with Entering if it is water-source heat pump.

  • Page 50: Table 4 - Standard Water-Source Connections

    The water-cooled only units have water Table 4 - Standard Water-Source supply to the bottom of the heat exchanger Connections and the return to the top. Supply and Return Tonnage Connection Size 003, 004 1" CU FPT 1-1/4" CU FPT 006, 007, 008, 1-1/2"...

  • Page 51: Table 5 - Freezing Points

    CAUTION CAUTION Each heat exchanger is equipped WATER PIPING with a refrigerant pressure relief device to relieve pressure should Follow national and local codes when excessive condensing pressures installing water piping. Connections (>675 psig) occur. Codes unit should incorporate require installing contractor vibration eliminators to reduce noise...

  • Page 52: Heat Exchanger Safeties

    CAUTION exceed recommended condenser fluid flow rates. Serious damage to or erosion of the heat exchanger tubes could occur. Heat Exchanger Safeties Electronic freeze protection and water flow safeties should be field installed or factory provided. If the leaving water temperature drops below 38°F or water flow has ceased the 24VAC control circuit will be broken to disable the cooling system.

  • Page 53: Heating Coils

    During mechanical cooling only mode of Table 6 – Steam Distributing Coil operation, condenser water flows around the waterside economizer coil with Connection Sizes waterside economizer bypass valve fully Supply and Return Model (M2-) open. The condenser water then passes Connection Size through the water-cooled condenser and the 005 - 036...

  • Page 54: Chilled Water Coils

    across the coil is going to be below this WARNING value, use a glycol solution to match the coldest air expected. Piping shall be in accordance with national and local codes. Pressure Water supply lines must be insulated, limiting devices, backflow preventers properly fastened, drained, and supported and all other safety requirements are according to local code requirements.

  • Page 55: Table 9 - Drain Trap Dimensions

    Note: The drain pan connection is a 1” MPT dimension. This ensures that enough water fitting. 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...

  • Page 56: Blower Wheels

    Blower Wheels indicated on the terminal strip (red wire). M2 Series units are equipped with backward curved blower wheels that are set to deliver the air volume specified according to unit size and/or job requirements. This is done...

  • Page 57: Banded Wheel Air Adjustment

    equipped with the air band but additional air delivery is needed, the band can be removed from the wheel. The air band is sized according to the air delivery specifications and can be ordered from the factory for field installation. The related photos of the wheel are provided for practical guidelines only in order to identify the air band location in the wheel.

  • Page 58: Figure 32 - Supply Fan Banding

    Figure 32 - Supply Fan Banding...

  • Page 59: Electric Heating

    Do not weld to a foam filled part. Electrical Verify the unit name plate agrees with power supply. M2 Series units are provided Note: Locations for field cut electrical with single point power wiring connections. entries are marked on the unit. Field cut...
  • Page 60 CAUTION Supply voltage must be within the min/max range shown on the unit nameplate. Installing Contractor is responsible Available short circuit current should not for proper sealing of the electrical exceed the SCCR rating shown on the unit and gas entries into the unit. Failure nameplate.

  • Page 61: Thermostat Control Wiring

    Table 11 - Control Wiring CAUTION Wire Size (Stranded) Total Wire Distance - Copper Conductors Allowable Only Rotation must be checked on all 20 AWG 200 ft MOTORS AND COMPRESSORS at 18 AWG 350 ft startup qualified service technician. Scroll compressors are 16 AWG 500 ft directional and can be damaged if...

  • Page 62: Gas Fired Duct Furnace

    5. Do not install unit where it may exposed Gas Fired Duct Furnace to potentially explosive or flammable vapors. WARNING 6. Do not locate unit in areas where Improper installation, adjustment, corrosive vapors (such as chlorinated, alteration, service, or maintenance halogenated, or acidic) are present in the cause property...

  • Page 63: Duct Furnace Component Identification

    4. A 1/8” NPT tap is provided on the inlet WARNING side of the gas valve to the heater. A fitting suitable for connection to a pressure gauge 1. When pressure testing at 1/2 psi or capable of measuring gas pressure should be less, close the manual shutoff valve connected to each heater serviced by a on the appliance before testing.

  • Page 64: Operating And Safety Instructions

    condensate buildup and possible heat drain tube be connected to the lower exchanger damage. condensate drain fitting as well. 3. If heating section is located downstream Gas Valve of a refrigeration system or cooling coil, condensation can occur during operation of conditioning, resulting condensation from warm, moist air in the...

  • Page 65: Startup

    13. At the end of the pre-purge the direct WARNING spark will be energized and gas valve will open. Do not store or use gasoline or other flammable vapors and liquids in the Check and Adjust Manifold Pressure vicinity of this or any other appliance. For 2 stage (TS) and modulating control (MD) systems manifold pressure should be 1.2”...

  • Page 66: Figure 37 - 1.2" W.c. Manifold Natural Gas

    Burner Flames burner flame should Prior to completing the start-up, check the predominately blue in color and well defined appearance of the main burner flame. See and centered at the tube entry as shown in Figure 37 - 1.2” w.c. Manifold and Figure Figure 37 - 1.2”...

  • Page 67: Shutdown

    FC- and FC+ terminals per figure. Meter Shutdown should read 0.7 uA or higher. If the meter reads below “0” on scale, meter leads are 1. Set thermostat or controller to lowest setting. reversed. Disconnect power and reconnect meter leads for proper polarity. 2.

  • Page 68: Table 13 - Gas Heater Troubleshooting

    of the air inlet or outlet to the unit. The high Ignition Control Diagnostics and Service limit switch will automatically reset when Guide (Fenwal 35-61 Series). LED flashes the temperature drops to 15ºF below the set on for ¼ second, and off for ¼ second point.

  • Page 69: Table 14 - Gas Heater Troubleshooting Continued

    Table 14 - Gas Heater Troubleshooting Continued System Description Actions Code Flame Fault Flame sense failure / flame present 1. Check for voltage to gas valve with thermostat Flash (No Call for with no call for heat. in off position. Valve should not be powered. Heat) 2.

  • Page 70: Furnace Maintenance

    Operating Control Systems CAUTION Two Stage (TN) - Low / High Fire / High Speed Inducer Only If any original wiring needs to be Modulating (MD) - Modulating (25 to replaced it must be replaced with 100%) / 2 Speed Draft Inducer - Mid-Fire wiring materials suitable for 105ºC.

  • Page 71: Energy Recovery Units

    Duct Furnace Operation Check from the warm, moist air stream to the 1. Turn on power to the unit and set cooler and/or drier air stream. thermostat or heat controller to call for heat, allowing duct furnace to operate. The initial setup and servicing of the energy recovery wheel is very important to maintain 2.

  • Page 72: Routine Maintenance And Handling

    seal and wheel. Racking of the unit or at a time to provide slip fit clearance when cassette during installation, and/or mounting the wheel is rotated by hand. of the unit on a non-level support or in other than the factory orientation can change seal Confirm that the wheel rotates freely.

  • Page 73: Cleaning

    rigging shown following A characteristic of all dry desiccants, such illustration. 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.

  • Page 74: Wheel Drive Components

    turn the wheel immediately after power is CAUTION applied with no visible slippage during start- Do Not use acid based cleaners, aromatic solvents, steam Installation Considerations temperatures in excess of 170°F; Energy recovery cassettes are incorporated damage to the wheel may occur! within the design of packaged units, packaged air handlers and energy recovery ventilators.

  • Page 75: Startup Procedure

    adjustable diameter seals away from surface Frame Bearing beams shown racked 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. Wheel 5. Start and stop wheel several times to confirm seal adjustment and to confirm belt Bearing beams...

  • Page 76: Service

    Service 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. Segment Installation & Replacement Figure 47 - Segment Installation Wheel segments are secured to the wheel frame by a Segment Retainer which pivots...

  • Page 77: Figure 48 - Belt Replacement

    4. While supporting weight of drive motor in 5. Loop the trailing end of the belt over the one hand, loosen and remove (4) mounting shaft (belt is partially through the opening). bolts. 6. Reinstall the bearing onto the wheel shaft, 5.

  • Page 78: Startup

    Startup Check Out (See back of the manual for startup form) Equipment should be thoroughly checked WARNING for loose wiring, a free spinning blower wheel, and well-fitting access panels. Air Improper installation, adjustment, handlers should not be operated without alteration, service or maintenance proper ductwork and access panels installed, cause property...
  • Page 79 2. Ensure there is no construction installed equipment, or ductwork can debris in the unit. affect readings. 3. Check the unit for external damage. 2. Perform condenser start-up checks in 4. Note all accessories installed. addition to these air handler checks 5.

  • Page 80: Commissioning

    2. Turn off gas supply at the manual Air Balancing shut-off valve (supplied by others). High performance systems commonly have 3. Turn off power to the unit at the complex air distribution and fan systems. disconnect switch. Unqualified personnel should not attempt to 4.

  • Page 81: Adjusting Refrigerant Charge

    Maintenance List provided later in this Checking Liquid Sub-Cooling manual. Measure the temperature of the liquid line as it leaves the condenser. Adjusting Refrigerant Charge Adjusting the charge of a system in the field Read the gauge pressure at the liquid line must be based on determination of liquid close to the point where the temperature was sub-cooling and evaporator superheat.

  • Page 82: Table 15 - Acceptable Air-Cooled Refrigeration Circuit Values

    Table 15 - Acceptable Air-Cooled CAUTION Refrigeration Circuit Values Air-Cooled Cond./Air-Source Heat Pump DO NOT OVERCHARGE! Sub-Cooling** 8-15°F / 2-4°F (HP)* Sub-Cooling with 8-15°F / 2-6°F (HP)* Refrigerant overcharging leads to Hot Gas Reheat** excess refrigerant in the condenser Superheat*** 8-15°F coils resulting in elevated compressor *In cooling mode operation...

  • Page 83: Table 17 - R-410A Refrigerant Temperature-Pressure Chart

    Table 17 - R-410A Refrigerant Temperature-Pressure Chart °F PSIG °F PSIG °F PSIG °F PSIG °F PSIG 78.3 134.7 213.7 321.0 463.2 80.0 137.2 217.1 325.6 469.3 81.8 139.7 220.6 330.2 475.4 83.6 142.2 224.1 334.9 481.6 85.4 144.8 227.7 339.6 487.8 87.2...

  • Page 84: Refrigeration Troubleshooting

    Refrigeration Troubleshooting Table 18 – Refrigeration Problems, Causes, and Solutions Problem Possible Cause Solutions Frosted evaporator coil, low Restricted air flow Clean, or replace filters suction pressure Low fan speed Check fan drives Reversed blower rotation Correct wiring Low refrigerant charge Add refrigerant Unit runs, but supplies warm Loss of refrigerant...

  • Page 85: Maintenance

    Fans, evaporator coils, and filters should be Fan Assembly inspected at least monthly. M2 Series units use backward curved fan wheels which are non-overloading, energy One week after start-up:  Check operating pressures.

  • Page 86: Belts

    Table 19 - Bearing Setscrew Torque Straightedge Recommendations Setscrew Locking Pulley Shaft Size Pulley Torque Belt (inches) Thread (in-lbs.) 1/4 - 28 66 - 85 Figure 50 - Parallel Misalignment 1 3/16 1/4 - 28 66 - 85 1 7/16 5/16 - 24 126 - 164 Correct by adjusting sheaves on one, or both...

  • Page 87: Indoor Coils

    Indoor Coils E-Coated Coil Cleaning Indoor cooling/evaporator coils must be Documented routine cleaning of e-coated cleaned regularly to maintain unit efficiency coils is required to maintain coating and operation. Dirty evaporator coils will warranty coverage. eventually freeze up and often result in a time consuming and expensive service call.
  • Page 88 dust, soot, greasy residue, lint and other CAUTION particulate: High velocity water from a pressure Enviro-Coil Concentrate, Part Number H- washer or compressed air should EC01. only be used at a very low pressure to prevent fin and/or coil damages. Recommended Chloride Remover The force of the water or air jet may CHLOR*RID DTS™...

  • Page 89: Electric Heating

    Electric Heating Duct Furnace Set thermostat in the heat mode; call for heat The duct furnace should be inspected to engage all electric heat strips. Check annually by a qualified service agency. The blower for proper rotation and voltage. condition of the burners, heat exchanger, Measure amperage voltage.

  • Page 90: Replacement Parts

    Table 20 - Fan Bearing Lubrication Replacement Parts Schedule Parts for AAON equipment may be obtained from your local AAON representative. Greasing Temp. Environ. When ordering parts, reference the unit Speed Interval serial number and part number. Up to 2 to 6 Clean 150 F...

  • Page 91: Phase And Brownout Protection Module

    Phase and Brownout Protection Module DPM Setup Procedure With the supply voltage active to the module, you can setup all of the DPM’s settings without the line voltage connected. To change the setpoint parameters use the right arrow key to advance forward through the setpoint parameters and the left arrow to backup if needed.
  • Page 92 Screens Manufacturer’s Screen R-K Electronics DPM v0.0.00 Average Voltage Screen VAvg Default – the default screen shows the real time voltage detected in each of the 3 phases: A-B B-C C-A Voltage Selection Screen (Vertical Format) Default = 460V, 3Ø 200, 1Ø;...

  • Page 93: Filter Replacement

    Filter Replacement Monthly air filter inspection is required to maintain optimum unit efficiency. It is strongly recommended that filter media be replaced monthly. Open access panel and pull filters straight out to inspect all of the filters. Replace filters with the size indicated on each filter.

  • Page 94: Table 23 - M2-018 And M2-022 Filters

    Table 23 - M2-018 and M2-022 Filters (Quantity) Size Filter Type M2-018 M2-022 2” Pleated - 30% Eff, MERV 8 4” Pleated - 30% Eff (MERV 8), 65% Eff (MERV 11), 85% Eff (MERV 13), (4) 25” x 20” (8) 20” x 20” or 95% Eff (MERV 14) (4) 20”...

  • Page 95: Figure 52 - Filter Layout

    Figure 52 - Filter Layout (Viewed from the Upstream Side of the Cooling Coil)

  • Page 96: Appendix A - Heat Exchanger Corrosion Resistance

    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 provides the corrosion resistance of stainless steel type AISI 316 and pure Copper (99.9%) in water, to a number of important chemical factors.
  • Page 97 Water Concentration Time Limits - AISI Copper Nickel Containing (mg/l or ppm) Analyze Before Alloy Alloy Total Hardness 4.0-8.5 No Limit (°dH) < 100 Nitrate (NO No Limit > 100 < 0.2 Iron (Fe) No Limit > 0.2 < 0.2 Aluminum (Al) No Limit >...

  • Page 98: Figure 53 - A/C Split System Piping, Suction Down

    Split System Piping Diagrams Figure 53 - A/C Split System Piping, Suction Down...

  • Page 99: Figure 54 - A/C Split System Piping, Suction Up

    Figure 54 - A/C Split System Piping, Suction Up...

  • Page 100: Figure 55 - A/C With Lac Split System Piping, Suction Up

    Figure 55 - A/C with LAC Split System Piping, Suction Up...

  • Page 101: Figure 56 - A/C With Modulating Hot Gas Reheat Split System Piping, Suction Down

    Figure 56 - A/C with Modulating Hot Gas Reheat Split System Piping, Suction Down...

  • Page 102: Figure 57 - A/C With Modulating Hot Gas Reheat Split System Piping, Suction Up

    Figure 57 - A/C with Modulating Hot Gas Reheat Split System Piping, Suction Up...

  • Page 103: Figure 58 - A/C With Hot Gas Bypass Split System Piping, Suction Down

    Figure 58 - A/C with Hot Gas Bypass Split System Piping, Suction Down...

  • Page 104: Figure 59 - A/C With Hot Gas Bypass Split System Piping, Suction Up

    Figure 59 - A/C with Hot Gas Bypass Split System Piping, Suction Up...

  • Page 105: Figure 60 - A/C With Modulating Hot Gas Reheat And Hot Gas Bypass Split System Piping

    Figure 60 - A/C with Modulating Hot Gas Reheat and Hot Gas Bypass Split System Piping, Suction Down...

  • Page 106: Figure 61 - A/C With Modulating Hot Gas Reheat And Hot Gas Bypass Split System Piping

    Figure 61 - A/C with Modulating Hot Gas Reheat and Hot Gas Bypass Split System Piping, Suction Up...

  • Page 107: Figure 62 - Heat Pump Split System Piping, Suction Down

    Figure 62 - Heat Pump Split System Piping, Suction Down...

  • Page 108: Figure 63 - Heat Pump Split System Piping, Suction Up

    Figure 63 - Heat Pump Split System Piping, Suction Up...

  • Page 109: Figure 64 - Heat Pump With Modulating Hot Gas Reheat Split System Piping, Suction Down

    Figure 64 - Heat Pump with Modulating Hot Gas Reheat Split System Piping, Suction Down...

  • Page 110: Figure 65 - Heat Pump With Modulating Hot Gas Reheat Split System Piping, Suction Up

    Figure 65 - Heat Pump with Modulating Hot Gas Reheat Split System Piping, Suction Up...

  • Page 111: Figure 66 - Heat Pump With Hot Gas Bypass Split System Piping, Suction Down

    Figure 66 - Heat Pump with Hot Gas Bypass Split System Piping, Suction Down...

  • Page 112: Figure 67 - Heat Pump With Hot Gas Bypass Split System Piping, Suction Up

    Figure 67 - Heat Pump with Hot Gas Bypass Split System Piping, Suction Up...

  • Page 113: Figure 68 - Heat Pump With Modulating Hot Gas Reheat And Hot Gas Bypass Split System Piping, Suction Down

    Figure 68 - Heat Pump with Modulating Hot Gas Reheat and Hot Gas Bypass Split System Piping, Suction Down...

  • Page 114: Figure 69 - Heat Pump With Modulating Hot Gas Reheat And Hot Gas Bypass Split System Piping, Suction Up

    Figure 69 - Heat Pump with Modulating Hot Gas Reheat and Hot Gas Bypass Split System Piping, Suction Up...
  • Page 115 M2 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 116 Ambient Temperature Ambient Dry Bulb Temperature ________°F Ambient Wet Bulb Temperature ________°F 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...
  • Page 117 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:_______________________________________ Unit Configuration Water-Cooled Condenser Air-Cooled Condenser No Water Leaks Condenser Safety Check Water Flow ________ gpm...
  • Page 118 Refrigeration System 2 - Cooling Mode Saturated Line Pressure Sub-cooling Superheat Temperature Temperature Discharge Suction Liquid Refrigeration System 3 - Cooling Mode Saturated Line Pressure Sub-cooling Superheat Temperature Temperature Discharge Suction Liquid Refrigeration System 4 - Cooling Mode Saturated Line Pressure Sub-cooling Superheat...
  • Page 119 Refrigeration System 4 - Heating Mode (Heat Pump Only) Saturated Line Pressure Sub-cooling Superheat Temperature Temperature Discharge Suction Liquid Air-Cooled Condenser Alignment Check Rotation Nameplate Amps________ Number Water/Glycol System 1. Has the entire system been flushed and pressure checked? 2. Has the entire system been filled with fluid? 3.
  • Page 120 Electric Heating Stages__________ Limit Lockout Aux. Limit Lockout Stage Amps Stage Amps Electric Preheating Limit Lockout Aux. Limit Lockout Outside Air Temperature Setpoint__________°F Preheat Leaving Air Temperature Setpoint__________°F Stage Amps Stage Amps...
  • Page 121 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 122 Literature Change History March 2010 Update of IOM adding gas heater, self-contained unit and packaged rooftop unit information. July 2010 Update of IOM adding PVC and CPVC piping Caution and split system piping information. November 2010 Update of IOM adding control wiring information, correcting M2-022 and M2-026 filter sizes and adding modulating hot gas reheat only piping diagram.
  • Page 123 May 2016 Updated base model description to include air flow. Added 30hp motor to motor size in the feature string. Included more details under heat capacity in the feature string. Added the CB_ modules to blank module feature string. Updated coil options in the coil module feature strings. Updated options in water-source heat pump module feature string Added Preparation for Storage section.
  • Page 124 R40681 · Rev. D · 170412 (ACP 30752) 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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