Table of Contents
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Vertical Self-Contained Units and
Installation, Operation
WARNING
QUALIFIED INSTALLER
Improper
installation,
alteration, service or maintenance
can
cause
property
personal injury or loss of life. Startup
and service must be performed by a
Factory Trained Service Technician.
A copy of this IOM should be kept
with the unit.
Indoor Air Handling Units
& Maintenance
adjustment,
damage,
SA SERIES
WARNING
If the information in this manual is not
followed exactly, a fire or explosion
may result causing property damage,
personal injury or loss of life.
WARNING
FOR YOUR SAFETY
Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of this or any other appliance.
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Table of Contents
Related Manuals for AAON SA-023
Summarization of Contents
Safety and Warnings
General Safety Statements
Defines NOTE, CAUTION, WARNING, and DANGER statements for user guidance.
Electrical, Fire, and Explosion Hazards
Highlights risks of electric shock, fire, and explosion, emphasizing proper servicing.
Equipment Handling and System Safety
Live Electrical Components and Grounding
Precautions for working with live electrical parts and grounding requirements.
Unit Handling and Rotating Component Safety
Guidance on safe unit lifting and warnings about rotating fan parts.
Freezing Temperature Coil Protection
Cautionary note on draining coils to prevent damage in freezing temperatures.
Operational Safety Precautions
Motor Rotation and Water Pressure Safety
Checks for motor rotation and water pressure limits to prevent damage.
Refrigerant Gas and Coil Cleaning Safety
Warnings about handling refrigerant gases and cleaning coil components.
Material and System Specific Hazards
Chemical Coil Cleaning and Material Compatibility
Precautions for chemical cleaners and compatibility with PVC/CPVC piping.
Open Loop, Water Freezing, and Condenser Hazards
Risks associated with open loop systems, freezing, and condenser chemicals.
Compressor Operation and Startup Safety
Compressor Cycling Limits
Minimum on/off times and maximum cycle rate for compressor longevity.
Startup, Service, and Unit Identification
Requirements for qualified technicians and referencing unit nameplate.
SA Series Feature String Nomenclature
Unit Size, Voltage, and Configuration Options
Details on unit sizes, voltage options, and general unit configuration.
Refrigerant, Coil, and Staging Options
Selection of refrigerant types, coil configurations, and cooling/heat pump staging.
Feature String Details
Heating, Airflow, and Discharge Configurations
Specifies heating types, plenum heights, and discharge configurations.
Economizer and Maintenance Options
Details on waterside economizer options and maintenance features.
SA Series Feature String Options
Supply Air Blower and Filter Specifications
Options for supply fan configuration, motor, and filter types.
Refrigeration Controls and Accessories
Selection of refrigeration control methods and accessory options.
Advanced Feature String Options
Special Controls and Water-Cooled Condensers
Options for specialized controls and water-cooled condenser configurations.
Economizer and System Options
Economizer Piping, Glycol, and Cabinet Options
Details on economizer piping, glycol percentage, and interior cabinet options.
Code Compliance and Shipping Options
Information on code options, crating, shipping splits, and control vendors.
General Information and Unit Setup
Unit Overview and Design Features
Description of SA Series units, their components, and intended use.
Codes, Standards, and Grounding Requirements
Adherence to industry codes, standards, and electrical grounding.
Unit Receiving and Nameplate Verification
Procedures for inspecting units upon receipt and checking nameplate data.
Storage and System Specifics
Equipment Storage Recommendations
Guidelines for storing units prior to installation.
Direct Expansion (DX) Systems Overview
Information on DX systems, components, and compressor cycling.
Crankcase Heater Operation and Safety
Details on crankcase heater function and precautions during power interruption.
Unit Specifications and Drains
Wiring Diagrams and Condensate Drain Pans
Location of wiring diagrams and requirements for condensate drain pans.
Unit Size and Model Configurations
Modular unit composition and available standard unit sizes.
Installation Procedures
Locating the Unit and Service Clearances
Considerations for unit placement, leveling, and required service access.
Lifting and Handling the Unit Safely
Guidelines for safe lifting, including test lifts and securing cables.
Unit Lifting Details
One Piece Single Unit Lifting Configurations
Diagrams illustrating lifting procedures for one-piece single units.
Two Piece Unit Lifting Details
Two Piece Single Unit Coil Section Lifting
Diagrams for lifting two-piece single units, coil section.
Fan Section Lifting Details
Two Piece Single Unit Fan Section Lifting
Diagrams for lifting two-piece single units, fan section.
Dual Unit Lifting Configurations
One Piece Dual Unit Lifting Procedures
Diagrams showing lifting methods for one-piece dual units.
Two Piece Dual Unit Lifting Procedures
Two Piece Dual Unit Coil Section Lifting
Diagrams for lifting two-piece dual units, coil section.
Dual Unit Fan Section Lifting Details
Two Piece Dual Unit Fan Section Lifting
Diagrams for lifting two-piece dual units, fan section.
Split Unit Assembly
General Assembly and Shipping Cover Removal
Instructions for assembling split units and removing shipping covers.
Section Alignment and Fastening
Steps for aligning and securing coil and fan sections.
Dual Unit Assembly Details
Dual Unit Splice and Fastener Details
Diagrams showing dual unit assembly, splices, and bolt details.
Dual Unit Splice Connections
Dual Unit Bolted Splice Connections
Illustration of dual units with completed splice connections.
Heat Exchanger Information
Refrigerant-to-Water Heat Exchanger Overview
Description of heat exchangers and waterside piping requirements.
Open Loop Applications and Corrosion Risks
Warnings about chlorides in open loop systems and corrosion potential.
Water Freezing Hazards in Heat Exchangers
Risks and damage caused by water freezing within heat exchangers.
Water System Management
Water Freezing Damage and Glycol Solutions
Consequences of freezing and recommendations for glycol solutions.
Water Piping Installation and Flow Control
Requirements for installing water piping, including pressure switches.
Condenser Water Connections and Piping
Condenser Water Connection Sizes
Table specifying connection sizes for different SA Series models.
Water Piping Safety and System Flushing
Safety guidelines for water piping installation and system flushing.
Heat Exchanger Pressure and System Components
Heat Exchanger Pressure Relief Devices
Information on pressure relief devices and routing relief piping.
Condenser Water System Balancing
Recommendations for balancing valves and system pressure ports.
Condenser Pressure Drop Data
Table showing pressure drops for various flow rates across heat exchangers.
Cleaning, Electrical, and Control Systems
Brazed Plate Heat Exchanger Cleaning Procedures
Methods for cleaning brazed plate heat exchangers using cleaning liquids.
Electrical Safety and Wiring Connections
Safety warnings for electrical work and details on power connection.
Electrical Installation and Safety
Cutting Electrical Openings Safely
Procedure for cutting openings for electrical entries and sealing them.
Electrical Grounding and Voltage Requirements
Guidance on grounding, voltage supply, and transformer wiring.
Voltage Imbalance and Motor Protection
Effects of voltage imbalance on motors and protection measures.
Control Wiring and Motor Checks
Motor Rotation and VFD Safety Checks
Ensuring correct motor rotation and VFD safety during operation.
Thermostat Control Wiring Guidelines
Recommendations for thermostat placement and control wiring distances.
Duct and Drain Piping Connections
Duct Connection Sizing and Materials
Guidelines for sizing duct connections and recommended materials.
Condensate Drain Piping Installation
Instructions for installing condensate drain piping with p-traps.
Economizer System Operation
Waterside Economizer Operation Modes
Details on the three operating modes of the waterside economizer.
Economizer Coil Condensate Drainage
Information on condensate drainage from the economizer coil.
Economizer Piping Installation
Waterside Economizer Piping Kit Installation
Instructions for connecting factory-provided piping assemblies.
Economizer Piping Diagrams
Air Conditioner Economizer Piping Diagram
Diagram illustrating the piping for air conditioner waterside economizers.
Heat Pump Economizer Piping Diagram
Water-Source Heat Pump Economizer Piping
Diagram showing piping for heat pump waterside economizers.
Coil and Fan System Installation
Hot Water and Chilled Water Coil Installation
Guidelines for installing hot water and chilled water coils.
Unit Startup Procedures Overview
Key checks required during unit startup, including airflow and charge.
Supply Fan Spring Isolator Adjustment
Procedure for adjusting spring isolators to ensure proper blower operation.
Spring Isolator Adjustment Details
Detailed Spring Isolator Adjustment Steps
Step-by-step guide for adjusting spring isolators for vibration attenuation.
Fan Maintenance and Airflow
Supply Fan Removal Safety Precautions
Safety warnings and steps for removing the supply fan assembly.
Fan Airflow Adjustment Methods
Techniques for adjusting fan airflow using volume bands or VFDs.
Blower Wheel Airflow Modifications
Blower Wheel Air Band Installation
Instructions for installing or removing air bands on blower wheels.
Refrigerant Charge and Filter Management
Filter Inspection and Replacement
Importance of filter inspection and replacement for unit efficiency.
Adjusting Refrigerant Charge Procedures
Methods for determining and adjusting refrigerant charge (sub-cooling/superheat).
Refrigerant Charge Calculations
Checking Liquid Sub-Cooling
Steps to measure and calculate liquid sub-cooling for refrigerant charge.
Checking Evaporator Superheat
Steps to measure and calculate evaporator superheat for refrigerant charge.
Sub-Cooling and Superheat Adjustments
Guidance on correcting overcharged or undercharged systems.
Refrigerant Data and Freeze Stat
R-410A Refrigerant Temperature-Pressure Chart
Reference chart for R-410A refrigerant pressure and temperature relationships.
Freeze Stat Startup Configuration
Setting up the freeze stat sensor to prevent evaporator coil freezing.
Operation and Maintenance Overview
Unit Control and Operation Modes
How units are controlled and descriptions of operation modes.
Routine Maintenance Checks
Recommended periodic checks for airflow, filters, and refrigerant charge.
DX Cooling and Condensate Drain Pan Maintenance
Checks for DX cooling operation and cleaning of condensate drain pans.
Coil Cleaning and Lubrication
E-Coated Coil Cleaning Procedures
Steps for cleaning e-coated coils to maintain warranty coverage.
Approved Coil Cleaning Agents
Recommendations for cleaners suitable for e-coated coils.
Chloride Removal and Fan Lubrication
Recommended Chloride Remover Application
Instructions for using CHLOR*RID DTS to remove soluble salts.
Supply Fan Lubrication Guidelines
Recommendations for lubricating supply fan motors and bearings.
System Protection and Monitoring
Phase and Brownout Protection Module Setup
Procedure for setting up the Digital Phase Monitor (DPM).
Recommended DPM Default Settings
Default values for DPM line voltage, trip times, and imbalance.
DPM Configuration and Faults
DPM Screen Navigation and Fault Identification
How to navigate DPM screens and interpret fault words.
Filter Replacement Guide
Filter Inspection and Replacement Procedures
Monthly filter inspection and replacement guidance with size tables.
Parts and Warranty Information
Obtaining Replacement Parts
Information on how to order replacement parts from AAON representatives.
AAON Warranty and Technical Support Contact
Contact details for warranty claims and technical assistance.
Appendix A - Heat Exchanger Corrosion Resistance
Corrosion Resistance Guide for Heat Exchangers
Table detailing corrosion resistance of materials against water contaminants.
Chloride Content and Material Compatibility
Chloride Content vs. Temperature Table
Table correlating chloride levels, temperature, and material compatibility.
Startup Forms and Logs
Pre Startup Checklist
A checklist for contractors to verify unit readiness before startup.
System Performance Data Recording
Supply Fan Assembly Data Recording
Fields for recording fan alignment, rotation, amps, and VFD frequency.
Compressor and Refrigeration System Data
Fields for compressor rotation, pressures, sub-cooling, and superheat.
Refrigeration System Performance Data
Cooling and Heating Mode Performance Data
Tables for recording performance data across various refrigeration systems.
Unit Configuration and System Checks
Unit Configuration and Water/Glycol System Checks
Configuration settings and checks for water/glycol systems.
Air-Cooled Condenser Fan Data
Fields for recording air-cooled condenser fan alignment and amperage.
Maintenance Log
Unit Service and Repair Log
Log for documenting unit service, repairs, and adjustments.
Literature Change History
Document Revision History
Chronological list of updates and revisions made to the manual.
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