AAON RZ Series Installation Operation & Maintenance
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AAON RZ Series Installation Operation & Maintenance

AAON RZ Series Installation Operation & Maintenance

Packaged rooftop units & outdoor air handling units
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Packaged Rooftop Units & Outdoor Air Handling Units
Installation, Operation,
R-454B
UL-60335
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, adjustment,
alteration, service or maintenance
can cause serious injury, death or
property damage.
A copy of this IOM must be kept
with the unit.
& Maintenance
o Do not store gasoline or other flammable
vapors and liquids in the vicinity of this or any
other appliance
o 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 your 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.
o Startup and service must be performed by a
Factory Trained Service Technician
competent in working with flammable
refrigerants.
RZ SERIES
(45-240 tons)
WARNING

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  • Page 1 RZ SERIES (45-240 tons) Packaged Rooftop Units & Outdoor Air Handling Units Installation, Operation, R-454B & Maintenance UL-60335 WARNING WARNING o Do not store gasoline or other flammable FIRE OR EXPLOSION HAZARD vapors and liquids in the vicinity of this or any...

  • Page 3: Table Of Contents

    Safety ..................................8 Installation and Maintenance ..........................8 System Integration ..............................8 Environmentally Friendly ............................8 Extended Life ................................. 8 RZ SERIES FEATURE STRING NOMENCLATURE ...................... 17 ..............................31 ENERAL NFORMATION Certification of Gas Heat Models ........................31 Certification of Steam or Hot Water Heat Models ....................31 Certification of Electric Heat Models........................
  • Page 4 Adjusting Refrigerant Charge ..........................49 Freeze Stat Startup .............................. 52 Refrigerant Filter Driers ............................56 Suction Filter Removal Instructions ........................57 Low Sound Condenser Fan EC Motor Startup ..................... 58 ................................. 59 PERATION Refrigerant Detection System ..........................59 Packaged DX Cooling Operation ......................... 59 Direct Fire Unit with Return Air Gas Heater Operation ..................
  • Page 5 DPM Setup Procedure ............................106 Average Voltage Screen ............................ 107 Fault Words: ..............................107 UV Lights ................................108 Filter Replacement ............................109 Replacement Parts ............................112 AAON Warranty, Service and Parts Department ....................112 ..............................112 ECOMMISSIONING A - H ....................115 PPENDIX...

  • Page 6: Tables

    Table 40- Maximum Temperature Rise Setpoint for Return Air Units ............ 102 Table 41- Air Disinfection UV Information ..................... 108 Table 42 - RZ Series Filter Sizes ......................109 Table 43 - Metal Mesh and HEPA Filter Sizes ..................111...
  • Page 7 Figure 2 - RZ Series Unit Orientation ......................31 Figure 3 - Base Rail Lifting Lug ......................... 32 Figure 4 - 4 Point Lift RZ Series Air-Cooled Condenser Unit ..............33 Figure 5 - 8 Point Lift RZ Series Air-Cooled Condenser Unit ..............34 Figure 6 - Curb Mounting ...........................

  • Page 8: Aaon® Rz Series Features And Options Introduction

    AAON® RZ Series Features and Options Introduction Energy Efficiency Installation and Maintenance Direct Drive Airfoil Plenum Supply Fans Clogged Filter Switch • • Variable Speed Scroll Color Coded Wiring Diagram • • Compressors Compressors in Isolated Compartment • AAON Evaporative Condenser Compressor Isolation Valves •...

  • Page 9: What To Do If You Smell Gas

    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 10 WARNING WARNING FIRE, EXPLOSION OR CARBON During installation, testing, servicing, MONOXIDE POISONING HAZARD and troubleshooting of the equipment it may be necessary to work with live Failure to replace proper controls components. Only could result in fire, explosion or carbon licensed electrician qualified...

  • Page 11: Unit Handling

    WARNING WARNING GROUNDING REQUIRED UNIT HANDLING All field installed wiring must be To prevent injury or death, lifting completed by qualified personnel. equipment capacity must exceed unit Field installed wiring must comply with weight by an adequate safety factor. NEC/CEC, local and state electrical Always test-lift unit not more than 24 code requirements.

  • Page 12: Water Pressure

    WARNING CAUTION WATER PRESSURE Do not clean DX refrigerant coils with hot water or steam. The use of hot Prior to connection of condensing water or steam on refrigerant coils will water supply, verify water pressure is cause high pressure inside the coil less than maximum pressure shown tubing and damage to the coil.

  • Page 13: Open Loop Applications

    Failure of the condenser as a result of light from any source, as personal chemical corrosion is excluded from injury may result. Wear gloves, face coverage under AAON Inc. warranties shield/glasses (per ANSI Z87.1) and heat exchanger cover all exposed skin.
  • Page 14 WARNING WARNING Connected ductwork must be free of Only auxiliary devices approved by potential ignition sources, such as hot manufacturer or declared suitable with surfaces above 700 ºC (1292 ºF) or the refrigerant may be installed in electrical devices prone to arcing or ductwork.
  • Page 15 WARNING WARNING Flammable refrigerant. Do not pierce The appliance shall be stored in a or burn tubing or refrigerant containing room without continuously operating components. ignition sources (i.e. open flames, an operating gas appliances or operating electric heater). CAUTION WARNING Disconnect power to the unit before servicing UV-C lamps Flammable refrigerant.
  • Page 16 If plenum return overload settings. These are set by is to be utilized, the return plenum must the AAON factory for the protection of be provided with a refrigerant detection these motors/compressors and must system or ventilation in accordance with not be adjusted over this factory ASHRAE 15 requirements.

  • Page 17: Model Options

    RZ Series Feature String Nomenclature A - 0 0 0 0 0 : N 0 - A A K A Q - J 0 0 - B F T 0 M - 0 0 0 0 0 - Q F - A 0 A A...
  • Page 18 RZ Series Feature String Nomenclature : N 0 - A A K A Q - J 0 0 - B F T 0 M - 0 0 0 0 0 - Q F - A 0 A A 0 0 0 0 0...

  • Page 19: Unit Orientation

    RZ Series Feature String Nomenclature A K A Q - J 0 0 - B F T 0 M - 0 0 0 0 0 - Q F - A 0 A A N 0 - A RZ A - 145 - D...
  • Page 20 RZ Series Feature String Nomenclature A K A Q - J 0 RZ A - 145 - D 0 - 3 - C A B 0 A - 0 0 0 0 0 : N 0 - A 0 - B F T 0 M - 0 0 0 0 0 - Q F - A 0 A A...

  • Page 21: Rz Series Feature String Nomenclature

    RZ Series Feature String Nomenclature 0 - 3 - C A B 0 A - 0 0 0 0 0 : N 0 - A A K A Q - J 0 0 - B F T 0 RZ A...
  • Page 22 RZ Series Feature String Nomenclature 0 - 3 - C A B 0 A - 0 0 0 0 0 : N 0 - A A K A Q - J 0 0 - B F T 0 0 0 0 0 0 -...
  • Page 23 RZ Series Feature String Nomenclature 0 - 3 - C A B 0 A - 0 0 0 0 0 : N 0 - A A K A Q - J 0 0 - B F T 0 M - 0 0 0 0 0 -...
  • Page 24 RZ Series Feature String Nomenclature 0 - 3 - C A B 0 A - 0 0 0 0 0 : N 0 - A A K A Q - J 0 0 - B F T 0 M - 0 0 0 0 0 - Q F -...
  • Page 25 RZ Series Feature String Nomenclature 0 - 3 - C A B 0 A - 0 0 0 0 0 : N 0 - A A K A Q - J 0 0 - B F T 0 M - 0 0 0 0 0 - Q F - A 0 A A...

  • Page 26: Safety Options

    RZ Series Feature String Nomenclature 0 - 3 - C A B 0 A - 0 0 0 0 0 : N 0 - A A K A Q - J 0 0 - B F T 0 M - 0 0 0 0 0 - Q F - A 0 A A...
  • Page 27 RZ Series Feature String Nomenclature 0 - 3 - C A B 0 A - 0 0 0 0 0 : N 0 - A A K A Q - J 0 0 - B F T 0 M - 0 0 0 0 0 - Q F - A 0 A A...

  • Page 28: Cabinet Options

    RZ Series Feature String Nomenclature 0 - 3 - C A B 0 A - 0 0 0 0 0 : N 0 - A A K A Q - J 0 0 - B F T 0 M - 0 0 0 0 0 - Q F - A 0 A A...
  • Page 29 RZ Series Feature String Nomenclature 0 - 3 - C A B 0 A - 0 0 0 0 0 : N 0 - A A K A Q - J 0 0 - B F T 0 M - 0 0 0 0 0 - Q F - A 0 A A...

  • Page 30: Warranty

    Corrosion Protection + Shrink Wrap 30: Miscellaneous Options (cont.) X = SPA + Premium AAON Gray Paint Exterior S = Additional Vestibule Heater Z = SPA + Premium AAON Gray Paint Exterior + T = Option A + S Interior Corrosion Protection 31: BLANK...

  • Page 31: General Information

    Certified as a forced air heating system 3500 meters (11,500 ft). with or without cooling. b. RZ Series hot water coils are designed for operation with no more than 82.2°C WARNING (180°F) water at a 1034 kpa (150 psig) working pressure.

  • Page 32: Codes And Ordinances

    Codes and Ordinances WARNING The RZ Series has been tested and certified by Intertek (ETL) to the following safety standards: Coils and sheet metal surfaces present sharp edges and care must be ANSI Z21.47-2016/CSA 2.3-2016 taken when working with this Gas-Fired Central Furnaces equipment.

  • Page 34: Storage

    A minimum 30.5 cm (12”) curb must be Installation used or the vent outlet shall be greater than AAON equipment is designed to be easily 30.5 cm (12”) off the ground/roof. installed and serviced. Flue gas is dangerously hot and contains...

  • Page 35: Curb Installation

    Left Side All roofing work must be performed by competent roofing contractors to avoid any possible leakage. Figure 2 - RZ Series Unit Orientation CAUTION Table 2 - Evaporative Condenser Unit Clearances 45-240 ton Where the supply or warm air duct...

  • Page 36: Lifting The Unit

    Lift the unit with the outside air hood in the horizontal return discharge downward shipping position. However, the applications, total height of mounting rail and unit may be lifted with the outside air hood in unit base rail must be high enough so that the open position.

  • Page 37: Figure 4 - 4 Point Lift Rz Series Air-Cooled Condenser Unit

    Figure 4 - 4 Point Lift RZ Series Air-Cooled Condenser Unit...

  • Page 38: Lifting Slot Locations Are Unit Specific

    Figure 5 - 8 Point Lift RZ Series Air-Cooled Condenser Unit Lifting slot locations are unit specific. Unit must be rigged at all marked lifting points.

  • Page 39: Duct Connection

    Duct Connection Figure 6 - Curb Mounting Figure 7 - Curb Detail Table 3 - Mounting Dimensions Tons m (ft) m (ft) m (ft) m (ft) 45-140 2.5 (8.3) 2.4 (8.0) 2.3 (7.7) 2.5 (8.1) 145-240 3.6 (11.8) 3.5 (11.5) 3.4 (11.2) 3.5 (11.6) Figure 8 - Curb &...

  • Page 40: Reassembling Split Units

    Reassembling Split Units 6. Apply butyl caulking to all seams and Some RZ Series units are built and shipped in perimeter of splice and to the perimeter of the roof splice cap against the roof of the two separate sections.

  • Page 41: Figure 11 - Staggered Assembly For Refrigeration Pipes

    2. Next remove the copper caps on each side Refrigeration Split Installation Procedure by using a pipe cutter at the brazed joint If a given unit is too large to be shipped on (Joint A and B). one truck bed, the unit must be split. If the 3.

  • Page 42: Outside Air Rain Hood

    Figure 12 - Air Hood Shown in the Open unit and environmental factors. Position End Flashing Installation On RZ Series D and E cabinet units which are CAUTION 360.7 cm (142”) wide (RZ-145, 160, 180, 200, 220, 240) the cabinet width will All wire terminations MUST BE made overhang the trailer on each side.

  • Page 43: Vestibule Exhaust Fan

    Motorized Exhaust & Rain Hood Failure to attach and seal the end of unit with Narrow (254 cm [100”]) – The motorized the flashings will result in water leakage into exhaust damper and rain hood ships inside of the curb. the return air section.

  • Page 44: Electrical

    Electrical For units not equipped with incoming power disconnect, means for all pole disconnection must be provided in the fixed wiring in accordance with local or national electrical codes. Verify the unit nameplate agrees with power supply. Connect power and control field wiring as shown on the unit specific wiring diagram provided laminated and attached to the door in the controls compartment.

  • Page 45: Figure 16 - Power Block

    premature failure. The maximum allowable Note: All units are factory wired for imbalance is 2%. 208/230V, 460V, or 575V. If unit is to be connected to a 208V supply, the transformer Voltage imbalance is defined as 100 times the must be rewired to 208V service. For 208V maximum deviation from the average voltage service interchange the yellow and red divided by the average voltage.

  • Page 46: Condensate Drain Piping

    Variable Speed Compressors the frequency range specified in this Variable speed compressors with VFD speed manual voids all warranties and may control are standard on RZ Series units. result in compressor failure. Variable speed compressors must not be operated below 50 Hz.

  • Page 47: Draw-Through Coils

    Condensate drain trapping and piping must Blow-through coils will have a positive static conform to all applicable governing codes. pressure in the drain pan. The condensate piping on Drainage of condensate directly onto the these drain pans must be trapped to prevent pressure roof may be acceptable in certain areas, refer loss through the drain.

  • Page 48: Blow-Through Coils

    Table 8 - Draw-Through Drain Trap Dimensions (Imperial) The bottom of the leaving pipe must be at least one half inch lower than the bottom of the drain Draw-Through pan connection. This ensures proper drainage Drain Pan Trap Dimensions when the unit is not running. Pressure Negative Static Note: It may be necessary to fill the trap...

  • Page 49: Startup (See Back Of The Manual For Startup Form)

    Table 10 - Blow-Through Drain Trap Dimensions (Imperial) without filters will result in clogged cooling and heating Blow-Through coils. Drain Pan Pressure Trap Dimension Positive Static (inches of water) (inch) Figure 19 - Top Clip and Side Spring Fastener Securing Filters in Place CAUTION Before completing startup and leaving the unit a complete operating cycle...

  • Page 50: Airflow Balancing And Checking

    Once the band has Curved Fans been inserted into the slots, it MUST BE RZ Series units are equipped with direct drive secured by bending the tabs over from the backward curved fan assemblies that are...

  • Page 51: Table 11 - Plenum Fan Set Screw Specifications

    required torque setting then tighten the first If the band is field installed, a hand held pop- set screw to the full required torque setting. rivet tool is recommended for connecting the band ends together. Caution must be taken to Table 11 - Plenum Fan Set Screw Specifications assure that the band is tightly installed and no SET SCREW...

  • Page 53: Back Draft Damper Setup

    Adjusting Refrigerant Charge Back Draft Damper Setup Adjusting the charge of a system in the field The counter balance is shipped loose and may must be based on determination of liquid sub- need to be installed during start-up on some cooling and evaporator superheat.
  • Page 54 Checking Evaporator Superheat reheat (dehumidification) mode to check for Measure the temperature of the suction line correct operation. close to the compressor. Units equipped with heat pump options must Read gauge pressure at the suction line close be charged in heating mode to get the proper to the compressor.

  • Page 55: Table 12 - Acceptable Fin & Tube Sub-Cooling And Superheat Temperatures

    - Acceptable Fin & Tube Sub-Cooling and Superheat Temperatures Table 12 Air-Cooled Condenser (Metric) Air-Cooled Condenser (Imperial) Sub-Cooling 4.4-8.3°C / 1.1- Sub-Cooling 8-15°F / 2-4°F 2.2°C (HP)* (HP)* Sub-Cooling with 4.4-8.3°C /1.1- Sub-Cooling with Hot 8-15°F /2-6°F Hot Gas Reheat 3.3°C (HP)* Gas Reheat (HP)*...

  • Page 56: Freeze Stat Startup

    Table 14 - Acceptable Microchannel Air-Cooled Condenser Coil Liquid Sub-Cooling Values (Imperial) Cooling Mode Liquid Sub-Cooling Values(°F) Evaporator Coil Saturation Temperature (°F) Ambient (°F) 9 - 14 8 - 13 8 - 13 7 - 12 5 - 10 10 - 15 9 - 14 9 - 14 8 - 13...

  • Page 57: Table 15 - Minimum Airflow And Room Areas

    Table 15 – Minimum Airflow and Room Areas Minimum Room Area in m Charge in kg Min Airflow in 1.8 m (6 ft) 2.2 m (7.2 ft) 3 m (10 ft) 3.7 m (12 ft) (oz) /h (CFM) release release release release height...

  • Page 58: Table 16 - Minimum Airflow And Room Areas (Continued)

    Table 16 – Minimum Airflow and Room Areas (continued) Minimum Room Area in m Charge of Largest Min Airflow in 2.2 m (7.2 ft) 3 m (10 ft) 1.8 m (6 ft) 3.7 m (12 ft) Circuit in kg /h (CFM) release release release...

  • Page 59: Table 17 - R-454B Refrigerant Temperature-Pressure Chart (Metric)

    Table 17 - R-454B Refrigerant Temperature-Pressure Chart (Metric) °C °C °C °C °C 1348.0 38.3 2034.6 -6.7 484.5 843.3 23.3 53.3 2946.9 1370.0 38.9 2064.1 -6.1 495.6 859.3 23.9 53.9 2985.7 1392.2 39.4 2093.9 -5.6 506.9 875.3 24.4 54.4 3024.9 1414.6 40.0 2123.9 55.0 -5.0...

  • Page 60: Refrigerant Filter Driers

    Table 18 - R-454B Refrigerant Temperature-Pressure Chart (Imperial) °F °F °F °F °F PSIG PSIG PSIG PSIG PSIG 427.4 70.3 122.3 195.5 295.1 433.0 71.9 124.6 198.7 299.4 73.5 127.0 201.9 303.7 438.7 75.2 129.3 205.2 308.0 444.5 76.8 131.7 208.5 312.5 450.3...

  • Page 61: Suction Filter Removal Instructions

    In an effort to help protect the compressors from contaminants during testing and startup, AAON factory installs pleated replaceable core suction line filters on the RZ Series. 5. Remove the pleated filter assembly Figure 27 - RPE-48-BD filter element One month after startup, remove the RPE-48- 6.

  • Page 62: Low Sound Condenser Fan Ec Motor Startup

    Low Sound Condenser Fan EC Motor 7. Evacuate the suction filter assembly Startup to 300 microns AAON Condenser Head Pressure Module is 8. Open both shut-off valves used for variable speed control of the motor to maintain a head pressure. The motor must...

  • Page 63: Operation

    The indoor blower, and any form of heat other than gas, Additional mitigation procedures or fault will resume normal operation. RDS alarm conditions initiated outside of AAON outputs available BACNet controls are the responsibility of the...

  • Page 64: Direct Fire Unit With Return Air Gas Heater Operation

    burners again. Should no flame be detected after 3 WARNING tries, the ignition control will lock out the system. Power to the ignition control shall be cycled to COMPRESSOR CYCLING reset the heater control. 3 MINUTE MINIMUM OFF TIME On a fault the gas train is shut down by a main limit prevent motor overheating...

  • Page 65: Electric Heating Operation

    4. When pilot flame is proven, the sparker is deactivated, main gas valve 1 and 2 are opened and the vent valve is closed. 5. The pilot valve is deactivated after a 10 second main flame establishing time. 6. The modulating gas valve can modulate to maintain capacity based on 0-10 VDC input to the modulating gas valve controller (the modulating gas valve...

  • Page 66: Maintenance

    Maintenance Recommended greases are: (See back of the manual for maintenance SHELL OIL - DOLIUM R log) CHEVRON OIL - SRI No. 2 TEXACO INC. - PREMIUM RB At least once each year, a qualified service technician must check out the unit. Fans, DX Cooling evaporator coils and filters must be inspected Set unit controls to cooling mode of operation...

  • Page 67: Air-Cooled Condenser

    689.5 kpa (100 psig) to warranty coverage for fin and tube and avoid damaging the fin edges. An elevated microchannel coils. See the AAON E- water temperature (not to exceed 54.4°C Coated Coil Maintenance Record sheet.
  • Page 68 The Enviro-Coil Cleaner: AAON PN: V82540 force of the water or air jet may bend the fin edges and increase airside GulfClean ™ Coil Cleaner ; AAON PN: Reduced unit pressure drop. G074480...

  • Page 69: Microchannel Coil Cleaning

    These chemicals have been tested for performance and safety and are the only Rinse - Using pressurized potable water such chemicals that AAON will warrant as correct as a garden hose, (< 689.5 kpa [100 psi]), for cleaning microchannel coils.

  • Page 70: Refrigerant Removal And Evacuation

    5. Repeat as necessary. warranty. #2 Water Flush AAON testing has determined that unless a This procedure can be used when the only chemical has a neutral pH (6-8) it must not be material to cause the coil to need cleaning is used.

  • Page 71: Options

    Work is to be undertaken under a controlled The recovery equipment must be in good procedure to reduce the amount of refrigerant working order with a set of instructions vapor present while work is being performed. concerning the equipment that is at hand. All maintenance staff and others working in Ensure that equipment is suitable for the the area are to be instructed on the nature of...

  • Page 72: Chilled Water Coil

    WARNING All valve controls for heating operation are Piping, pressure limiting devices, field supplied and field installed. Hot backflow preventers and all other waterand steam coil connections are spun safety requirements shall copper tube. accordance with national and local codes. Water coils must not be subjected to entering air temperatures below 3.3°C (38°F) to prevent coil freeze-up.

  • Page 73: Table 24 - Min And Max Water Pressures And Temps

    Table 24 - Min and Max Water Pressures and Temps Chilled Water Hot Water Min. Entering Air 15.6°C (60°F) 4.4 °C (40°F) Max Entering Air 37.8°C (100°F) 26.7°C (80°F) Min. Entering Water 1.7°C (35°F) 60°C (140°F) Max Entering Water 18.3°C (65°F) 93.3°C (200°F) Min.

  • Page 74: Note: Multiple Units With Multiple Unit Controllers

    units must be switched off during the heating time to clear any liquid accumulation out of season. the compressor before it is started. Evaporator Coil Always control the unit from the control panel, never at the main power supply, except WARNING for emergency or complete shutdown of the unit.

  • Page 75: Evaporative Condenser

    Remove the screws that attach the orifice to Connect the suction and liquid copper the condenser assembly. connections to the evaporator coil. Reinstall the expansion valve bulbs and/or the valve With the wires disconnected and the screws controller on the suction lines. removed, the fan, motor and orifice assembly can be lifted off the unit.

  • Page 76: Performance

    WARNING WARNING Batch-loading chemicals into the unit The evaporative condenser must be is NOT PERMITTED. The control thoroughly cleaned on a regular basis system must regulate the chemical to minimize the growth of bacteria, feed. including Legionella Pneumophila, to avoid the risk of sickness or death. Service personnel must wear proper Evaporative Condenser Location The recirculating water system contains...

  • Page 77: Temporary Drain-Evaporative Condenser

    Cleanliness enter the sump tank during transportation. Dirt and debris may accumulate in the sump AAON provides a temporary drain system during shipping and storage. The sump must while the unit is in transit. The temporary be cleaned prior to start-up to prevent drain consist of an adapter that will connect a clogging the water distribution system.

  • Page 78: Pump Operation

    If the water in the sump is below the low probe, it will not allow the condenser pump Condenser Fan Motors or the sump heater to operate. It will activate The direct-drive condenser motors on AAON the makeup water solenoid to try to fill the evaporative condensers 1200-rpm sump assuming water is flowing to the unit.

  • Page 79: Water Treatment System

    Never use Water Treatment System hydrochloric acid (muriatic acid) as it will All AAON evaporative condensers come corrode stainless steel. equipped with a water treatment system that must be maintained by a local water...

  • Page 80: Figure 32 - Evaporative Cooled Condenser

    Figure 32 – Evaporative Cooled Condenser...

  • Page 81: Storage

    A sensor measures the water temperature in rotating element free and bearings fully the pump discharge line. If the sump water functional. temperature exceeds 40.6°C (105°F), the For long term storage, the pump must be cooling system will be shut down thereby placed in a vertical position in a dry preventing damage to the evaporative environment.

  • Page 82: Bearings - Lubrication

    12. If the issues persists, repeat these steps as six (6) months thereafter. If a leak is found, needed. use the following steps to adjust the fit of the door. This process will require at least two (2) Bearings - Lubrication people.

  • Page 83: Air Inlet

    Do not attempt to mechanically clean the heat of rejection is accomplished with the copper tubing in the evaporative condenser. desuperheater. Water usage of the AAON Do not use wire brushes or any other evaporative condenser is approximately 22% mechanical device on the copper tubing.
  • Page 84 less than evaporative condensers Evaporation Rate equipped with a desuperheater. One method of calculating evaporation and = 2.19 gpm bleed in gallons per minute (gpm) is shown as follows: Assuming 4 cycles of concentration: Evaporation Rate 2.19 Bleed Rate 4−1 = 0.73 gpm Bleed Rate Example:...

  • Page 85: Energy Recovery Units

    Energy Recovery Units performance. Some RZ Series units have been equipped with an energy recovery wheel. AAON Controls provides options for either an aluminum variety controls electrical energy recovery wheel or a polymer energy accessories may be provided with the recovery wheel.

  • Page 86: Wheel Set Purge Angle

    warm, moist air stream to the cooler and/or drier air stream. The initial setup and servicing of the energy recovery wheel is very important to maintain proper operation efficiency and building occupant comfort. Normal maintenance requires periodic inspection of filters, the cassette wheel, drive belts, air seals, wheel drive motor, and its electrical connections.

  • Page 87: Wheel Check Purge Seal

    1. Loosen the three purge adjusting screws. 2. Adjust purge sector to the specified If it is necessary to adjust a purge seal to the angle. face of the wheel, loosen the two or three screws along the bearing beam and adjust to the proper distance from the media surface.

  • Page 88: Wheel To Air Seal Clearance

    energy transfer segments must be accessible Wheel to Air Seal Clearance for service and maintenance. This design To check wheel to seal clearance; first requires that adequate clearance be provided disconnect power to the unit, in some units outside the enclosure. Where cassettes are the energy recovery wheel assembly can be permanently installed in a cabinet, access to pulled out from the cabinet to view the air...

  • Page 89: Wheel Startup Procedure

    Wheel Startup Procedure CAUTION Keep hands away from rotating wheel! Contact with rotating wheel can cause physical injury. By hand, turn wheel clockwise (as viewed from the pulley side), to verify wheel turns freely through 360º rotation. Before applying power to drive motor, Diameter Seal Adjustment confirm wheel segments are fully engaged in wheel frame and segment...

  • Page 90: Wheel Drive Components

    Wheel Drive Components The wheel drive motor bearings are pre- lubricated and no further lubrication is necessary. The wheel drive pulley is secured to the drive motor shaft by a combination of either a key or D slot and set screw. The set screw is secured with removable locktite to prevent loosening.

  • Page 91: Figure 35 - Polymer Wheel Segment Removal Pattern

    1. Disconnect power from the wheel. 2. Gain access to the wheel and slide wheel frame out of cabinet. 3. Unlock two segment retainers (one on each side of the selected segment opening. 4. With the embedded stiffener facing the motor side, insert the nose of the segment between the hub plates.

  • Page 92: Wheel Drive Motor And Pulley Replacement

    Wheel Drive Motor Pulley CAUTION Replacement Disconnect power to wheel drive motor. Protect hands and belt from possible Remove belt from pulley and position sharp edges of hole in Bearing temporarily around wheel rim. Support Beam. Loosen set screw in wheel drive pulley using a hex head wrench and remove pulley from motor drive shaft.

  • Page 93: Table 25 - Energy Recovery Wheel Cleaning Frequency

    Class 1 air has low contaminant concentration Energy Recovery Wheel General Cleaning with inoffensive odor and sensory irritation Routine maintenance of the Energy Recovery intensity. Wheel includes periodic cleaning of the Class 2 air has moderate contaminant Energy Recovery Wheel as well as inspection concentration, with mildly offensive odors or of the Air Seals and Wheel Drive sensory-irritation intensity.

  • Page 94: Aluminum Wheel Cleaning

    ventilation of machine shop areas for CAUTION example, annual washing of energy transfer may be necessary to maintain latent transfer Disconnect electrical power before efficiency. Proper cleaning of the energy servicing energy recovery cassette. recovery wheel will restore latent Always keep hands away...

  • Page 95: Gas Or Electric Heating

    Soak in the solution until grease and tar deposits are loosened (Note: some staining of the desiccant may remain and is not harmful to performance). Before removing, rapidly run finger across surface of segment to separate polymer strips for better cleaning action.

  • Page 96: Table 26 - Rz 45-140 Ton Electric Heating Capacities

    Prolonged overheating of the heat exchanger Table 27 - RZ 45-140 ton Gas Heating Capacities Gas Heat Model will shorten its life. Option B3 Capacity If unit has not been selected as a 100% Input Output outside air unit (makeup air unit) the return (MBH) (MBH) air duct must be sealed to the unit and the...

  • Page 97: Gas Heating

    (Canada) National Fuel & Propane Gas Heating Installation Code CSA B149.1 or B149.2. WARNING After verifying gas inlet pressure and manifold pressure the service technician shall FOR YOUR SAFETY time the gas flow rate through the gas meter Read entire heating with a stopwatch to verify the gas input rate.

  • Page 98: Table 33 - Rz 145-240 Ton Unit Gas Piping Connections

    Table 33 - RZ 145-240 ton Unit Gas Piping Connections Connections RZ Medium See unit nameplate for unit gas heating Gas Input capacities or the Unit Rating Sheet, which can Quantity Size (MBH) obtained from AAON sales representative. 1200 1600 2-1/2” 2000 2400 3100 3800 3” 4500 Note: 2 1/2”...

  • Page 99: Table 37 - (Imperial) Propane (Kbtu/Hr) Maximum Piping Capacities

    Table 37 – (Imperial) Propane (kBtu/hr) Maximum Piping Capacities Specific Gravity = 1.52, Supply Pressure = 0.34 psi, Pressure Drop, 0.5” w.c. Length of Pipe Pipe Size 20 ft 50 ft. 100 ft. 150 ft. 200 ft. 1-1/4” 1495 1-1/2” 2295 1415 2”...

  • Page 100: Table 38 - Piping Support Intervals (Metric)

    19.1 to 25.4 Every 2.4 m 44.5 or Larger Every 3 m AAON gas fired heat exchangers are (Horizontal) designed to be non-condensing. These heat 31.8 or Larger Every Floor exchangers are mounted downstream of the Table 39 - Piping Support Intervals cooling coils.
  • Page 101 condensate is generally between a 2.9 and 4 pH level. DANGER Do not use open flame or other source Condensation made in the heat exchanger of ignition for leak testing. Fire or during the heating mode may need to be explosion could result...

  • Page 102: Figure 38 - Gas Heater Rain Hood

    Rain Hoods Gas heating units include factory provided exterior rain hoods. The hoods are fastened in place with sheet metal screws. Higher heating capacity units will have two banks of gas fired heat exchanges (see Figure 37). All of the provided hoods shall be installed after the unit is set in place.
  • Page 103 Gas Heater Operating Instructions...
  • Page 104 Cleaning shall only be done by a to the heating mode of operation. qualified service agency and only after consultation with AAON service The combustion ventilation motor will representative. enable. The control will automatically supply If induced draft blower/motor assembly has power to the igniter and the gas valve after the heating call is made.

  • Page 105: Direct Fired Gas Heating

    Gas Heat Exchanger Removal WARNING Electric shock hazard. Shut off all electrical power to the unit to avoid shock hazard or injury from rotating parts. DANGER Figure 40- Gas Heat Exchanger LEAK CHECK GAS PIPE The gas pipe in the unit shall be Attach the heat exchanger to the bulkhead checked for leaks before operation using the holes around the perimeter.

  • Page 106: Table 40- Maximum Temperature Rise Setpoint For Return Air Units

    Inlet and Manifold Pressures Direct Fire Units with Return Air - For units with Direct Fire Heat, the Recirculating Operating Limits minimum inlet gas pressure to the unit is Minimum return temperature -40°F 13.8 kpa (2 psi) and maximum inlet gas Maximum return temperature 35°C (95°F) pressure to the unit is 34.5 kpa (5 psi).
  • Page 107 6. The modulating gas valve can modulate The burner comes with a pilot to ignite the to maintain capacity based on 0-10 VDC flame and the pilot includes an adjustable input to the modulating gas valve orifice. An ignition transformer and spark controller (the modulating gas valve igniter provide the spark to ignite the pilot controller sends a 0-20 VDC signal to the...
  • Page 108 checked by authorized service technician. Direct Fired Initial Start-up Procedure: Check the condition of the mixing plates, 1. Bleed air from main gas line. burner body drillings, as well as the general 2. Verify proper incoming gas pressure. mechanical installation of the burner and a.

  • Page 109: Figure 42 - Removing Piping Scale With Pin Vise

    Inspection and Maintenance of Gas Ports: There is an observation viewport window 1. Conduct an initial inspection within the in the gas piping compartment. first month after commissioning. Visually 9. Observe the flame pattern and take any check the gas ports of new burner necessary steps to correct any velocity assemblies for any piping scale or debris.

  • Page 110: Phase And Brownout Protection Module

    the setpoint parameters and the left arrow to Phase and Brownout Protection Module backup if needed. When each parameter is displayed use the up/down keys to change and set the parameter. After adjustments are made or if no adjustments are made it will take 2 to 4 minutes before the DPM energizes the output relay unless there is an out of tolerance issue with the incoming line voltage.

  • Page 111: Average Voltage Screen

    Screens Average Voltage Screen Manufacturer’s Screen VAvg R-K Electronics DPM v0.0.00 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 112: Uv Lights

    Useful lamp life shall be 9000 hours (minimum) with no more than a 15% output loss at the end of the lamps life. Use AAON Part # R68860 for lamp replacement. Table 41- Air Disinfection UV Information Estimated...

  • Page 113: Filter Replacement

    Filter Replacement Monthly air filter inspection is required to maintain optimum unit efficiency. Replace filter media monthly. Filters are located upstream of the evaporator coil in the filter and economizer section. Open access door and pull filters straight out to inspect all of the filters. Replace filters with the size indicated on each filter or as shown in Table 42.

  • Page 114: Table 42 - Rz Series Filter Sizes

    Table 42 - RZ Series Filter Sizes 4” Filters OR Cartridge Filters 32” Bag Filters Unit Tonnage MERV 8 Filters Box A Box B Box C Box A Box B Box C Air Cooled Evaporative Condenser Condenser (24) 16x24 38,400 cfm...

  • Page 115: Table 43 - Metal Mesh And Hepa Filter Sizes

    Filter Conversion Table Inches Centimeters [16 x 20 x 4] [40.6 x 50.8 x 10.2] [16 x 24 x 4] [40.6 x 61 x 10.2] [40.6 x 63.5 x 10.2] [16 x 25 x 4] [50.8 x 61 x 10.2] [20 x 24 x 4] [50.8 x 50.8 x 2.5] [20 x 20 x 1]...

  • Page 116: Replacement Parts

    Replacement Parts Ensure any equipment that may be needed Always use AAON specified parts. Parts for for handling refrigerant cylinders safely is AAON equipment may be obtained from you available. Equipment and cylinders used for local AAON representative. When ordering...
  • Page 117 Warranty Refer to the Limited Warranty Certificate for the unit warranty details. Contact your AAON representative for a unit specific copy of the certificate for your serial number.

  • Page 119: Appendixa - 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 120 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 121: Appendixb - Thermistor Temperature Vs . Resistance Values

    Appendix B - Thermistor Temperature vs. Resistance Values Deg C Deg F Resistance (kOhms) Deg C Deg F Resistance (kOhms) 2889.6 15.07 2087.22 12.73 1522.20 10.79 1121.44 9.20 834.72 7.87 627.28 6.77 475.74 5.85 363.99 5.09 280.82 4.45 218.41 3.87 171.17 3.35 135.14...

  • Page 122: Rz Series Startup Form

    RZ Series Startup Form Date: Job Name: Job Address: Model Number: Serial Number: Tag: Startup Contractor: Contractor Address: Phone: Pre Startup Checklist Installing contractor must verify the following items. 1. Is there any visible shipping damage? 2. Is the unit level? 3.
  • Page 123 Supply Fan Assembly Alignment Check Rotation Nameplate Amps Number L1 Volts/Amps L2 Volts/Amps L3 Volts/Amps VFD Frequency VAV Controls Energy Recovery Wheel Assembly Wheel(s) Spin Freely Check Rotation Number L1 Volts/Amps L2 Volts/Amps L3 Volts/Amps Power Return Assembly Alignment Check Rotation Nameplate Amps Number L1 Volts/Amps...
  • Page 124 Outside Air/Economizer Dampers Operation Check Damper Actuator Type: Economizer Changeover Type and Operations: Damper Wiring Check Gears Check Unit Configuration Water-Cooled Condenser Air-Cooled Condenser No Water Leaks Evaporative Condenser Condenser Safety Check Water Flow Water Inlet Temperature °F Water Outlet Temperature °F Compressors / DX Cooling Head...
  • Page 125 Ambient DB Temperature __________°C/°F Ambient WB Temperature ______°C/°F Coil Entering Air DB Temperature _______°C/°F Coil Entering Air WB Temp ______°C/°F Coil Leaving Air DB Temperature _______°C/°F Coil Leaving Air WB Temp _______°C/°F Refrigeration System 1 Saturated Line Pressure Sub-cooling Superheat Temperature Temperature Discharge...
  • Page 126 Condenser Fans Alignment Check Rotation Nameplate Amps Number L1 Volts/Amps L2 Volts/Amps L3 Volts/Amps VFD Frequency Evaporative Condenser Pumps Check Rotation Number L1 Volts/Amps L2 Volts/Amps L3 Volts/Amps Water/Glycol System 1. Has the entire system been flushed and pressure checked? 2.
  • Page 127 Gas Heating Natural Gas Propane Purge Air from Lines Verify Pilot Spark Stage Manifold Pressure (w.c.) inlet Manifold Pressure (w.c.) outlet Electric Heating Stages Limit Lockout Aux. Limit Lockout Stage Volts/Amps...
  • Page 128 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 129: Maintenance Log (E-Coated Coil)

    Maintenance Log (E-Coated Coil)

  • Page 130: Literature Change History

    November 2023 Start of new UL 60335 version of RZ series IOM. Added New UL 60335 tables and standard. Added 35 and 65 KAIC tables. Add Min and Max Water temps and pressures table. Added 454B Pressure Temperature charts as well as metric and imperial versions of 410A and 454B. Add new warning labels.
  • Page 131 September 2024 Added text providing details to the RDS mitigation board operation.

  • Page 136: Aaon

    Maintenance G147570 · Rev. B · 240926 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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