Table of Contents
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Vertical Indoor Air Handling Units
Installation, Operation
WARNING
QUALIFIED INSTALLER
Improper
installation,
alteration, service or maintenance can
cause property damage, 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.
& Maintenance
adjustment,
V3 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 V3-B
Summarization of Contents
Safety Information
Gas Leak Safety Procedures
Instructions for responding to the smell of gas, including immediate actions and contacting authorities.
Electrical Safety Precautions
Warnings regarding electrical shock hazards during servicing and installation, emphasizing power disconnection.
General Safety Warnings
General safety notes and definitions for CAUTION, WARNING, and DANGER statements.
Hazard Warnings and Precautions
Fire, Explosion, and CO Hazards
Warnings about fire, explosion, and carbon monoxide poisoning risks.
Electrical and Rotating Component Safety
Safety guidelines for working with live electrical components and rotating parts.
Grounding Requirements
Mandatory grounding procedures for field-installed wiring to prevent serious injury or death.
Unit Handling and System Safety
Unit Handling and Lifting Safety
Guidelines for safe lifting and handling of the unit to prevent injury or death.
Water Pressure and Coil Cleaning Safety
Warnings and cautions related to water pressure testing and chemical coil cleaning.
Motor Rotation and Electrical Safety
Cautions regarding motor rotation checks and the use of specific electrical safety practices.
Component and System Safety Guidelines
Refrigerant Coil and Foam Panel Safety
Precautions for cleaning refrigerant coils and welding/cutting foam panels to avoid hazards.
Ventilation and Refrigerant Gas Safety
Safety advice on ensuring adequate airflow and handling refrigerant or nitrogen gas leaks.
Access Door and Piping Safety
Guidelines for safe access to compartments and precautions for PVC/CPVC piping systems.
Installation and Operation Guidelines
General Installation Precautions
Key considerations for installing and operating the unit, including ventilation and component checks.
Manual and Safety Precautions
Emphasis on reading the entire manual and safeguarding literature for future reference.
V3 Series Feature String Nomenclature
Cooling and Heating Options
Details on cooling types, stages, FPI, and heating types, designations, and stages.
Supply Fan and Control Configurations
Specifications for supply air blowers, motors, and additional control options.
Refrigeration, Special, and Additional Controls
Options for refrigeration, special controls, additional controls, and mixing box configurations.
Filter, Coil, and Expansion Valve Features
Details on filter boxes, filter options, coil coatings, and expansion valve controls.
Tonnage, Energy Recovery, and Control Panel Features
Specifications for unit tonnage, energy recovery types, GPM, and control panel options.
Cabinet, Exhaust Fan, and Warranty Features
Information on energy recovery cabinet, exhaust fans, crating, pulley combinations, warranty, and unit type.
General Information
Unit Certifications and Model Types
Details on certifications for gas heat, steam/hot water heat, electric heat, and cooling models.
Warranty and Documentation
Information on the limited warranty and the importance of reading the installation manual.
Codes, Ordinances, and Receiving Unit
Codes and Standards Compliance
List of standards and codes the V3 Series units comply with, including electrical and gas codes.
Receiving Unit Inspection Procedures
Guidelines for inspecting the unit upon receipt for damage and verifying nameplate information.
Storage and Direct Expansion (DX) Systems
Unit Storage Recommendations
Guidelines for storing the equipment to prevent damage, emphasizing dry and protected areas.
DX System Operation and Crankcase Heaters
Information on DX systems, refrigerant charging, and the function of crankcase heaters.
Operational Modes and Drainage
Low Ambient Operation Considerations
Notes on operating DX units at low ambient temperatures and recommended options.
Gas and Electric Heating Operation
Guidelines for operating gas and electric heating, including airflow and overheating precautions.
Condensate Drain Pan Requirements
Requirements for condensate drain pans, including p-traps and emergency drain pans.
Installation and Unit Placement
Installation Design and Assembly
Overview of AAON's design for easy installation and options for unit assembly (assembled or split).
Locating the Unit and Clearances
Considerations for unit placement relative to ductwork, electrical, and plumbing, including flue discharge clearances.
Clearances and Control Panel Access
V3 Series Unit Clearances
Minimum clearance requirements for access, service, and operation based on unit size.
Internal Control Panel Access
Description of removable access panels for the internal control panel on V3 units.
Unit Mounting and Orientation
Floor Mounted Unit Installation
Requirements for mounting the unit level on a platform, considering condensate line p-trap depth.
Unit Orientation and Airflow Direction
Explanation of unit orientation (left/right hand) and airflow direction for proper installation.
Lifting, Handling, and Unit Assembly
Safe Lifting and Handling Procedures
Guidelines for safely lifting and handling the unit, including required equipment capacity.
Unit Assembly and Section Connections
Instructions for assembling the unit if shipped in sections, including connecting power and control wiring.
Connecting Unit Sections and Sealing
Connecting Unit Sections
Procedure for connecting unit sections using flanges, gasket material, and self-tapping screws.
Re-attaching Panels and Final Sealing
Steps for re-attaching access panels and sealing penetrations to prevent air infiltration.
Control Box, Ducting, and Drainage
External Control Box Mounting
Instructions for mounting the external control box, ensuring secure installation.
Duct Connection and Airflow Sizing
Guidelines for attaching ductwork, sizing, and material selection for duct connections.
Condensate Drain Piping Requirements
Detailed requirements for installing condensate drain piping, including p-traps and air breaks.
Heating Coil Installation
Steam Distributing Coil Connections
Specifications for steam distributing coil sweat connection sizes and installation.
Hot Water Coil Connections and Installation
Details on hot water coil connections, installation, and insulation requirements.
Chilled Water Coil Installation
Chilled Water Coil Connections
Specifications for chilled water coil sweat connection sizes and piping requirements.
Water Coil Freeze Protection
Precautions for preventing water coil freeze-up, including glycol solutions.
Refrigeration System Components
Evaporator Coil Installation and Piping
Guidelines for installing evaporator coils, including refrigerant piping and solder connections.
Thermal Expansion Valve (TXV) Installation
Proper mounting procedures for TXV sensing bulbs based on suction line size.
Hot Gas Reheat and Bypass Systems
Information on the purpose and installation of hot gas reheat and bypass systems.
System Features and Components
Purge Circuit Installation
Requirements for installing the purge circuit on hot gas reheat or bypass lines.
Energy Recovery Unit Setup and Maintenance
Guidelines for setting up, maintaining, and understanding the operation of energy recovery units.
Energy Recovery Wheel Operation and Maintenance
Wheel to Air Seal Clearance Adjustment
Procedure for checking and adjusting air seal clearances for optimal energy recovery wheel performance.
Airflow Balancing and System Controls
Importance of professional airflow balancing and identifying unit controls.
Routine Maintenance and Cleaning
Routine Maintenance of Energy Recovery Cassettes
Periodic inspection of ER cassettes, including air seals and drive components.
Energy Recovery Wheel Cleaning Procedures
Detailed steps for cleaning the energy recovery wheel, including approved cleaners and methods.
Energy Recovery Cassette Components and Installation
Air Seal Adjustments for ER Cassettes
Procedure for adjusting diameter seals on energy recovery cassettes to minimize air transfer.
Wheel Drive Components and Installation
Information on wheel drive motor bearings, pulleys, and belt tension for energy recovery units.
ER Cassette Installation Considerations
Key considerations for ER cassette installation, including accessibility and orientation.
Energy Recovery Wheel Startup Procedure
Startup Procedure for ER Wheel Rotation
Steps to verify wheel rotation, segment engagement, and seal adjustments.
Correcting Cassette Frame Racking
Methods to correct frame racking in cassettes to ensure proper drive belt function.
Energy Recovery Cassette Assembly and Service
Hub Seal Adjustment Procedure
Procedure for adjusting hub seals on the energy recovery wheel assembly.
Segment Installation and Replacement
Detailed steps for installing and replacing segments in the energy recovery wheel.
Wheel Drive Component Replacement
Wheel Drive Motor and Pulley Replacement
Instructions for replacing the wheel drive motor and pulley assembly.
Belt Replacement for ER Wheel Drive
Procedure for replacing the drive belt on the energy recovery wheel assembly.
Electrical Connections and Safety
Electrical Service Verification
Verifying unit nameplate matches power supply and understanding wiring connections.
Electrical Overcurrent Protection
Requirements for field-supplied electrical overcurrent and short circuit protection.
Electrical Connections and Openings
Control Box and Panel Wiring Entry
How electrical supply enters units with external control boxes or internal panels.
Cutting Electrical Openings in Foam Panels
Procedure for safely cutting openings for conduit in foam panels, ensuring proper sealing.
Electrical System Checks and Wiring
Three Phase Voltage Imbalance
Understanding voltage imbalance effects on motors and how to check it.
Motor Rotation and Wiring Checks
Importance of checking motor rotation and ensuring supply voltage is within limits.
Control Wiring and Gas Heating Installation
Thermostat Control Wiring Guidelines
Proper placement and wiring practices for thermostats to ensure adequate control voltage.
Gas Heating Unit Location and Clearances
Requirements for locating gas heating units, ensuring adequate combustion air and clearances.
Condensate Management Systems
Condensate Drain Piping and Freeze Protection
Installation requirements for condensate drain piping, including p-traps, air gaps, and freeze protection.
Condensate Neutralization Requirements
Information on condensate neutralization kits and freeze protection for outside installations.
General Venting Requirements
Proper Vent System Operation
Ensuring a properly operating vent system for safe exhaust of combustion products.
Vent Pipe Material and Installation
Guidelines for selecting and installing vent pipes, including material compatibility and support.
Venting Configurations
Open Combustion Venting
Installation requirements for open combustion venting, including vent termination and pipe sizing.
Separated Combustion Venting
Requirements for Separated Combustion
Details on the two-pipe system, vent materials, and terminal location for separated combustion.
Gas Supply, Piping, and Connections
Gas Pipe Leak Testing
Critical safety procedures for checking gas pipes for leaks before startup and annually.
Gas Piping Capacities and Pressures
Gas Piping Capacity Tables
Tables for determining maximum piping capacities for natural gas and propane.
Gas Inlet and Manifold Pressure Specifications
Required gas inlet and manifold pressures for unit operation, including altitude adjustments.
Gas Piping Sizing and Support
Piping Sizing Examples
Examples illustrating how to size gas piping based on capacity and length.
Gas Pressure Regulator and Piping Supports
Requirements for gas pressure regulators and support intervals for gas supply piping.
Additional Gas Piping and Leak Testing
Additional Gas Piping Considerations
Local code requirements for shutoff valves, unions, sediment traps, and piping compounds.
Fire and Explosion Hazard Warnings
Critical warnings about fire and explosion hazards related to gas leaks and testing methods.
Gas System Warnings and Input
Gas Pressure Testing Warnings
Warnings regarding gas pressure testing limits and precautions to avoid damaging gas valves.
Unit Input and Startup Odor Precautions
Information on unit input control and precautions regarding residual oil odors during startup.
Startup Procedures and Supply Fans
General Startup Checks
Necessary checks during startup, including air flow, filters, and refrigerant charge.
Supply Fan Air Flow Adjustment
Procedures for adjusting supply fan airflow using Electronically Commutated Motors (ECM).
Fan Speed Control and Refrigerant Charge Adjustment
Potentiometer for Fan Speed Control
Using the potentiometer to set maximum fan speed and modulating speed via 0-10 VDC signal.
Adjusting Refrigerant Charge
Field adjustment of refrigerant charge based on liquid sub-cooling and evaporator superheat.
Checking Refrigerant Liquid Sub-Cooling
Measuring Liquid Sub-Cooling
Procedure for measuring and calculating liquid sub-cooling for refrigeration systems.
Acceptable Refrigeration Circuit Values
Table of acceptable values for liquid sub-cooling based on unit type and operating mode.
Checking and Adjusting Superheat
Measuring Evaporator Superheat
Procedure for measuring and calculating evaporator superheat for refrigeration systems.
Adjusting Sub-Cooling and Superheat Temperatures
Guidance on correcting overcharged or undercharged systems and adjusting TXV.
R-410A Refrigerant Data
Refrigerant Temperature-Pressure Chart
Reference chart for R-410A refrigerant showing PSIG and corresponding temperatures.
Gas Heater Operation
Gas Heater Operating Instructions
Step-by-step instructions for operating the gas heater, including safety precautions.
Procedure to Turn Off Gas to Appliance
Steps for safely shutting off the gas supply to the appliance for service or shutdown.
Gas Heater Startup and Ignition
Gas Heater Startup Sequence
Detailed sequence for starting up the gas heater, including pressure checks and gas control operations.
Troubleshooting Ignition Failures
Common causes and procedures for addressing ignition failures in the gas heater.
Burner Flame Characteristics
Natural Gas Burner Flame Appearance
Description of the proper flame appearance for natural gas burners and potential causes of poor flames.
Propane Gas Burner Flame Appearance
Description of the proper flame appearance for propane gas burners and potential causes of poor flames.
Unit Operation Modes
Thermostat Operation Controls
How to operate the unit using thermostat settings for heating, cooling, and air circulation.
System Operation Modes
Details on operating the unit in various modes: DX Cooling, Chilled Water, Electric Heat, Gas Heater.
Gas Heater Controls and Shutdown
Gas Heater Operating and Safety Instructions
Safety instructions for operating the gas heater, including leak testing and manual handling.
Shutdown and Normal Operation Procedures
Steps for safely shutting down the unit and returning it to normal operation.
Service Checks and Ignition Control
Flame Sensor Current Check
Procedure for measuring flame current using a microammeter to ensure proper ignition.
Ignition Control Sequence of Operation
Table detailing the ignition control sequence, actions, and fault codes.
Ignition Control Module and Safety Switches
Ignition Control Module Functions
Description of the integrated direct spark ignition control and its functions.
Air Pressure and Blocked Flue Switches
Function of air pressure switches for airflow verification and blocked flue detection.
Rollout Switch Operation
Details on the manual reset rollout switch for burner overheating protection.
High Limit Switches and LED Diagnostics
High Limit Switch Functions
Description of the two high limit switches for overheat protection due to airflow or flue gas temperature.
Gas Heater LED Diagnostics
Table explaining the meaning of LED flash codes for gas heater diagnostics.
Maintenance Overview
Unit Maintenance Schedule
Recommended annual and monthly checks for unit components like fans, coils, and filters.
DX Cooling System Checks
Checks to perform on DX cooling systems, including fan direction, amperage, and voltage.
Condensate Drain Pan Cleaning
Importance and procedure for cleaning condensate drain pans to prevent microbial growth and blockage.
Gas Heating Maintenance
Annual Furnace and Burner Inspection
Annual inspection of flue product areas and main burners for continued safe operation.
Combustion Air and Venting Checks
Annual checks for debris in combustion air and vent outlets, and replacement considerations.
Furnace Maintenance Procedures
Condensate Drainage System Inspection
Inspection of drain lines, freeze protection, p-traps, and neutralizer cartridges.
Furnace Exhaust Vent Termination Inspection
Inspection of vent terminations for ice accumulation and cleaning of nearby areas.
Furnace Inspection and Operation Checks
Annual Furnace Inspection Checklist
Comprehensive checklist for inspecting furnace components, controls, and wiring.
Furnace Operation Verification
Steps to check proper start-up, ignition, burner flame, airflow, and condensate flow.
E-Coated Coil Cleaning
Coil Cleaning Safety Precautions
Safety warnings for cleaning coils, including electrical hazards and chemical usage.
Coil Surface Preparation and Cleaning
Procedures for removing surface dirt and applying approved cleaners to E-coated coils.
E-Coated Coil Cleaning Procedures
Recommended Coil Cleaner Application
Step-by-step guide for applying recommended coil cleaner and rinsing.
Warranty Protection Steps for Coil Cleaning
Detailed steps for coil cleaning to maintain warranty coverage, including power lockout and rinsing.
Coil Cleaning and Winterization
Chloride Removal and Coil Rinsing
Steps for removing soluble salts and rinsing coils to complete the cleaning process.
Winterizing Water Coils
Procedure for winterizing water coils to prevent freezing, including draining and antifreeze.
Supply Fan Inspection and Cleaning
Importance of inspecting and cleaning blower wheels to prevent imbalance and component failure.
Phase and Brownout Protection Module
DPM Setup Procedure and Settings
Instructions for setting up the Digital Phase Monitor (DPM) parameters.
DPM Default Setup Parameters
Default configuration settings for Line Voltage, Over/Undervoltage, and Trip Time Delay.
Digital Phase Monitor Screens and Faults
DPM Voltage and Imbalance Screens
Screens displaying average voltage, imbalance, and voltage selection options.
DPM Fault Screens and Words
Information on fault screens, fault codes, and fault words for troubleshooting the DPM.
Filter Replacement and Support
Monthly Filter Replacement
Importance of monthly filter inspection and replacement for optimal unit efficiency.
Obtaining Replacement Parts
How to obtain replacement parts through local AAON representatives.
Contacting AAON Technical Support
Information for contacting AAON Technical Support, including contact details and required information.
V3 Series Cabinet Pre-Filters
Feature 6A Pre-Filter Specifications
Table detailing V3 Series E Cabinet Pre-Filter options, sizes, and MERV ratings.
V3 Series Cabinet Unit Filters
V3 Series A Cabinet Unit Filters
Table detailing V3 Series A Cabinet Unit Filter options, sizes, and MERV ratings.
V3 Series B Cabinet Unit Filters
Table detailing V3 Series B Cabinet Unit Filter options, sizes, and MERV ratings.
Additional V3 Series Filter Information
V3 Series C Cabinet Unit Filters
Table detailing V3 Series C Cabinet Unit Filter options, sizes, and MERV ratings.
V3 Series D Cabinet Unit Filters
Table detailing V3 Series D Cabinet Unit Filter options, sizes, and MERV ratings.
Energy Recovery OA Filters
Table detailing V3 Series Energy Recovery OA Filter options, sizes, and MERV ratings.
Refrigerant Piping Diagrams
Condensing Unit Piping Diagrams Reference
Reference to the matching Condensing Unit IOM for detailed piping diagrams.
V3 Series Startup Form
Pre Startup Checklist Items
Checklist for the installing contractor to verify unit conditions before startup.
Startup Form - Component Checks
Supply and Exhaust Fan Assembly Checks
Sections for recording alignment, rotation, amps, and VFD frequency for fans.
Energy Recovery Wheel and Damper Checks
Sections for checking ER wheel spin, rotation, FLA, and damper operations.
Startup Form - Refrigeration Cooling Data
Refrigeration System Cooling Mode Parameters
Tables for recording discharge, suction, liquid pressures, temperatures, sub-cooling, and superheat.
Compressor/DX Cooling Data
Section for recording compressor L1, L2, L3, head/suction pressure, and crankcase heater amps.
Startup Form - Fan and Refrigeration Heating Data
Air-Cooled Condenser Fan Data
Sections for recording alignment, rotation, and nameplate amps for condenser fans.
Refrigeration System Heating Mode Parameters
Tables for recording parameters for heat pump systems in heating mode.
Startup Form - System and Heating Data
Water/Glycol System Checks
Checklist for water/glycol system flushing, filling, bleeding, concentration, load, and insulation.
Electric and Gas Heating Data Recording
Sections for recording electric heating stages, amps, lockout settings, and gas heating stages, pressures.
Maintenance Log
Service and Repair Documentation
Log for documenting service, repair, and adjustments performed on the unit.
Literature Change History
Document Revision Information
Information on the initial version and reasons for separate IOMs for H3 and V3 series.
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