AAON LF Series Installation Operation & Maintenance
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AAON LF Series Installation Operation & Maintenance

Air-cooled chillers
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Installation, Operation,
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.
Air-Cooled Chillers
& Maintenance
LF Series
WARNING
QUALIFIED INSTALLER
Improper
installation,
alteration, service or maintenance can
cause property damage, personal
injury or loss of life. Installation and
service must be performed by a
Factory Trained Service Technician. A
copy of this IOM should be kept with
the unit.
adjustment,

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Summary of Contents for AAON LF Series

  • Page 1 LF Series Air-Cooled Chillers 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 can personal injury or loss of life.

  • Page 2: Table Of Contents

    Table of Contents AAON LF Series Features and Options Introduction ..............4 Safety .............................. 5 LF Series Feature String Nomenclature ..................7 General Description ........................12 Receiving Unit ........................... 12 Chiller ............................13 Wiring Diagrams ........................14 General Maintenance ......................... 14 Primary Pumping Package ......................
  • Page 3 Figure 1 - Pressure Relief Valve ....................15 Figure 2 - Forklifting an LF Series A, B and C Cabinet, 4-17, 22 and 24 tons ......16 Figure 3 - Lifting Details of a 4-17, 22 and 24 ton Standard Unit ..........17 Figure 4 - Lifting Details of a 21 and 26-55 ton Standard Unit ............

  • Page 4: Aaon Lf Series Features And Options Introduction

    AAON LF Series Features and Options Introduction Energy Efficiency Installation and Maintenance • • Staged or 10-100% Variable Capacity Double Wall Rigid Polyurethane Foam R-410A Scroll Compressors Injected Panel Construction • • High Efficiency Air-Cooled Access Doors with Full Length Stainless...

  • Page 5: 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 6 WARNING CAUTION COMPRESSOR CYCLING PVC (Polyvinyl Chloride) and CPVC (Chlorinated Polyvinyl Chloride) are 5 MINUTE MINIMUM OFF TIME vulnerable attack certain prevent motor overheating chemicals. Polyolester (POE) oils compressors must cycle off for a used with R-410A other minimum of 5 minutes. refrigerants, even in trace amounts, in a PVC or CPVC piping system will 2 MINUTE MINIMUM ON TIME...

  • Page 7: Lf Series Feature String Nomenclature

    LF Series Feature String Nomenclature Model Options Unit Feature Options LF A - 031 - D - 0 - 3 - D A C 0 E 0 0 0 0 : C 0 - 0 0 0 0 - 0 0 0 0 - 0 0 0 0 - 0 0 - 0 0 0...
  • Page 8 LF Series Feature String Nomenclature Model Options Unit Feature Options C 0 - 0 0 0 LF A - 031 - D - 0 - 3 - D A C 0 E - 0 0 0 0 : 0 - 0 0 0 0 - 0 0 0 0 - 0 0 - 0 0 0...
  • Page 9 LF Series Feature String Nomenclature Model Options Unit Feature Options 0 - 0 0 0 0 - 0 0 0 0 - 0 0 - 0 0 0 LF A - 031 - D - 0 - 3 - D A C 0 E...
  • Page 10 LF Series Feature String Nomenclature Model Options Unit Feature Options LF A - 031 - D - 0 - 3 - D A C 0 E - 0 0 0 0 : C 0 - 0 0 0 0 - 0 0 0 0 - 0 0 0 0 - 0 0 - 0 0 0...
  • Page 11 B = Premium AAON Gray Paint Exterior 27: Blank E = Option B + Shrink Wrap 0 = Standard X = Special Pricing Authorization + Premium AAON Gray Paint Exterior 28: Blank 1 = Option X + Shrink Wrap 0 = Standard...

  • Page 12: General Description

    Conditioning failure of your system and possible Engineers Handbook. voiding of the warranty. Installation of LF Series units must conform to the ICC standards of the International Receiving Unit Mechanical Code, the International Building When received, the unit should be checked...

  • Page 13: Chiller

    handling damaged goods, repairs, and freight Never cut off the main power supply to the claims: (918) 382-6450. unit, except for complete shutdown. When power is cut off from the unit, any NOTE: Upon receipt check shipment for compressors using crankcase heaters cannot items that ship loose.

  • Page 14: Wiring Diagrams

    Always control the system from the control CAUTION panel, never at the main power supply (except for emergency or for complete shutdown of FIELD WIRED CONNECTIONS the system). Some units may require field wired The standard compressors must be on a connections.

  • Page 15: Glycol

    This pump has a swing split-flapper increases. In order to compensate for these valve in the discharge port to prevent liquid forces, AAON recommends pre- recirculation when only one pump is pressurized diaphragm compression tank that operating.

  • Page 16: Differential Pressure Gauge And Thermometers

    4-7 AND 9 TON UNITS leaks. Forks or Fork Extensions must be at Installation least 48” in length. Forks Figure 2 - Forklifting an LF Series A, B and C Cabinet, 4-17, 22 and 24 tons...

  • Page 17: Lifting The Unit

    Hoist unit to a point directly above the curb Lifting the Unit If cables or chains are used to hoist the unit or concrete pad. Be sure that the gasket they must be the same length. Minimum material has been applied to curb. cable length is 99”...

  • Page 18: Locating The Unit

    Table 3 - 14-17, 22 & 24 ton Service Locating the Unit The LF Series chiller is designed for outdoor Clearances applications and mounting at ground level or Location Clearance on a rooftop. It must be placed on a level and Left 42”...

  • Page 19: Mounting Isolation

    Installing Contractor is responsible for pressure in the receiver, allowing the system proper sealing of the water piping and to operate properly. LF Series chillers use an electrical entries into the unit. Failure LAC valve for low ambient operation. to seal the entries may result in...

  • Page 20: Lac Valve

    LAC Valve The LAC valve is a non-adjustable three way valve that modulates to maintain receiver pressure. As the receiver pressure drops below the valve setting (295 psig for R-410A), the valve modulates to bypass discharge gas around the condenser. The discharge gas warms the liquid in the receiver and raises the pressure to the valve setting.

  • Page 21: Condenser Flooding

    power to the unit according to the wiring Condenser Flooding In order to maintain head pressure in the diagram provided with the unit. refrigeration system, liquid refrigerant is kept in the condenser to reduce condenser surface. Table 7 - Nameplate Voltage Markings The following chart shows the percentage Nameplate Min/Max...
  • Page 22 Protect the branch circuit in accordance with Note: Startup technician must check motor code requirements. The unit must be amperage to ensure that the amperage listed electrically grounded in accordance with on the motor nameplate is not exceeded. local codes, or in the absence of local codes, current National Electric...

  • Page 23: Startup

    components are in place, water flow is Startup present, and the power supply is energized. (See back of the manual for startup form.) Using the controller keypad, individually set WARNING the outputs in “Manual On” to confirm relay closure and compressor operation. Electric shock hazard.

  • Page 24: Maintenance

    Read the gauge pressure at the liquid line Adjusting Refrigerant Charge close to the point where the temperature was All AAON chillers are shipped with a full taken. You must use liquid line pressure as it factory charge. Periodically additional charge will vary from discharge pressure due to may be required.

  • Page 25: Table 9 - Acceptable Refrigeration Circuit Values

    Compare calculated sub-cooling to the table Table 9 - Acceptable Refrigeration Circuit below for the appropriate unit type and Values options. Air-Cooled Condenser Sub-Cooling 12-18°F Checking Evaporator Superheat Superheat 10-15°F Measure the temperature of the suction line One compressor running in tandem close to the compressor.

  • Page 26: Lubrication

    Table 10 - 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 27: Service

    If 3. Record voltage, amperage per phase, and assistance is required, the service technician must contact AAON. Note: Service technician must provide the Pump/Fan Motor Maintenance model and serial number of the unit in all Cleaning - Remove oil, dust, water, and correspondence with AAON.

  • Page 28: Propeller Fans And Motors

    E-Coated Coil Maintenance Record document is available on the AAON Step one is to clean the coil with the below website. approved coil cleaner (see approved products list under the "Recommended Coil Cleaners” section.
  • Page 29 Recommended Chloride Remover – Step 2 100 psig to avoid damaging the unit and coil fin edges. CHLOR*RID® Concentrate, assuming it is used in accordance with the manufacturer's directions on the container for proper mixing, has been approved for use on E-coated coils CAUTION to remove chlorides/salts &...

  • Page 30: Microchannel Coil Cleaning

    middle). Work in sections/panels water). Using a pump up sprayer, fill ensuring that all areas are covered and to the appropriate level with potable kept wetted. water and add the correct amount of 7. Apply the cleaner to unit interior air CHLOR*RID®...
  • Page 31 #1 Simple Green performance fall off, and potentially leaks Simple Green is available from AAON Parts requiring coil replacement. Supply (Part# T10701) biodegradable with a neutral 6.5 pH. Documented routine cleaning Recommendation is to use it at a 4 to 1 mix.

  • Page 32: Replacement Parts

    A spray that is too hard AAON testing has determined that unless a will bend the fins. Spray from the fan side chemical has a neutral pH (6-8) it should not of the coil.

  • Page 33: Appendix - Water Piping Component Information

    Appendix - Water Piping Component Information Water Pressure Relief Valve DESIGN CERTIFIED and listed by C.S.A. Automatic Air Vent Valves ASME Rated, Design Certified and Listed by C.S.A Automatic Air Vent Valves provide air venting for hot or cold water distribution Used for protection against excessive systems.

  • Page 34: Pumps: Installation And Operating Instructions

    above stated temperature levels, pump casing Pumps: Installation and Operating temperatures may exceed 100°C/212°F and Instructions not withstanding pump insulation techniques appropriate measures must be taken to Introduction This document contains specific information minimize risk for operating personnel. regarding the safe installation, operating and maintenance of Vertical In-Line pumps and Storage should be read and understood by installing,...
  • Page 35 Note: Handling, transportation CAUTION installation of this equipment should only be undertaken by trained personnel with proper Discharge valve only is to be used to use of lifting equipment. throttle pump flow. Remove coupling guard and place lifting straps on each side of coupling, use spacer Caution bar if necessary to protect motor fan cover.
  • Page 36 fitted with seal flush/vent lines piped to the operating head is equal to the nameplate pump suction area. When these units operate value. residual air is drawn out of the pump towards the suction piping. Any noise or vibration usually disappears. The system designer or operator should be Energize the motor momentarily and check made aware of this soon as some adjustment...
  • Page 37 The split-coupled pump is flushed from the WARNING pump discharge because the mechanical seal chamber is isolated from the liquid in the Electric shock hazard. Before pump by a throttle bushing. Because the seal attempting to perform any service or chamber is isolated, seal environmental maintenance pumping...
  • Page 38 5. Voltage supply OK? Note: Particular care must be taken to check the 6. Overload protection OK? following before the pump is put into 7. Is the system clean? operation: 8. Is the area around the pump clean? 1. Pump primed? 2.

  • Page 39: Dual Pump Specific Information

    pressure may cause the arm to rotate quickly Dual Pump Specific Information with force when unlocked. Dual Pump Flapper Valve Operating Instructions 6. Close the seal flush line interconnect valve This unit is fitted with internal valves to allow and restart pump. isolation of one pump for service and to automatically prevent recirculation of the Valve Operation...
  • Page 40 3. Rotate discharge valve shaft (16) towards WARNING the pump to be isolated. The orientation of the shaft is indicated by the center pin on the Care should taken when locking arm. (4). performing procedures 3 and 4. Read 4. Raise the locking handle (3) so that the cam instructions carefully.
  • Page 41 NOTE: Keep hands and tools away from WARNING suction valve locking arm when freed by locking handle as differential pressure may Care should taken when cause arm to rotate quickly with force when performing procedures 3 and 4. Read unlocked. instructions carefully.

  • Page 44: Suction Guides

    Suction Guides Inspection Suction guides are thoroughly tested and Introduction inspected before shipment to assure they Suction guides are designed for bolting meet with your order requirements. All units directly onto the suction flange of horizontal must be carefully examined upon arrival for or vertical shaft centrifugal pumps.

  • Page 45: Flo-Trex Combination Valve

    Replace the cover into the body. Ensuring that the strainer is properly seated, tighten the cover bolts diagonally, evenly and firmly. Flo-Trex Combination Valve Introduction The Flo-Trex combination valves are designed for installation on the discharge side of centrifugal pumps, and incorporate three functions in one valve: 1.
  • Page 46 Recommended Bolt Tightening Procedure 4. Position the adjoining flange or the pipe to the Armgrip flange adapter and install Field Conversion (Straight to Angle the remaining bolts. The two locking Pattern Valve: bolts should be tightened first in order to 1.
  • Page 47 Step 2. With valve in fully open position, line horizontally across to valve size being locate the pressure differential on left hand used. Drop line vertically down and read flow side of the Flo-Trex Performance Curve with rate from bottom of chart. Valve in Full Open Position chart and extend Flow Measurement with the valve in the Note: The valve is shipped in closed...
  • Page 48 Step 4. Locate percentage of valve opening this point project line horizontally across to on the bottom scale of Inherent Flow the left of the chart and record the percentage Characteristic Curve with Valve in Throttled of maximum flow rate. Position.
  • Page 49 Step 5. Remove and replace the O ring Note: To prevent premature valve failure it is not recommended that the valve gasket. operate in the throttled position with more than 25 ft pressure differential. Instead the Step 6. Install the valve bonnet. pump impeller should be trimmed or Step 7.
  • Page 50 Pressure-Temperature Limits Flo-Trex Cross Section...

  • Page 51: Lf Series Startup Form

    LF 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 52 Water/Glycol System 1. Has the entire system been flushed and pressure checked? 2. Have isolation valves to the chiller been installed? 3. Has the entire system been filled with fluid? 4. Has air been bled from the heat exchangers and piping? 5.
  • Page 53 Refrigeration System 1 - Cooling Mode Saturated Line Pressure Sub-cooling Superheat Temperature Temperature Discharge Suction Liquid Refrigeration System 2 - Cooling Mode Saturated Line Pressure Sub-cooling Superheat Temperature Temperature Discharge Suction Liquid Condenser Fans Alignment Check Rotation Nameplate Amps________ Number Pumping Package Flow (gpm) Chiller Pump #1...

  • Page 54: 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 55: Literature Change History

    Literature Change History July 2015 Initial version of document. August 2016 Removed mention of copper coils and air scoops. Only microchannel coils are used on the LF and air scoops are not factory provided. October 2017 Added water connection sizes. Added a phase imbalance example. May 2018 Updated technical support contact information.
  • Page 56 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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