F1 Series Indoor Air Handing Units Installation, Operation & Maintenance WARNING QUALIFIED INSTALLER Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Installation and service must be performed by a trained, qualified installer. A copy of this IOM should be kept with the unit. NOTICE These instructions are addressed primarily to the installer; however, useful maintenance information is included.
Table of Contents Safety .............................................................................................................................................. 6 F1 Base Model and Features Description ..................................................................................... 10 General Description ...................................................................................................................... 11 Codes and Ordinances ...................................................
Refrigerant Piping ..................................................................................................................... 28 Determining Refrigerant Line Size ........................................................................................... 29 Equivalent Line Length ............................................................................................................. 29 Predetermined Line Sizes ..................................................................................
Index of Table and Figures Tables: Table 1 - Electric Heat Minimum Circuit Ampacity .................................................................... 16 Table 2 - Electric Heat Maximum Overcurrent Protection ........................................................... 17 Table 3 - Factory Preset Air Flow................................................................................................. 17 Table 4 - Cooling Fan Speed Tap Settings ...............................................................
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.
WARNING During installation, testing, servicing and troubleshooting of the equipment it may be necessary to work with live electrical components. Only a qualified licensed electrician or individual properly trained in handling live electrical components shall perform these tasks. Standard NFPA-70E, an OSHA regulation requiring an Arc Flash Boundary to be field established and marked for identification of where appropriate Personal Protective Equipment (PPE) be worn, should be followed.
WARNING Do not use oxygen, acetylene or air in place of refrigerant and dry nitrogen for leak testing. A violent explosion may result causing injury or death. WARNING Always use a pressure regulator, valves and gauges to control incoming pressures when pressure testing a system. Excessive pressure may cause line ruptures, equipment damage or an explosion which may result in injury or death. WARNING Do not work in a closed area where refrigerant or nitrogen gases may be leaking.
CAUTION PVC (Polyvinyl Chloride) and CPVC (Chlorinated Polyvinyl Chloride) are vulnerable to attack by certain chemicals. Polyolester (POE) oils used with R-410A and other refrigerants, even in trace amounts, in a PVC or CPVC piping system will result in stress cracking of the piping and fittings and complete piping system failure. 1. The unit is for indoor use only. See General Information section for more unit information. 2.
F1 Base Model and Features Description Model/Feature Number F1 Series and Generation - A Rev. - 060 Unit Size - 1 Voltage - M App. C Heat : C 0 0 0 C 000 0 0 Mtrs Filters Cntls Blank Refri.
General Description F1 Series air handling units are designed for safe operation when installed, operated and maintained within design specifications and the instructions set forth in this manual. It is necessary to follow these instructions to avoid personal injury or damage to equipment or property during equipment installation, operation, start-up and maintenance. WARNING Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life.
this unit. Failure to follow these regulations may harm the environment and can lead to the imposition of substantial fines. Because regulations may vary due to passage of new laws, AAON suggests a certified technician perform any work done on this unit. Should you have any questions please contact the local office of the EPA. WARNING Do not, under any circumstances, connect ductwork to any other heat producing device such as fireplace insert, stove, etc.
4. Do not move or discard damaged freight packaging materials 5. After losses have been acknowledged by the freight carrier, contact factory for a repair or replacement part quote. 6. With permission of freight carrier, order parts and/or make repairs. 7. Stay in contact with freight carrier to ensure payment of your claim. Nameplate should be checked to ensure the correct model sizes and voltages have been received to match the job requirements.
CAUTION This unit must be stored indoors if installation is not to occur immediately following delivery. Unprotected units could develop corrosion if left exposed to the environment. Damage resulting from improper storage will not be covered by the limited warranty. Installation AAON equipment has been designed for quick and easy installation. General F1 Series air handling units are designed as heating, cooling or combination units for indoor installation only.
Figure 1 - Typical Vertical and Horizontal Unit Installation Methods Sealing It is very important to keep outside air from infiltrating the unit cabinet. Seal all piping penetrations with Armaflex, Permagum, or other suitable sealant. Also seal around drain connections, electrical connections, and other inlets where air may enter the cabinet. This is especially important when the unit is installed in an unconditioned area.
Heating Equipment Field Wiring - MCA and MOP Hot Water Heating: Water supply lines must be insulated, properly fastened, drained and supported according to local code requirements. Electric Heating: Installing Electric Heat Strip into the Unit: 1. Remove front control panel(s) of the unit 2. Remove screws and panel covering heat strip compartment 3. Open the heat strip kit and remove assembly from package 4. Install strip heat into opening and secure with 4 (four) screws 5.
Table 2 - Electric Heat Maximum Overcurrent Protection 230V 208V kW 5 10 15 20 25 kW 3.75 7.50 11.25 15.00 18.75 Line 1 MOP 30 60 60 60 60 Line 2 MOP Line 3 MOP 30 60 60 30 Heat Pump For heat pump equipped split system configurations, the heat pump is the primary heat source during a call for heat. During operation at low ambient temperatures where the heat pump alone cannot satisfy the space temperature set point, electric resistance heat elements are activated.
In this comfort cooling application of the ECM fan motor, heat and cool taps, A & D have the same effect on motor speed. dropped then dehumidification mode will begin. Humidity Control: Adjust the DELAY tap for humidity control that is suitable for the climate according to Table 5. Table 5 - Climate Settings CLIMATE DELAY Tap Humid A Sub-humid/Dry B Semi-Arid C Arid/Hyper-Arid D Heating: The fan speed for the heating cycle is selected by adjusting the HEAT tap (see FIGURE 2) according to TABLE 6.
2. 3. 4. 5. service of the air handling unit with the placement of the check valve. b. For horizontal discharge units. Connect the hot gas line from the outdoor unit to the upper stub-out connection of the reheat coil. Connect the check valve (shipped loose) to the lower stub-out in a direction so that the refrigerant is leaving the bottom side of the reheat coil. Be sure to not block access for service of the air handling unit with the placement of the check valve.
Condensate Piping A drain trap must be connected to the drain pan at the unit. Condensate connections are provided on each side of the unit. Condensate piping should be installed according to local codes. The line should be the same pipe size as the drain nipple and should pitch downward toward the building drain. All cooling coils must have drain pans equipped with “P” traps to avoid pulling air from outside the unit back through the drain line. All drain connection ports are sealed.
CAUTION The Clean Air Act of 1990 bans the intentional venting of refrigerant as of July 1, 1992. Approved methods of recovery, recycling, or reclaiming must be followed. Before Charging The unit being charged must be at or near full load conditions before adjusting the charge. Units equipped with hot gas reheat must have the hot gas reheat valves closed to get the proper charge. Units equipped with hot gas reheat must be charged with the hot gas valve closed while the unit is in cooling mode.
Table 7 - Acceptable Air-Cooled Refrigeration Circuit Values AirCooled Condenser Subcooling (°F) Superheat (°F) Sub-cooling with Hot Gas Reheat (°F) 12-18* 8-15** 15-22* pressure drop of all valves, components, fittings and other pipes in the sections. * Sub-cooling must be increased by 2°F per 20 feet of vertical liquid line rise for R410A ** Superheat will increase with long suction line runs.
°F 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 PSIG 78.3 80.0 81.8 83.6 85.4 87.2 89.1 91.0 92.9 94.9 96.8 98.8 100.9 102.9 105.0 107.1 109.2 111.4 113.6 115.8 118.1 120.3 122.7 125.0 127.4 129.8 132.2 Table 8 - R-410A Refrigerant Temperature-Pressure Chart PSIG PSIG PSIG °F °F °F 134.7 213.7 321.0 47 74 101 137.2 217.1 325.6 48 75 102 139.7 220.6 330.2 49 76 103 142.2 224.1 334.9 50 77 104 144.8 227.7 339.6 51 78 105 147.4 231.3 344.4 52 79 106 150.1 234.9 349.
Startup General ONLY QUALIFIED, AUTHORIZED PERSONNEL SHOULD POWER ON, OR STARTUP THIS EQUIPMENT. Before starting up the equipment, building construction should be complete, and startup personnel should: Have a working knowledge of general HVAC and mechanical commissioning procedures and practices. Be familiar with unit functions, features, optional unit accessories, and all control sequences. Have appropriate literature on hand for consultation.
WARNING Do not alter factory wiring. Deviation from the supplied wiring diagram will void all warranties, and may result in equipment damage or personal injury. Contact the factory with wiring discrepancies. Electric Heat Section Procedures 1. Perform final visual inspection. Check all equipment ductwork and piping to verify that all work is complete. Improperly installed equipment or ductwork can affect readings. 2. Ensure that there is no construction debris in the unit. 3.
3. Verify that the condenser hot gas valve and reheat hot gas valve are wired as shown in the wiring diagram. 4. Verify that the Modulating Hot Gas Reheat system is working properly. Run for five minutes in the reheat mode and verify that the temperature of the supply air stream matches the reheat temperature set point. Commissioning Air Balancing High performance systems commonly have complex air distribution and fan systems.
Annually: Clean the condenser and evaporator coils with steam or a non-corrosive cleaner. Clean the drain line, “P” trap and condensate pan. Check refrigerant pressures and temperatures every spring and correct unusual readings. Check heating section every fall. Check all electrical connections for tightness and check heater elements for indications of overheating. Determine cause and replace elements if necessary.
CAUTION Never flip a dirty filter to allow airflow in the opposite direction. The blower and motor bearings are permanently lubricated and do not require additional lubrication. It is recommended that the owner have available at least one set of replacement fuses of the size supplied with the original equipment. Important: Keep coils, fans and filters clean.
Determining Refrigerant Line Size CAUTION Line sizes must be selected to meet actual installation conditions, not simply based on the connection sizes at the condensing unit or air handling unit. The piping between the condenser and low side must assure: 1. Minimum pressure drop, and 2. Continuous oil return, and 3.
glass should not be used to determine if the system is properly charged. Use temperature and pressure measurements to determine liquid sub-cooling, not the sight glass. Liquid Line Routing Care should be taken with vertical risers. When the system is shut down, gravity will pull liquid down the vertical column, and back to the condenser when it is below the evaporator. This could potentially result in compressor flooding.
It is important to consider part load operation when sizing suction lines. At minimum capacity, refrigerant velocity may not be adequate to return oil up the vertical riser. Decreasing the diameter of the vertical riser will increase the velocity, but also the frictional loss. A double suction riser can be applied in this situation. The double suction riser is designed to return oil at minimum load while not incurring excessive frictional losses at full load.
suction line. Connect the drip line a minimum of 1-inch above the bottom of the drain leg. Insulate the entire length of the hot gas line with a minimum 1-inch thick Armaflex insulation. Hot Gas Reheat Guidelines Maintain velocities below a maximum of 3500 fpm. A general minimum velocity guideline is 2000 fpm. Predetermined Line Sizes To aid in line sizing and selection, AAON has predetermined line sizes for the liquid and suction lines in comfort cooling applications.
accessories and vertical rise must be considered when determining horizontal length available from the total equivalent line length. Figure 3 is presented in terms of the liquid line, but it assumes that the line lengths for the suction and hot gas bypass are similar, as these lines will commonly be routed together to minimize the space and cost required for split system installation. CAUTION Before using this table read the When to Use Predetermined Line Sizes section.
Figure 3 - Riser Height Versus Total Equivalent Line Length for R-410A Split System Applications with Two Step Scroll Compressor CB-024 through CB-060 units. The region of acceptable riser height is the lighter area. Select the corresponding predetermined line size from Table 8 above. CAUTION Total Equivalent Line Length in this figure is limited to 160 equivalent feet.
Refrigerant Piping Diagrams Figure 4 - Modulating Hot Gas Reheat Piping Diagram with Air Handling Unit above Condensing Unit.
Figure 5 - Modulating Hot Gas Reheat Piping Diagram with Air Handling Unit below Condensing Unit 36
Figure 6 - Modulating Hot Gas Reheat Piping Diagram with Air Handling Unit above Condensing Unit with Optional Accumulator 37
Figure 7 - Modulating Hot Gas Reheat Piping Diagram with Air Handling Unit below Condensing Unit with Optional Accumulator 38
Figure 8 - Heat Pump Piping Diagram with Indoor Unit above Outdoor Unit 39
Figure 9 - Heat Pump Piping Diagram with Outdoor Unit above Indoor Unit 40
Figure 10 - Heat Pump Piping Diagram with Modulating Hot Gas Reheat and Indoor Unit above Outdoor Unit 41
Figure 11 - Heat Pump Piping with Modulating Hot Gas Reheat and Outdoor Unit above Indoor Unit 42
Thermostat Installation and Wiring Figure 12 - 2 Stage Cooling with Electric Heat 43
Figure 13 - 2 Stage Cooling with Heat Pump and Electric Heat 44
Figure 14 - 2 Stage Cooling and Electric Heat with Hot Gas Reheat and Humidistat 45
Figure 15 - Main Control Board for Units Equipped with Modulating Hot Gas Reheat 46
Figure 16 - Field Wiring Connections for an F1 Series Air Handling Unit. Electric heating connections are made at LVTB3.
Figure 17 - 5kW Electric Heat 48
Figure 18 - 10 kW Electric Heat
Figure 19 - 15 kW Electric Heat 50
Figure 20 - 20 kW Electric Heat
Figure 21 - 25 kW Electric Heat 52
F1 Series Startup Form Job Name:_______________________________________________ Date:______________ Address:______________________________________________________________________ ______________________________________________________________________________ Model Number:_________________________________________________________________ Serial Number:_____________________________________________ Tag:_______________ Startup Contractor:______________________________________________________________ Address:___
Supply Fan Assembly Alignment Number Check Rotation hp L1 Nameplate Amps________ L2 L3 1 Compressors/DX Cooling Check Rotation Number L1 L2 L3 Head Pressure PSIG Suction Pressure PSIG Crankcase Heater Amps 1 - Full Capacity 2Reduced Capacity Refrigeration System 1 Full Capacity - Cooling Mode Saturated Line Pressure Temperature Temperature Discharge Suction Liquid Refrigeration System 1 Reduced Capacity - Cooling Mode Saturated Line Pressure Temperature Temperature Discharge Suction Liquid Sub
Unit Configuration Water-Cooled Condenser Air-Cooled Condenser No Water Leaks Condenser Safety Check Water Flow ________ gpm Water Inlet Temperature ________°F Water Outlet Temperature ________°F Water/Glycol System 1. Has the entire system been flushed and pressure checked? Yes No 2. Has the entire system been filled with fluid? Yes No 3. Has air been bled from the heat exchangers and piping? Yes No 4. Is the glycol the proper type and concentration (N/A if water)? Yes No 5.
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. The responsibility for proper startup, maintenance and servicing of the equipment falls to the owner and qualified licensed technician. Entry Date 56 Action Taken Name/Tel.
Literature Change History November 2009 Update of the IOM formatting to match with other IOMs and adding some variable capacity scroll compressor information. April 2009 Update of the IOM adding the F1 Series model number description. June 2010 Revision of the IOM adding PVC and CPVC piping Caution. April 2012 Update of the IOM adding the electronic startup form, adding the index of tables and figures, and updating the table of contents.
AAON 2425 South Yukon Ave. Tulsa, OK 74107-2728 Phone: 918-583-2266 Fax: 918-583-6094 www.aaon.com F1 Series Installation, Operation & Maintenance R58420 · Rev. B · 120509 (ACP 29902) 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. Copyright © AAON, all rights reserved throughout the world.
