AAON CL SERIES Installation Operation & Maintenance

Safety ............................................................................................................................................................. 6 CL Series Feature String Nomenclature ...................................................................................................... 11 GENERAL DESCRIPTION ........................................................................................................................ 14 Unpacking: ............................................................................................................................................... 14 OWNER'S INFORMATION ....................................................................................................................... 14 Warning: .................................................................................................................................................. 14 Wiring Diagrams: ..................................................................................................................................... 15 General Maintenance: .............................................................................................................................. 15 INSTALLATION ........................................................................................................................................ 15 Lifting and Handling: ............................................................................................................................... 15 Condenser Placement: .............................................................................................................................. 15 Compressor Compartment Exhaust Fan: ................................................................................................. 15 Mounting Isolation: .................................................................................................................................. 16 Access Doors: .......................................................................................................................................... 16 Standard Evacuation Instructions: ........................................................................................................... 16 Low Ambient & Modulating Reheat System Evacuation Instructions: ................................................... 17 Charging Refrigerant: .............................................................................................................................. 18 Before Charging: ...................................................................................................................................... 18 Checking Liquid Sub-cooling: ................................................................................................................. 19 Checking Evaporator Superheat: ............................................................................................................. 19 Special Low Ambient Charging Instructions: .......................................................................................... 20 Low Ambient Operation: ......................................................................................................................... 20 LAC Valve: .............................................................................................................................................. 21 Electrical .................................................................................................................................................. 22 Refrigerant Piping Connections: .............................................................................................................. 24 Evaporative Condenser Field Piping Connections: ................................................................................. 24 STARTUP .................................................................................................................................................... 26 Pre-Startup: .............................................................................................................................................. 26 Startup: ..................................................................................................................................................... 26 Axial Flow Fans: ...................................................................................................................................... 27 Insert Blades: ........................................................................................................................................... 28 SERVICING AND MAINTENANCE ........................................................................................................ 29 General: .................................................................................................................................................... 29 Compressors:............................................................................................................................................ 29 Refrigerant Suction Line Filter: ............................................................................................................... 29 Suction Filter Removal Instructions ........................................................................................................ 29 Refrigerant Liquid Line Filter Driers:...................................................................................................... 30 Evaporator/Heat Exchangers: .................................................................................................................. 30 Lubrication: .............................................................................................................................................. 30 Service Information: ................................................................................................................................ 30 Replacement Parts: ................................................................................................................................... 30 AAON Technical Support ........................................................................................................................ 30 Severe Service: ......................................................................................................................................... 31 Safety: ...................................................................................................................................................... 31 Performance: ............................................................................................................................................ 32 Warranties: ............................................................................................................................................... 32 Condenser Tube Inspection: .................................................................................................................... 32

Recirculating Water System: ................................................................................................................... 32 EVAPORATIVE CONDENSER - PRE START-UP .................................................................................. 32 Cleanliness: .............................................................................................................................................. 32 Pump Operation: ...................................................................................................................................... 32 Running: ................................................................................................................................................... 32 Condenser Fan Motors: ............................................................................................................................ 33 Water Make-up Valve: ............................................................................................................................. 33 Water Treatment System: ........................................................................................................................ 34 Sequence of Operation: ............................................................................................................................ 34 EVAPORATIVE CONDENSER - MAINTENANCE REQUIREMENTS ................................................ 35 Pump Maintenance: ................................................................................................................................. 35 Fan Motor Maintenance: .......................................................................................................................... 35 Access Doors: .......................................................................................................................................... 35 Bearings - Lubrication: ............................................................................................................................ 35 Required Monthly Inspection: ................................................................................................................. 35 Mist Eliminators: ..................................................................................................................................... 35 Air Inlet: ................................................................................................................................................... 35 Stainless Steel Base Pan: ......................................................................................................................... 35 Propeller Fans and Motors: ...................................................................................................................... 35 Required Annual Inspection: ................................................................................................................... 35 Cleaning: .................................................................................................................................................. 35 EVAPORATIVE CONDENSER - WATER QUALITY ............................................................................ 36 Recirculating Water Quality Guidelines: ................................................................................................. 36 Mechanical Cleaning: .............................................................................................................................. 36 Parts: ........................................................................................................................................................ 36 AIR-COOLED CONDENSER .................................................................................................................... 36 E-Coated Coil Cleaning ........................................................................................................................... 36 REFRIGERANT PIPING FOR THE CL SERIES ...................................................................................... 39 General: .................................................................................................................................................... 39 Determining Refrigerant Line size: ......................................................................................................... 39 Equivalent Line Length: .......................................................................................................................... 39 Liquid line sizing: .................................................................................................................................... 40 Liquid Line Routing:................................................................................................................................ 40 Liquid Line Insulation: ............................................................................................................................ 40 Liquid Line Guidelines: ........................................................................................................................... 40 Liquid Line Accessories: ......................................................................................................................... 40 Suction Line Sizing: ................................................................................................................................. 40 Suction Line Routing: .............................................................................................................................. 40 Suction Line Traps: .................................................................................................................................. 41 Suction Line Insulation: ........................................................................................................................... 41 Suction Line Guidelines:.......................................................................................................................... 41 Suction Line Accessories: ........................................................................................................................ 42 Hot Gas Bypass Line: .............................................................................................................................. 42 Hot Gas Bypass Piping Considerations for Evaporator Above Condensing Unit: .................................. 42 Hot Gas Bypass Piping Considerations for Evaporator Below Condensing Unit: .................................. 42 Hot Gas Bypass Line Guidelines: ............................................................................................................ 42 Hot Gas Reheat Line: ............................................................................................................................... 42

Literature Change History........................................................................................................................ 58 Index of Tables and Figures Tables: Table 1 - Service Clearances ........................................................................................................................ 15 Table 2 - Acceptable Refrigerant Circuit Values ......................................................................................... 19 Table 3 - % Charge to Flood Condenser Coil for Ambient Below 70°F ..................................................... 20 Table 4 - Nameplate Voltage Markings & Tolerances ................................................................................ 22 Table 5 - Liquid Line Filter Drier Pressure Drop ........................................................................................ 30 Table 6 - Water Quality ............................................................................................................................... 36 Figures: Figure 1 - CU evacuation connections ......................................................................................................... 16 Figure 2 - CU evacuation connections ......................................................................................................... 17 Figure 3 - AHU evacuation connections ...................................................................................................... 18 Figure 4 - Piping Schematic of Example system using the LAC valve ....................................................... 21 Figure 5 - Refrigerant Piping Connections .................................................................................................. 24 Figure 6 - Evaporative Condenser Section Water Treatment Components ................................................. 25 Figure 7 - Water Level Sensor ..................................................................................................................... 33 Figure 8 - Double Suction Riser .................................................................................................................. 41 Figure 9 - Oil Return Piping ........................................................................................................................ 42 Figure 10 - Hot Gas Bypass Piping Diagram with air handler above condenser ........................................ 44 Figure 11 - Hot Gas Bypass Piping Diagram with air handler below condenser ........................................ 45 Figure 12 - Hot Gas Reheat Piping Diagram with air handler above condenser ......................................... 46 Figure 13 - Hot Gas Reheat Piping Diagram with air handler below condenser ......................................... 47 Figure 14 - Hot Gas Reheat Piping Diagram with air handler above condenser and field installed suction line accumulator ........................................................................................................................................... 48 Figure 15 - Hot Gas Reheat Piping Diagram with air handler above condenser and field installed suction line accumulator ........................................................................................................................................... 49 Figure 16 - Reheat/Hot Gas Bypass Piping Diagram with air handler above condenser ............................ 50 Figure 17 - Reheat/Hot Gas Bypass Piping Diagram with air handler below condenser ............................ 51 Figure 18 - Reheat/Hot Gas Bypass Piping Diagram with air handler evaporator above condenser and field installed suction line accumulator ................................................................................................................ 52 Figure 19 - Reheat/Hot Gas Bypass Piping Diagram with air handler below condenser and field installed suction line accumulator .............................................................................................................................. 53 R10110 · Rev. C · 200910

Energy Efficiency  Air-Cooled or Energy Saving Evaporative Condenser  Direct Expansion Systems  Tandem Scroll Compressors  VFD Controlled Condenser Fans Humidity Control  Modulating Hot Gas Reheat Safety  Phase and Brownout Protection  Automatic Low Pressure and Manual Reset High Pressure Safety Cut-outs  Schrader Valves  Internal Overload Protection on Tandem Scroll Compressors  Aluminum Tread Plate Floor Covering  Compressor Isolation Valves Installation and Maintenance  Access Doors with Hinges, Lockable Handles and Rain Gutters  Walk-In Weatherproof Compressor Compartment  Run Test Report and Installation Manuals Included in Controls Compartment  Color Coded Wiring and Wiring Diagrams  Double Pane Viewing Windows  Compressors are Deck Mounted with Rubber Isolation  Three-Chemical Water Treatment System for Evaporative Condenser  Aluminum Tread Plate Floor  Foam Insulated Double Wall Construction  Replaceable Core Filter Driers System Integration  Single Point Power Connection  Air-Cooled or Evaporative Condensers Environmentally Friendly  R-410A Refrigerant Extended Life  2,500 Hour Salt Spray Tested Exterior Corrosion Paint  Optional 5 Year Non-Prorated Compressor Warranty  Sloped Condenser Coils with Outer Protection

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. DANGER - Danger statements are given to prevent actions that will result in equipment damage, property damage, severe personal injury or death. QUALIFIED INSTALLER Improper installation, adjustment, 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 must be kept with the unit. WARNING ELECTRIC SHOCK, FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exactly could result in dangerous operation, serious injury, death or property damage. Improper servicing could result in dangerous operation, serious injury, death, or property damage.  When servicing controls, label all wires prior to disconnecting. Reconnect wires correctly.  Verify proper operation after servicing. Secure all doors with key-lock or nut and bolt. WARNING ELECTRIC SHOCK Electric shock hazard. Before servicing, shut off all electrical power to the unit, including remote disconnects, to avoid shock hazard or injury from rotating parts. Follow proper Lockout-Tagout procedures. WARNING

that can cause serious injury. Do not remove grill containing fans until the power to the unit has been disconnected and fan has stopped rotating. WARNING LIVE ELECTRICAL 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, must be followed. WARNING FIRE, EXPLOSION OR CARBON MONOXIDE POISONING HAZARD Failure to replace proper controls could result in fire, explosion or carbon monoxide poisoning. Failure to follow safety warnings exactly could result in serious injury, death or property damage. Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this appliance. WARNING GROUNDING REQUIRED All field installed wiring must be completed by qualified personnel. Field installed wiring must comply with NEC/CEC, local and state electrical code requirements. Failure to follow code requirements could result in serious injury or death. Provide proper unit ground in accordance with these code requirements. WARNING VARIABLE FREQUENCY DRIVES Do not leave VFDs unattended in hand mode or manual bypass. Damage to personnel or equipment can occur if left unattended. When in hand mode or manual bypass mode VFDs will not respond to controls or alarms. WARNING

place of refrigerant and dry nitrogen for leak testing. A violent explosion may result causing injury or death. WARNING VARIABLE FREQUENCY DRIVES Electric motor over-current protection and overload protection may be a function of the Variable Frequency Drive to which the motors are wired. Never defeat the VFD motor overload feature. The overload ampere setting must not exceed 115% of the electric motors FLA rating as shown on the motor nameplate. CAUTION PVC PIPING 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. CAUTION 3-PHASE ROTATION Rotation must be checked on all MOTORS AND COMPRESSORS of 3 phase units at startup by a qualified service technician. Scroll compressors are directional and can be damaged if rotated in the wrong direction. Compressor rotation must be checked using suction and discharge gauges. Fan motor rotation must be checked for proper operation. Alterations must only be made at the unit power connection CAUTION UNIT HANDLING To prevent injury or death lifting equipment capacity shall exceed unit weight by an adequate safety factor. Always test-lift unit not more than 24 inches high to verify proper center of gravity lift point to avoid unit damage, injury or death. WARNING DOOR LATCHES Door compartments containing hazardous voltage or rotating parts are equipped with door latches that allow locks. Door latches are shipped with a nut and bolt requiring tooled access. If the shipping hardware is not replaced with a pad lock, always re- install the nut and bolt after closing the door to maintain tooled access. CAUTION

where refrigerant or nitrogen gases may be leaking. A sufficient quantity of vapors may be present and cause injury or death. WARNING COMPRESSOR LUBRICANT Polyolester (POE) and Polyvinylether (PVE) oils are two types of lubricants used in hydrofluorocarbon (HFC) refrigeration systems. Refer to the compressor label for the proper compressor lubricant type. CAUTION COIL CLEANERS To prevent damage to the unit, do not use acidic chemical coil cleaners. Do not use alkaline chemical coil cleaners with a pH value greater than 8.5, after mixing, without first using an aluminum corrosion inhibitor in the cleaning solution. CAUTION COIL CLEANERS Some chemical coil cleaning compounds are caustic or toxic. Use these substances only in accordance with the manufacturer’s usage instructions. Failure to follow instructions may result in equipment damage, injury or death. WARNING COIL CLEANING Do not clean DX refrigerant coils with hot water or steam. The use of hot water or steam on refrigerant coils will cause high pressure inside the coil tubing and damage to the coil. CAUTION CONVENIENCE OUTLETS Factory installed convenience outlets are not intended for use while the unit is operating. WARNING

a Factory Trained Service Technician. 2. The unit is for outdoor use only. See General Information section for more information. 3. Every unit has a unique equipment nameplate with electrical, operational, and unit clearance specifications. Always refer to the unit nameplate for specific ratings unique to the model purchased. 4. READ THE ENTIRE INSTALLATION, OPERATION AND MAINTENANCE MANUAL. OTHER IMPORTANT SAFETY PRECAUTIONS ARE PROVIDED THROUGHOUT THIS MANUAL. 5. Keep this manual and all literature safeguarded near or on the unit. COMPRESSOR CYCLING 3 MINUTE MINIMUM OFF TIME To prevent motor overheating compressors must cycle off for a minimum of 3 minutes. 5 MINUTE MINIMUM ON TIME To maintain the proper oil level compressors must cycle on for a minimum of 5 minutes. The cycle rate must not exceed 7 starts per hour. WARNING

Model Options Feature Options GEN SIZE VLT INT PRT A1 A2 A3 A4 B1 B2 B3 1A 1B 1C 1D 2 3 4 5A 5B 5C 6A 6B 6C 7 8 9 10 11 12 13 14A 14B CL - 125 - 3 - 0 - B E 0 4 - 0 0 0 : 0 0 0 0 - 0 0 0 - 0 0 0 - 0 0 0 - J A F 0 0 B H - 0 0 - 0 0 0 A 0 0 B 0 B 15 16 17 18 19 20 21 22 23 11 CL Series Feature String Nomenclature MODEL OPTIONS Series and Generation CL Unit Size 045 = 45 Nominal Tons 060 = 60 Nominal Tons 070 = 70 Nominal Tons 075 = 75 Nominal Tons 095 = 95 Nominal Tons 100 = 100 Nominal Tons 110 = 110 Nominal Tons 125 = 125 Nominal Tons 134 = 134 Nominal Tons 135 = 135 Nominal Tons 155 = 155 Nominal Tons 170 = 170 Nominal Tons 190 = 190 Nominal Tons 210 = 210 Nominal Tons 230 = 230 Nominal Tons Voltage 2 = 230V/3Φ/60Hz 3 = 460V/3Φ/60Hz 4 = 575V/3Φ/60Hz 8 = 208V/3Φ/60Hz Interior Corrosion Protection 0 = Standard A1: Cooling - Compressor Style B = R-410A Dual Circuited Scroll Compressor R = R-410A Independently Circuited Compressors A2: Cooling - Condenser Style A = Air-Cooled Condenser E = Evaporative Condenser A3: Cooling - Coating 0 = Standard B = Polymer E-Coated (Condenser) A4: Cooling - Staging 2 = 2 Stage 3 = 3 Stage 4 = 4 Stage 6 = 6 Stage 8 = 8 Stage B1: Heating - Type 0 = No Heat B2: Heating - Designation 0 = No Heat B3: Heating - Staging 0 = No Heat UNIT FEATURE OPTIONS 1A: Blank 0 = Standard 1B: Blank 0 = Standard 1C: Blank 0 = Standard 1D: Blank 0 = Standard 2: Blank 0 = Standard 3: Blank 0 = Standard 4: Blank 0 = Standard

Model Options Feature Options GEN SIZE VLT INT PRT A1 A2 A3 A4 B1 B2 B3 1A 1B 1C 1D 2 3 4 5A 5B 5C 6A 6B 6C 7 8 9 10 11 12 13 14A 14B CL - 125 - 3 - 0 - B E 0 4 - 0 0 0 : 0 0 0 0 - 0 0 0 - 0 0 0 - 0 0 0 - J A F 0 0 B H - 0 0 - 0 0 0 A 0 0 B 0 B 15 16 17 18 19 20 21 22 23 12 5A: Blank 0 = Standard 5B: Blank 0 = Standard 5C: Blank 0 = Standard 6A: Blank 0 = Standard 6B: Blank 0 = Standard 6C: Blank 0 = Standard 7: Refrigeration Control 0 = Standard A = 5 Min Time Delay Relay Off B = 20 Sec Time Delay Relay C = 115V Outlet, Field Wired D = 115V Outlet, Factory Wired E = Options A + B F = Options A + C G = Options A + D H = Options A + B + C J = Options A + B + D K = Options B + C L = Options B + D 8: Refrigeration Options 0 = Standard A = Hot Gas Bypass on Lead Stage D = Hot Gas Bypass on Lead and Lag Stages 9: Refrigeration Accessories 0 = Standard A = Sight Glass B = Compressor Isolation Valves C = Sight Glass + Compressor Isolation Valves F = Compressor Isolation Valves + Condenser Fan VFDs G = Compressor Isolation Valves + Condenser Fan VFDs + Sight Glass 10: Power Options 0 = Standard Single Point Power Block A = Single Point Power Non-Fused Disconnect (250A) B = Single Point Power Non-Fused Disconnect (400A) C = Single Point Power Non-Fused Disconnect (600A) D = Single Point Power Non-Fused Disconnect (800A) E = Single Point Power Non-Fused Disconnect (1200A) 11: Blank 0 = Standard 12: Controls 0 = Standard B = Phase & Brown Out Protection 13: Special Controls 0 = Standard D = VAV Unit Controller E = Constant Volume Unit Controller F = Make up Air Unit Controller H = Field Installed DDC Controls by Others J = Factory Installed DDC Controls by Others

Model Options Feature Options GEN SIZE VLT INT PRT A1 A2 A3 A4 B1 B2 B3 1A 1B 1C 1D 2 3 4 5A 5B 5C 6A 6B 6C 7 8 9 10 11 12 13 14A 14B CL - 125 - 3 - 0 - B E 0 4 - 0 0 0 : 0 0 0 0 - 0 0 0 - 0 0 0 - 0 0 0 - J A F 0 0 B H - 0 0 - 0 0 0 A 0 0 B 0 B 15 16 17 18 19 20 21 22 23 13 14A: Blank 0 = Standard 14B: Blank 0 = Standard 15: Blank 0 = Standard 16: Blank 0 = Standard 17: Blank 0 = Standard 18: Warranty 0 = Standard Warranty A = Extended Compressor Warranty Years 2-5 19: Code Options 0 = Standard ETL USA Listing A = M.E.A. (New York) D = Chicago - Cool Only H = ETL USA + Canada Listing 20: Blank 0 = Standard 21: Evaporative Condenser Option 0 = Standard, No Evaporative Condenser A = Basic Package B = Low Ambient Package 22: Blank 0 = Standard 23: Paint and Special Pricing Authorization B = Standard Paint U = Special Price Authorization and Special Paint X = Special Price Authorization w/ Standard Paint

assembled, wired, and shipped with a 100 psi nitrogen holding charge. Models are available for air-cooled and evaporative condenser applications. Unpacking: When received, check unit for damage that might have occurred in transit. If damage is found it must be noted on the carrier’s Freight Bill. A request for inspection by carrier’s agent must be made in writing at once. Also, check the unit nameplate to ensure the correct model size and voltage have been received to match the job requirements. OWNER'S INFORMATION Warning: Failure to observe the following instructions will result in premature failure of your system, and possible voiding of the warranty. Never cut off the main power supply to the unit, except for complete shutdown. When power is cut off from the unit, any compressors using crankcase heaters cannot prevent refrigerant migration. This means the compressor will cool down, and liquid refrigerant may accumulate in the compressor. Since the compressor is designed to pump refrigerant gas, damage may occur when power is restored. Before unit operation, the main power switch must be turned on for at least twenty four hours for units with compressor crankcase heaters. This will give the crankcase heater time to clear any liquid accumulation out of the compressor before it is required to run. Always control the system from the thermostat, or control panel, never at the main power supply (except for emergency or for complete shutdown of the system). 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 qualified installer, service agency or if gas fired units, the gas supplier. Refer to installation instructions provided with the unit and this manual. The compressors must be on a minimum of 5 minutes and off for a minimum of 3 minutes. The cycle rate must be no more than 7 starts per hour. The compressor life will be seriously shortened by reduced lubrication, and the pumping of excessive amounts of liquid oil and refrigerant. QUALIFIED INSTALLER Improper installation, adjustment, 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 must be kept with the unit. WARNING Scroll compressors will be damaged by operation with the wrong rotation. THE SUCTION PRESSURE TRANSDUCER HAS BEEN DISCONNECTED AFTER TESTING AT THE FACTORY. The wiring must be reconnected and proper rotation determined at the time of start-up by a qualified service technician using suction and discharge pressure gauges. Any alteration must be made at the unit power connection. WARNING

both ladder and point-to-point form are laminated in plastic and located inside the control compartment door. General Maintenance: When the initial startup is made and on a periodic schedule during operation, it is necessary to perform routine service checks on the performance of the condenser. This includes reading and recording suction pressures and checking for normal sub-cooling and superheat. See the evaporative condenser and air-cooled condenser sections in this manual for specific details. INSTALLATION Lifting and Handling: If cables or chains are used to hoist the unit they must be the same length and care must be taken to prevent damage to the cabinet. Before lifting unit, be sure that all shipping material has been removed from unit. If the unit includes an evaporative condenser, make sure the tank is empty before lifting. Secure hooks and cables at all lifting points/lugs provided on the unit. Do not push, pull or lift the unit from anything other than its base. UNIT MUST BE RIGGED AT ALL MARKED LIFTING POINTS (Typical) Condenser Placement: The AAON condenser is designed for outdoor applications and mounting at ground level or on a rooftop. It must be placed on a level and solid foundation that has been prepared to support its weight. When installed at ground level, a one- piece concrete slab must be used with footings that extend below the frost line. With ground level installation, care must be taken to protect the coil fins from damage due to vandalism or other causes. The placement relative to the building air intakes and other structures must be carefully selected. Be sure to observe the dimensions that are on the rating plate of the condenser for operational and service clearances, which will appear as follows: Table 1 - Service Clearances Location Unit Size 045-135 134-230 Front - Vestibule Door Side 100" 142" Back - Opposite of Front 100" 142" Left Side - Condenser End 100" 100" Right Side - Opposite of Left 100" 100" Top UNOBSTRUCTED Condenser coils and fans must be free of any obstructions in order to start and operate properly with a correct amount of airflow. For proper unit operation, the immediate area around condenser must remain free of debris that may be drawn in and obstruct airflow in the condensing section. Consideration must be given to obstruction caused by snow accumulation when placing the unit. Compressor Compartment Exhaust Fan: Prior to unit operation the compressor compartment exhaust fan shipping support MUST BE removed from the exterior of the unit. The exhaust fan also requires the installation of the exterior rain hood provided with the unit.

vibration transmission is a factor, vibration isolators may be used. Access Doors: A lockable access door is provided to the compressor and electrical compartment. A light switch is on the wall of the compressor control compartment. Standard Evacuation Instructions: Proper system evacuation is critical to remove moisture and non-condensables from the system before charging the system with refrigerant. Use the following procedure to ensure the entire system is pulled into a good vacuum. 1. System evacuation must be performed anytime a system is open to atmospheric pressure. The POE oils used with R-410A are extremely hydroscopic in nature and immediately begin pulling in moisture once the system is opened to the atmosphere. 2. Before starting to evacuate the system, you MUST ensure that there are no leaks by pressurizing the system with 400 psig of dry nitrogen and verifying no pressure loss after one hour. 3. Four valve manifold gauge sets are more effective than standard manifold gauge sets due to the extra hose port in combination with a 3/8’’ evacuation port. The larger diameter evacuation port will expedite system evacuation. 4. Connect the manifold set to the condensing unit with one hose on the suction line service valve, one hose on the liquid line service valve and if an extra Schrader valve is field installed on the suction line, connect a third hose. Connect the vacuum pump to the manifold set using a 3/8” vacuum rated hose. Figure 1 - CU evacuation connections 5. An accurate micron gauge must be used and checked by pulling a vacuum on the gauge by itself and verify a rapid drop to less than 100 microns within a few minutes. 6. Do not attach the micron gauge to the system until the gauge manifold is reading 28’’ of vacuum to ensure the micron gauge does not see pressure and is thus damaged. MICRON GAUGES WILL BE DAMAGED BY PRESSURE!!! 7. It is a good practice to replace the vacuum pump oil after one hour of the evacuation process. The oil can be broken down in the pump in the initial first hour causing system evacuation to take longer than it should. 8. The minimum micron level required by AAON is 350 microns for systems using POE oils. 9. The system must then be isolated and the pump turned off to check for vacuum rise due to leaks or moisture in the system. The micron gauge must not rise above 500 microns after 30 minutes of wait time.

Evacuation Instructions: Proper system evacuation is critical to remove moisture and non-condensables from the system before charging the system with refrigerant. Systems with low ambient flooded condenser option require the following procedure to ensure the entire system is pulled into a good vacuum. 1. Perform system evacuation anytime a system is open to atmospheric pressure. The POE oils used with R-410A are extremely hydroscopic in nature and immediately begin pulling in moisture once the system is opened to the atmosphere. 2. Open the reheat valve to 50% when evacuating. 3. Before starting to evacuate the system, you MUST ensure that there are no leaks by pressurizing the system with 400 psig of dry nitrogen and verifying no pressure loss after one hour. 4. Four valve manifold gauge sets are more effective than standard manifold gauge sets due to the extra hose port in combination with a 3/8’’ evacuation port. The larger diameter evacuation port will expedite system evacuation. 5. Connect the manifold set to the condensing unit with one hose on the suction line service valve, one hose on the liquid line service valve, and a third hose on the reheat line service valve. Connect the vacuum pump to the manifold set using a 3/8” vacuum rated hose. Figure 2 shows two circuits. The first circuit has a reheat line, the second circuit is just the suction and liquid line. Figure 2 - CU evacuation connections 6. FAILURE to connect to the liquid line service valve will result in the receiver tank not being fully evacuated and most likely lead to non-condensables in the system. 7. An accurate micron gauge must be used and checked by pulling a vacuum on the gauge by itself and verify a rapid drop to less than 100 microns within a few minutes. 8. Do not attach the micron gauge to the system until the gauge manifold is reading 28’’ of vacuum to ensure the micron gauge does not see pressure and is thus damaged. MICRON GAUGES WILL BE DAMAGED BY PRESSURE!!!

the reheat line where it enters the air handler unit. See Figure 3 below. Figure 3 - AHU evacuation connections 10. It is a good practice to replace the vacuum pump oil after one hour of the evacuation process. The oil can be broken down in the pump in the initial first hour causing system evacuation to take longer than it should. 11. The minimum micron level required by AAON is 350 microns for systems using POE oils. 12. The system must then be isolated and the pump turned off to check for vacuum rise due to leaks or moisture in the system. The micron gauge must not rise above 500 microns after 30 minutes of wait time. Charging Refrigerant: Charging a system in the field must be based on determination of liquid sub-cooling and evaporator superheat. On a system with a thermostatic expansion valve liquid sub-cooling is more representative of the charge than evaporator superheat but both measurements must be taken. Before Charging: Refer to the Unit Nameplate to determine the proper refrigerant to charge the system with. The unit being charged must be at or near full load conditions before adjusting the charge. Units equipped with hot gas bypass must have the hot gas bypass valve 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. After adding or removing charge the system must be allowed to stabilize, typically 10-15 minutes, before making any other adjustments. The type of unit and options determine the ranges for liquid sub-cooling and evaporator superheat. Refer to Table 2 when determining the proper sub- cooling. The vertical rise of the liquid line must be known in order to adjust the sub-cooling range for proper charge. Units equipped with low ambient (0°F) option see special charging instructions at the end of the charging instructions. CLEAN AIR ACT 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. WARNING Reheat Line on the Outside of the Air Handler

1. Measure the temperature of the liquid line as it leaves the condenser coil. 2. Read the gauge pressure reading of the liquid line close to the point where the temperature was taken. You must use liquid line pressure as it will vary from discharge pressure due to condenser coil pressure drop. 3. Convert the pressure obtained in Step 2 to a saturated temperature using the appropriate refrigerant temperature-pressure chart. 4. Subtract the measured liquid line temperature in Step 1 from the saturated temperature in Step 3 to determine the liquid sub-cooling. 5. Compare calculated sub-cooling to Table 2 for the appropriate unit type and options. Checking Evaporator Superheat: 1. Measure the temperature of the suction line close to the evaporator. 2. Read gauge pressure at the suction line close to the evaporator. 3. Convert the pressure obtained in Step 2 to a saturated temperature using the appropriate refrigerant temperature-pressure chart. 4. Subtract the saturated temperature in Step 3 from the measured suction line temperature in Step 1 to determine the evaporator superheat. 5. Compare calculated superheat to Table 2 for the appropriate unit type and options. Table 2 - Acceptable Refrigerant Circuit Values Sub- cooling (°F) Superheat (°F) Sub-cooling W/Hot Gas Reheat (°F) Air Cooled Condenser 8-15* 8-15** 5-15* Evaporative Cooled Condenser 6-10* 8-15** 8-12* Water Cooled Condenser 6-10* 8-15** 8-12* * Sub-cooling must be increased by 1°F per 10 feet of vertical liquid line rise for R-410A ** Superheat will increase with long suction line runs. The system is undercharged if: 1. The superheat is too high and 2. The sub-cooling is too low Correct an undercharged system by adding refrigerant to the system to reduce superheat and raise sub-cooling. If the sub-cooling is correct and the superheat is too high, the TXV may need adjustment to correct the superheat. Refrigerant overcharging leads to excess refrigerant in condenser coils resulting in elevated compressor discharge pressure. DO NOT OVERCHARGE! CAUTION

For units equipped with low ambient refrigerant flood back option being charged in the summer when the ambient temperature is warm: If the ambient is above 70°F, charge to approximately 1-2°F of sub-cooling measured at the inlet to the expansion valve. Once enough charge has been added to get the evaporator superheat and sub-cooling values to the correct setting more charge must be added. Add the calculated charge amount to flood the condenser coil. The additional charge is required for the system when running in cold ambient conditions. Contact Technical Support for this charge amount. AAON Technical Support Ph: (918) 382-6450 [email protected] For units equipped with low ambient refrigerant flood back option being charged in the winter when the ambient temperature is cold: 1. If the ambient is below 70°F, charge to approximately 1-2°F of sub-cooling measured at the inlet to the expansion valve. Once enough charge has been added to get the evaporator superheat and sub-cooling values to the correct setting, more charge may need to be added. If the ambient temperature is 0°F, no more charge is required. If the ambient temperature is between 0°F and 70°F, multiply the charge amount needed at 70°F ambient (call AAON Technical Support to get this value) by the percentage below that corresponds to the ambient temperature. The result is the additional charge that must be added to the circuit. Table 3 - % Charge to Flood Condenser Coil for Ambient Below 70°F Condenser Ambient Temperature °F % of flooded charge needed at 70°F ambient 60 60% 50 37% 40 24% 30 15% 20 8% 0 0% 2. Check the unit for proper operation once the ambient temperature is above 80°F. Low Ambient Operation: The AAON low ambient (condenser flood-back) system is used to operate a refrigerant system below 35°F outside air temperature. As the ambient temperature drops, the condenser becomes more effective therefore lowering the head pressure. When the head pressure gets too low, there will be insufficient pressure to operate the expansion valve properly. During low ambient temperatures, it is difficult to start a system because the refrigerant will migrate to the cold part of the system (condenser) and make it difficult for refrigerant to flow. The AAON low ambient system maintains normal head pressure during periods of low ambient by restricting liquid flow from the condenser to the receiver, and at the same time bypassing hot gas around the condenser to the inlet of the receiver. This backs liquid refrigerant up into the condenser reducing its capacity that in turn increases the condensing pressure. At the same time the bypassed hot gas raises liquid pressure in the receiver, allowing the system to operate properly. There are different types of low ambient control used. The following describe the different systems. Inspect the unit to determine the system used.

valve that modulates to maintain receiver pressure. As the receiver pressure drops below the valve setting (180 psig for R-22 and 295 psig for R-410A), the valve modulates to bypass discharge gas around the condenser. The discharge gas warms the liquid in the receiver and raises the pressure to the valve setting. The following schematic shows an example system using the LAC valve. Figure 4 - Piping Schematic of Example system using the LAC valve

Verify the unit nameplate agrees with the power supply. Connect power and control field wiring as shown on the unit wiring diagram provided with the unit. Table 4 - Nameplate Voltage Markings & Tolerances Hz Nameplate Voltage Nominal System Voltage Operating Voltage Range 1 Acceptable Performance Range2 Min Max Min Max 60 115 120 104 127 108 126 208/230 208/240 187 254 187 252 208 208 187 228 187 228 230 240 208 254 216 252 265 277 240 293 249 291 460 480 416 508 432 504 575 600 520 635 540 630 50 230 230 198 254 208 254 400 400 344 440 360 440 Notes: 1. Operating voltage is the min and max voltage for which the unit can function. Never operate outside of this min and max voltage. 2. The Acceptable Performance Range is the min and max voltage for which the unit performance is designed and rated to give acceptable performance. Route power and control wiring, separately, through the utility entry. Do not run power and signal wires in the same conduit. Size supply conductors based on the unit MCA rating. Supply conductors must be rated a minimum of 167°F (75°C). Protect the branch circuit in accordance with code requirements. The unit must be electrically grounded in accordance with local codes, or in the absence of local codes, the current National Electric Code, ANSI/NFPA 70 or the current Canadian Electrical Code CSA C22.1. NOTE: Units are factory wired for 208V, 230V, 460V, or 575V. In some units, the 208V and 230V options may also be provided in single or three phase configurations. The transformer configuration must be checked by a qualified technician prior to startup. ELECTRIC SHOCK Electric shock hazard. Before attempting to perform any installation, service, or maintenance, shut off all electrical power to the unit at the disconnect switches. Unit may have multiple power supplies. Failure to disconnect power could result in dangerous operation, serious injury, death or property damage. WARNING

disconnect. All wiring beyond this point has been done by the manufacturer and cannot be modified without affecting the unit's agency/safety certification. All units require field supplied electrical overcurrent and short circuit protection. Device must not be sized larger than the Maximum Overcurrent Protection (MOP) shown on the unit nameplate. Supply voltage must be within the min/max range shown on the unit nameplate. Available short circuit current must not exceed the short circuit current rating (SCCR) shown on the unit nameplate. Three phase voltage imbalance will cause motor overheating and premature failure. The maximum allowable imbalance is 2%. Voltage imbalance is defined as 100 times the maximum deviation from the average voltage divided by the average voltage. Example: (221V+230V+227V)/3 = 226V, then 100*(226V- 221V)/226V = 2.2%, which exceeds the allowable imbalance. Check voltage imbalance at the unit disconnect switch and at the compressor terminal. Contact your local power company for line voltage corrections. NOTE: Startup technician must check for proper motor rotation and check fan motor amperage listed on the motor nameplate is not exceeded. Motor overload protection may be a function of the variable frequency drive and must not be bypassed. Wire control signals to the unit’s low voltage terminal block located in the controls compartment. 3-PHASE ROTATION Rotation must be checked on all MOTORS AND COMPRESSORS of three phase units. Condenser fan motors must be checked by a qualified service technician at startup and any wiring alteration must only be made at the unit power connection. Variable frequency drives are programmed to automatically rotate the fan in the correct rotation. Do not rely on fans with variable frequency drives for compressor rotation. CAUTION SEALING ELECTRICAL ENTRIES Installing Contractor is responsible for proper sealing of the electrical entries into the unit. Failure to seal the entries may result in damage to the unit and property. CAUTION Three phase voltage imbalance will cause motor overheating and premature failure. CAUTION

CL condensing unit refrigerant piping connections are located in the upper corner of the service vestibule side of the unit (opposite the condenser section) as shown in Figure 5. The piping connections are protected with a shipping cover that must be removed prior to copper connection and installation. Figure 5 - Refrigerant Piping Connections Evaporative Condenser Field Piping Connections: There are two field water connections that must be made for the evaporative condenser. There is a ¾” PVC socket city make-up water connection and a 2” PVC socket drain connection (as shown on the next page). Connect this drain to a sanitary sewer or other code permitted drain. These connections can go through the base or the wall of the unit. There is a cutout in the base with a cap that is 1” tall and the cap is sealed to the unit base to prevent any leaks in the unit from penetrating into the building. Any piping through the base must go through a field cutout in this cap. The pipes must be sealed to the cap once the piping is complete to prevent any leaks in the unit from penetrating into the building. A field cutout must be made in the wall if the evaporative condenser piping is to go through the unit wall. This cutout must be sealed once the piping is installed to prevent water from leaking into the unit.

startup of the condenser be sure that these items have been checked. 1. Verify that electrical power is available to the unit. 2. Verify that any remote stop/start device is requesting the condenser to start. While performing the Startup, use the Condensing Startup Form at the back of this booklet to record motor amps and any other comments. Startup: Use the General Check List at the top of the Startup Form to make a last check that all the components are in place and the power supply is energized. Note: Condensing fan operation should start with the first compressor. Cycle through all the compressors to confirm that all are operating within tolerance. When unit is running, observe the system for a complete operation cycle to verify that all systems are functioning properly. While performing the check, use the Condenser Startup Form to record observations of amps and refrigerant pressures. When all is running properly, place the controller in the Run mode and observe the system until it reaches a steady state of operation. Before leaving installation, a complete operating cycle must be observed to verify that all components are functioning properly. COMPRESSOR ROTATION Scroll compressors are directional and will be damaged by operation in the wrong direction. Low pressure switches on compressors have been disconnected after factory testing. Rotation must be checked by a qualified service technician at startup using suction and discharge pressure gauges and any wiring alteration must only be made at the unit power connection. 3-PHASE ROTATION Rotation must be checked on all MOTORS AND COMPRESSORS of three phase units. Condenser fan motors must all be checked by a qualified service technician at startup and any wiring alteration must only be made at the unit power connection. Variable frequency drives are programmed to automatically rotate the fan in the correct rotation. Do not rely on fans with variable frequency drives for compressor rotation. CAUTION CAUTION CAUTION

Multi-Wing Z Series Aluminum Fan Blade Pitch Angle Setting Instructions: Before You Begin, to maintain balance of fan: 1. Mark the hub castings across a joint, so the fan hub can be reassembled in the same orientation. 2. Mark the location of any balancing weight. Balancing weight will be on the outer bolt circle, in the form of washers, and/or longer bolts, or an additional balancing nut. 3. Number the blades and blade sockets, so that they are replaced into their original position. 4. If possible, note the location of the pitch setting pin in the blade socket, and whether pin is located in the Hub or Retainer half of the fan. Step 1. Determine Boss Location Code: “A” or “B” The boss is the center section of the hub through which the fan is mounted to the shaft, and typically contains either setscrews or a center- tapered hole where the bushing inserts. Select boss location A or B: A is the boss on air inlet, including AS configurations. B is the boss on air discharge, including BS. For flange mounted fans, use boss location A for R rotation fans, and boss location B for L rotation fans. Step 2. Find Blade Pitch Angle: ( 20, 25, 27.5, 30, 32.5, 35, 37.5, 40, 45 or 50 ) • Carefully disassemble fan on flat surface and note in which groove the pin is located. Refer to groove number code diagram. • Using diagrams in step 5, determine if the pin was in the hub (HUB) or retainer side (RET) of fan. • Using table in step 4, find the possible blade pitch. • Using table in step 3, select your blade angle based on whether your pin was in the HUB or RET. Step 3. Determine Hub/Retainer Code: “HUB” or “RET” Step 4. - Determine Groove Number: 1 or 2 or 3 or 4

Definition of HUB and RET for purposes of instructions. For 2-piece hubset: Using the HUB or RET code found in Step 3:  If code is HUB, place the hub down on work surface first (one or two pieces, depending on above).  If code is RET, place one retainer ring only down on the work surface first. (A weighted coffee can could be used to elevate the fan from the work surface).  Using the groove number, place the locking pin in the groove number that was found in Step 4. Insert Blades: Place the blade over the pin in the hub/retainer blade socket, so that the pin also fits into the appropriate pitch angle groove in the blade. Repeat for all blades. Assemble hub set together, aligning the match marks that were made. Replace any balancing weight to its original position. To finish, tighten the bolts in a cross pattern to 5 to 6 ft-lbs of torque. Multi-Wing W Series Black Glass Reinforced Polypropylene Fan Blade Pitch Angle Setting Instructions: Step 1. Note original position of retaining plates, center boss and all hardware including additional hardware used for balancing. Step 2. Remove all the bolts and nuts. Step 3. Determine blade rotation – on the concave side of the blade is a blade marking showing 6WR, 6WL, 7WL, 7WR, or 9WR. The “L” and “R” denote the rotation of the blade. Step 4. Replace the pitch insert in the blade root with an insert of the desired pitch. Step 5. Replace blades to their original location. Step 6. Replace all nuts, bolts, and washers on the fan hub. Step 7. Replace retaining plates and center boss to original location. Step 8. Tighten nuts and bolts to 14 ft-lbs of torque.

General: Qualified technicians must perform routine service checks and maintenance. This includes reading and recording the condensing and suction pressures and checking for normal sub-cooling and superheat (see Charging Refrigerant:). Air-cooled and evaporative condenser units require different maintenance schedules/procedures. Unit specific instructions for both types are included in this manual. Compressors: The scroll compressors are fully hermetic and require no maintenance except keeping the shell clean. Refrigerant Suction Line Filter: Each refrigerant circuit contains a replaceable core suction line filter. One month after start- up, remove the filter element. The replaceable core suction filters are provided with pressure taps and shutoff valves for isolation when removing the filter. For safety purposes a service manifold must be attached prior to filter maintenance. Suction Filter Removal Instructions 1. Shut down operation of the unit 2. Close both shut-off valves to isolate the suction filter 3. Reclaim the refrigerant from the suction filter section 4. Remove the bolts from the suction filter end plate 5. Remove the pleated filter assembly 6. Replace the suction filter end plate and bolts 7. Evacuate the suction filter assembly to 500 microns 8. Open both shut-off valves Prior to filter core service, a service manifold MUST BE attached to in and out pressure connections to assure no pressure exists during filter maintenance. Non-compliance could result in injury or violation of EPA regulations. Service gauges MUST BE connected before operating the isolation valves for the replaceable core filter. WARNING WARNING

Each refrigerant circuit contains a replaceable core filter drier. Replace when there is excessive pressure drop across the assembly or moisture is indicated in a liquid line sight glass. Table 5 - Liquid Line Filter Drier Pressure Drop The filter driers are provided with pressure taps and shutoff valves for isolation when changing the core. For safety purposes a service manifold must be attached prior to filter maintenance. Evaporator/Heat Exchangers: Normally no maintenance or service work will be required for a matching direct expansion evaporator with a thermal expansion valve to regulate refrigerant. Lubrication: All original motors and bearings are furnished with an original factory charge of lubrication. Certain applications require bearings be re- lubricated periodically. The schedule will vary depending on operating duty, temperature changes, or severe atmospheric conditions. Re-lubricate bearings at normal operating temperatures, but not when running. Rotate the fan shaft by hand and add only enough grease to purge the seals. DO NOT OVERLUBRICATE. Service Information: If the unit will not operate correctly and a service company is required, only a company with service technicians qualified and experienced in both condensing units and air conditioning are permitted to service the systems to keep warranties in effect. If assistance is required, the service technician must contact AAON. Replacement Parts: Parts for AAON equipment may be obtained from your local AAON representative. When ordering parts reference the unit serial number and part number. AAON Technical Support 2424 S. Yukon Ave. Tulsa, OK 74107 Ph: (918) 382-6450 [email protected] www.AAON.com Note: Before calling, technician must have model and serial number of the unit available for the service department to help answer questions regarding the unit Prior to filter core service, a service manifold MUST BE attached to in and out pressure connections to assure no pressure exists during filter maintenance. Non-compliance could result in injury or violation of EPA regulations. Service gauges MUST BE connected before operating the isolation valves for the replaceable core filter. WARNING WARNING

Evaporative cooling equipment rejects heat by evaporating a portion of the recirculated water spray and discharging it from the unit with the hot, saturated air. As the spray water evaporates, it leaves behind the mineral content and impurities of the supply water. If these residuals are not purged from the water distribution system, they will become concentrated and lead to scaling, corrosion, sludge build-up and biological fouling. A water treatment monitoring and control system has been furnished with this unit. Be sure to read the complete manual that has been furnished. All water treatment is a combination of bleed water and chemical treatment for proper control of the residuals and to prevent any biological contamination. Severe Service: The following maintenance procedures are basic requirements for normal operating environments. For severe operating conditions, the frequency of inspection and service must be increased. Air containing industrial and chemical fumes, salt, dust, or other airborne contaminates and particulates will be absorbed by the recirculating water system and may form solutions and deposits harmful to the products and personnel. Safety: The recirculating water system contains chemical additives for water quality control and biological contaminants removed from the air by the washing action of the water. Personnel exposed to the saturated effluent, drift, or direct contact must use proper precaution. Proper location of the evaporative condenser requires good judgment to prevent the air discharge from entering fresh air intakes or to avoid allowing contaminated building exhaust from entering the condenser. Follow local and national codes in locating the evaporative condenser but as minimum the evaporative condenser sump must be 15 feet from the nearest intake. Batch-loading chemicals into the unit IS NOT PERMITTED. The control system must regulate the chemical feed. The evaporative condenser must be thoroughly cleaned on a regular basis to minimize the growth of bacteria, including Legionella Pneumophila, to avoid the risk of sickness or death. Service personnel must wear proper personal protective equipment. DO NOT ATTEMPT ANY SERVICE UNLESS THE FAN MOTOR IS LOCKED OUT. WARNING WARNING

may seriously degrade the capacity of the equipment. Make sure the equipment is located such that discharge air from the condenser does not enter the condenser air inlet. Warranties: Please refer to the limitation of warranties in effect at the time of purchase. Condenser Tube Inspection: The coil is leak tested at 450 psig before shipment. AAON will not be responsible for loss of refrigerant. It is the responsibility of the installer to verify that the system is sealed before charging with refrigerant. If the unit is operated during low ambient temperature conditions, freeze protection for the recirculating water system must be provided. Freeze Protection: In order to prevent water temperatures from dropping below 50°F, this unit is equipped with a variable frequency drive (VFD) on the fan motors when the refrigeration system is operating. Recirculating Water System: Electric sump heaters are available to keep the sump water from freezing when the refrigeration system is not operating. An electric resistance heater is supplied in the vestibule when sump heaters are selected. Note: The condenser must not be operated with the fan on and the pump cycled on and off to maintain head pressure control under any conditions. The unit is equipped with a water temperature controller which varies fan speed to maintain sump water temperature. This unit is not equipped with a compressor discharge pressure controller for fan speed modulation and therefore must not be operated without water flow. EVAPORATIVE CONDENSER - PRE START-UP Do not start the evaporative condenser or compressors without installation of proper water treatment chemicals. Contact your local water treatment expert for correct selection of water treatment chemical, adjustment of chemical feed and bleed rates. Reverse osmosis and deionized water is corrosive and cannot be used on the CL evaporative cooled condensing units. Cleanliness: Dirt and debris may accumulate in the sump during shipping and storage. Clean the sump prior to start-up to prevent clogging the water distribution system. Any surfaces that show contamination must be cleaned ONLY with a commercial stainless steel cleaner to restore the initial appearance. Inspect the inlet screens for foreign material. Pump Operation: Before initial start of the pump, check as follows: 1. Be sure that pump operates in the direction indicated by the arrow on the pump casing. Check rotation each time motor leads have been disconnected. 2. Check all connections of motor and starting device with wiring diagram. Check voltage, phase and frequency of line circuit with motor name plate. 3. Check suction and discharge piping and pressure gauges for proper operation. 4. Turn rotating element by hand to assure that it rotates freely. Running: Periodically inspect pump while running, but especially after initial start-up and after repairs. 1. Check pump and piping for leaks. Repair immediately.

reference. 3. Record voltage, amperage per phase, and kW. Condenser Fan Motors: The direct-drive condenser motors on AAON evaporative condensers are 1200-rpm premium efficiency motors controlled by a VFD. These motors are totally enclosed air over motors with weep holes in the bottom end bell so that any condensation can drain out of the motor. The motors have a small electric resistance heater installed inside the casing to keep the motors warm when they are deactivated. The heaters are designed to keep the interior of the motor 10°F warmer than the surrounding ambient temperature. This prevents condensation from forming inside the motor. Ensure that fan is tightly mounted to the motor shaft and the motor mounting bolts are aligned and secure. Water Make-up Valve: The sump water level is controlled by a set of conductivity probes at different levels in the sump. This water level controller is located in the vestibule behind the condenser pump. There are four conductivity probes in this controller. There is a reference probe (shown as “ref” on the wiring diagram). This probe is one of the two longest probes. The other long probe is the low water level probe (shown as “lo” on the wiring diagram). The medium length probe is for the medium water level (shown as “med” on the wiring diagram). The short probe is for the high water level (shown as “hi” on the wiring diagram). There is a solenoid valve in the make-up water line that is activated by the water level controller. The water level controller determines the level of water in the sump based on conductivity between two probes. If the controller sees conductivity between two probes, it knows that water is at least at the level of that probe. If the water in the sump is below the low probe, it will not allow the condenser pump or the sump heater to operate. It will activate the make-up water solenoid to try to fill the sump assuming water is flowing to the unit. Once water is above the low probe, it will allow the condenser pump and sump heater (if ordered and the ambient temperature is below 40°F) to operate. The make- up water solenoid will remain activated until water gets to the high water level. The make-up water solenoid will deactivate until water gets to the medium water level. In normal operation, the water level will swing between the medium and high water levels. The maximum high water level is 1” below the overflow drain which occurs after the make-up water valve shuts off when the water level reaches the high level probe. Figure 7 - Water Level Sensor Maintain make-up water supply pressure between 15 and 60 psig for proper operation of the valve. Inspect the make-up water valve assembly monthly and adjust as required. Replace the valve seat if leakage occurs when the valve is in the closed position.

All AAON evaporative condensers come equipped with a water treatment system that must be maintained by a local water treatment professional trained in the water treatment of evaporative condensers. This system consists of a controller, three chemical pumps and storage tanks, a conductivity sensor, a motorized ball valve for water bleed, and a water meter. One chemical pump and tank is typically used for a descaling chemical to prevent scale from forming in the condenser. The other two pumps and tanks are typically used for two different biocides (to kill any microorganisms that could grow in the condenser). Two biocides are used to prevent organisms from becoming resistant to one chemical. The mineral content of the water must be controlled. All make-up water has minerals in it. As water is evaporated from the condenser, these minerals remain. As the mineral content of the water increases, the conductivity of the water increases. The water treatment controller monitors this conductivity. As the water conductivity rises above set point, the controller will open a motorized ball valve on the discharge side of the condenser pump and dumps water into the condenser drain until conductivity is lowered. While the motorized ball valve is opened, the controller will not disperse chemicals. The chemicals are dispersed by the water treatment controller based on the scheduled input by the water treatment professional. (See the separate manual for the water treatment controls for specific programming information.) The water meter measures the quantity of make- up water used by the condenser. Any water treatment program must be compatible with stainless steel, copper, aluminum, ABS plastic and PVC. Batch feed processes must never be used as concentrated chemicals can cause corrosion. Never use hydrochloric acid (muriatic acid) as it will corrode stainless steel. Sequence of Operation: On a call for cooling, the condenser pump is activated. A pressure switch in the pump discharge is bypassed for six seconds by a time delay relay in order for the pump to establish recirculating water flow. If flow is not proven within the six seconds, the pressure switch opens, breaking the safety circuit, thereby shutting down the entire system. This pressure switch is set to close at 3 psi and open at 1 psi. A Johnson Controls S350C measures the water temperature in the pump discharge line. If the sump water temperature exceeds 105°F, the cooling system will be shut down thereby preventing damage to the evaporative condenser. If a fault occurs in the evaporative condenser fan motor VFD, normally closed fault terminals on the VFD will interrupt the safety circuit, thereby shutting down the system. If the VFD does fault and cannot be reset, there is a VFD bypass switch mounted near the VFD. This switch has four positions—line, off, drive, and test. The “line” position will bypass the VFD, sending power to the motor. In this position, the condenser fans will run at full speed. The “off” position will not allow power to pass through the switch. This functions as a disconnect switch. The “drive” position runs power through the VFD. This is the normal operation for the switch. The “test” position routes power to the VFD but not to the motor. This is useful for running tests on the VFD without sending power to the motor. A Johnson Controls A350P controls the VFD speed. This device sends a 0-10 VDC signal to the VFD. This controller is set to maintain a sump temperature of 70°F. On a rise in sump temperature, the controller increases the voltage to the VFD, increasing the speed of the condenser fans. Conversely, on a drop in sump temperature, the controller will decrease the voltage to the VFD, decreasing the speed of the condenser fans. An outside air thermostat does not allow the condenser to operate when the ambient temperature is below 35°F.

MAINTENANCE REQUIREMENTS Pump Maintenance: Cleaning - Remove oil, dust, water, and chemicals from exterior of motor and pump. Keep motor air inlet and outlet open. Blow out interior of open motors with clean compressed air at low pressure. Labeled Motors - It is imperative for repair of a motor with Underwriters’ Laboratories label that original clearances be held; that all plugs, screws, other hardware be fastened securely, and that parts replacements be exact duplicates or approved equals. Violation of any of the above invalidates Underwriters’ Label. Fan Motor Maintenance: Same as pump maintenance Access Doors: If scale deposits or water is found around the access doors, adjust door for tightness. Adjust as necessary until leaking stops when door is closed. Bearings - Lubrication: Every 6 months or after a prolonged shut down. Use waterproof, lithium based grease. Below 32°F - Esso Exxon or Beacon 325. Above 32°F – Mobil Mobilox EP2, Shell Alvania EP2 or Texaco RB2. Required Monthly Inspection: 1. Clean sump section interior. Dirt and other impurities which have accumulated in the sump must be removed from the sump area. Shut off make-up water ball valve and open the drain connection for flushing of the sump. 2. Clean dirt out of sump using a water hose (not a pressure washer). 3. Clean sump suction strainer. 4. Check water operating level. Adjust float as required. 5. Inspect fan motor(s) and water circulation pump(s) and lubricate per the lubrication nameplate or manufacture’s recommendations. 6. Inspect axial fans and eliminators removing any debris which may have accumulated during operation. 7. Inspect the water distribution system to insure that nozzles and spray orifices are functioning correctly. The inspection must be made with the circulation pump on and fans off. Mist Eliminators: The mist eliminators must be correctly positioned when they are replaced during cleaning or service. Air Inlet: Inspect the air inlet louvers and mist eliminators into the condenser section on a monthly basis to remove any paper, leaves or other debris that may block the airflow. Stainless Steel Base Pan: The base pan under the tube bundles is stainless steel and may sometimes become tarnished due to contamination. Inspect these surfaces annually to ensure they remain clean of any contamination that may result in damage. Any surfaces that show contamination must be cleaned ONLY with a commercial stainless steel cleaner to restore the initial appearance. Propeller Fans and Motors: The fans are directly mounted on the motor shafts and the assemblies require minimal maintenance except to assurance they are clear of dirt or debris that would impede the airflow. Required Annual Inspection: In addition to the above maintenance activities, a general inspection of the unit surface must be completed at least once a year. Remove spray header and flush out. Cleaning: Mechanical cleaning, including pressure washing, must never be performed as surfaces and seals could be damaged. Chemical cleaning that is safe for stainless steel, copper, aluminum, ABS plastic

the evaporative condenser. A proper water treatment program should reduce cleaning needs. EVAPORATIVE CONDENSER - WATER QUALITY Recirculating Water Quality Guidelines: Table 6 - Water Quality Cycles of concentration (the ratio of dissolved solids in recirculated water to dissolved solids in make-up), must be determined and monitored frequently by a competent water treatment expert. To limit cycles of concentration to maintain the above guideline, it is necessary to “bleed” a certain portion of the recirculated water. This is achieved automatically with a solenoid valve actuated by a conductivity meter set at the desired conductivity corresponding to the desired cycles of concentration. These are guidelines and even though these individual values are met, under certain conditions the water quality can be aggressive. For example, water with very low alkalinity and levels of chlorides and sulfates approaching maximum recommended levels can be corrosive. Mechanical Cleaning: Do not attempt to mechanically clean the copper tubing in the evaporative condenser. Do not use wire brushes or any other mechanical device on the copper tubing. Severe damage may result. Contact your water treatment expert for recommendations on chemical cleaning procedures. Parts: Contact your local AAON Representative for factory authorized parts. Orders must include the Serial Number from the product nameplate OR visit www.aaonparts.com for more information. AIR-COOLED CONDENSER The air-cooled condenser section rejects heat by passing outdoor air over the fin tube coils for cooling of the hot refrigerant gas from the compressors. The heated air will discharge from the top of the section through the axial flow fans. Inspect the condenser coils annually to ensure unrestricted airflow. If the installation has a large amount of airborne dust or other material, clean the condenser coils with a water spray in a direction opposite to airflow. Care must be taken to prevent bending of the aluminum fins on the copper tube. E-Coated Coil Cleaning Documented routine cleaning of e-coated coils is required to maintain coating warranty coverage for fin and tube and microchannel coils. See the AAON E-Coated Coil Maintenance Record sheet. Surface loaded fibers or dirt must be removed prior to water rinse to prevent restriction of airflow. If unable to back wash the side of the coil opposite of the coils entering air side, then surface loaded fibers or dirt must be removed with a vacuum cleaner. If a vacuum cleaner is not available, a soft non-metallic bristle brush may be used. In either case, the tool must be applied in the direction of the fins. Coil surfaces can be easily damaged (fin edges bent over) if the tool is applied across the fins. Use of a water stream, such as a garden hose, against a surface loaded coil will drive the fibers Electric shock hazard. Shut off all electrical power to the unit to avoid shock hazard or injury from rotating parts. WARNING

efforts more difficult. Surface loaded fibers must be completely removed prior to using low velocity clean water rinse. A monthly clean water rinse is recommended for coils that are applied in coastal or industrial environments to help to remove chlorides, dirt, and debris. It is very important when rinsing, that water temperature is less than 130°F and pressure is less than 100 psig to avoid damaging the fin edges. An elevated water temperature (not to exceed 130°F) will reduce surface tension, increasing the ability to remove chlorides and dirt. Quarterly cleaning is essential to extend the life of an e-coated coil and is required to maintain coating warranty coverage. Coil cleaning shall be part of the unit’s regularly scheduled maintenance procedures. Failure to clean an e-coated coil will void the warranty and may result in reduced efficiency and durability. For routine quarterly cleaning, first clean the coil with the below approved coil cleaner. After cleaning the coils with the approved cleaning agent, use the approved chloride remover to remove soluble salts and revitalize the unit. Recommended Coil Cleaner The following cleaning agent, when used in accordance with the manufacturer’s directions on the container for proper mixing and cleaning, has been approved for use on e-coated coils to remove mold, mildew, dust, soot, greasy residue, lint, and other particulate: GulfClean ™ Coil Cleaner ; AAON PN: G074480 Recommended Chloride Remover GulfClean Salt Reducer™ ; AAON PN: G074490 GulfClean Salt Reducer™ is used to remove soluble salts from the e-coated coil, follow the manufacturer’s instructions. This product is not intended for use as a degreaser. Any grease or oil film must first be removed with GulfClean ™ Coil Cleaner. Remove Barrier - First ensure the power to the unit is off and locked out. Clean the area around the unit if needed to ensure leaves, grass or loose debris will not be blown into the coil. Soluble salts adhere themselves to the substrate. For the effective use of this product, the product must be able to come in contact with the salts. These salts High velocity water from a pressure washer or compressed air must only be used at a very low pressure to prevent fin and/or coil damages. The force of the water or air jet may bend the fin edges and increase airside pressure drop. Reduced unit performance or nuisance unit shutdowns may occur. CAUTION Harsh chemicals, household bleach, or acid cleaners must not be used to clean outdoor or indoor e-coated coils. These cleaners can be very difficult to rinse out of the coil and can accelerate corrosion and attack the e-coating. If there is dirt below the surface of the coil, use the recommended coil cleaners. CAUTION

therefore, these barriers must be removed prior to application of this product. As in all surface preparation, the best work yields the best results. Application- Apply GulfClean ™ Coil Cleaner directly onto the substrate. Sufficient product must be applied uniformly across the substrate to thoroughly wet out surface, with no areas missed. This may be accomplished by use of a pump-up sprayer or conventional spray gun. Apply the cleaner to unit interior air exiting side coil surfaces first. Work in sections/panels moving side to side and from top to bottom. Allow the cleaning solution to soak for 5 to 10 minutes. Then move on to the exterior using the same method. Rinse - Using pressurized potable water such as a garden hose, (< 100 psi), rinse the coils and continue to always work in sections/panels. Continue until all coil areas on the inside of the unit have been rinsed. Note: Coils must always be cleaned / back flushed, opposite of airflow to prevent impacting the dirt into the coil. Repeat these steps with GulfClean ™ Salt Reducer. When finished replace all panels and tops that were removed.

CL SERIES General: Piping from the condensing unit to the air handler is the responsibility of the installing contractor. Use only clean type “ACR” copper tubing that has been joined with high temperature brazing alloy. The pipe or line sizes must be selected to meet the actual installation conditions and NOT simply based on the connection sizes at the condensing unit or air handler. All AAON CL condensing units have factory furnished liquid and suction line shutoff valves. These must remain closed until the system is ready for start-up after installation. Upon completion of piping connection, the interconnecting piping and air handler MUST BE evacuated to 500 microns or less; leak checked and charged with refrigerant. Care must be taken not to cross the circuits on multiple circuit systems. Determining Refrigerant Line size: The piping between the condenser and low side must assure: 1. Minimum pressure drop, and 2. Continuous oil return, and 3. Prevention of liquid refrigerant slugging, or carryover Minimizing the refrigerant line size is favorable from an economic perspective, reducing installation costs, and reducing the potential for leakage. However, as pipe diameters narrow, pressure-reducing frictional forces increase. Excessive suction line pressure drop causes loss of compressor capacity and increased power usage resulting in reduced system efficiency. Excessive pressure drops in the liquid line can cause the liquid refrigerant to flash, resulting in faulty expansion valve operation and improper system performance. In order to operate efficiently and cost effectively, while avoiding malfunction, refrigeration systems must be designed to minimize both cost and pressure loss. The pipe sizes must be selected to meet the actual installation conditions, and not simply based on the connection sizes at the evaporator and/or condensing unit. Equivalent Line Length: All line lengths discussed in this manual, unless specifically stated otherwise, are Equivalent Line Lengths. The frictional pressure drop through valves, fittings, and accessories is determined by establishing the equivalent length of straight pipe of the same diameter. Always use equivalent line lengths when calculating pressure drop. Special piping provisions must be taken when lines are run up vertical risers or in excessively long line runs. Do not run underground refrigerant lines. REFRIGERANT PIPING This section is for information only and is not intended to provide all details required by the designer or installer of the refrigerant piping between the condenser or condensing unit and the air handling unit. AAON, Inc. is not responsible for interconnecting refrigerant piping. Consult ASHRAE Handbook – Refrigeration and ASME Standards. CAUTION

When sizing the liquid line, it is important to minimize the refrigerant charge to reduce installation costs and improve system reliability. This can be achieved by minimizing the liquid line diameter. However, reducing the pipe diameter will increase the velocity of the liquid refrigerant which increases the frictional pressure drop in the liquid line, and causes other undesirable effects such as noise. Maintaining the pressure in the liquid line is critical to ensuring sufficient saturation temperature, avoiding flashing upstream of the TXV, and maintaining system efficiency. Pressure losses through the liquid line due to frictional contact, installed accessories, and vertical risers are inevitable. Maintaining adequate sub-cooling at the condenser to overcome these losses is the only method to ensure that liquid refrigerant reaches the TXV. Liquid risers decrease head pressure. If the evaporator section is below the condenser, and the liquid line does not include risers, the gravitational force will increase the pressure of the liquid refrigerant. This will allow the refrigerant to withstand greater frictional losses without the occurrence of flashing prior to the TXV. A moisture indicating sight glass may be factory installed in the liquid line to indicate the occurrence of premature flashing or moisture in the line. The sight glass must 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 must 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. A check valve can be installed in the liquid line where the liquid column rises above the condenser to prevent this. The liquid line is typically pitched along with the suction line, or hot gas line, to minimize the complexity of the configuration. Liquid Line Insulation: When the liquid line is routed through regions where temperature losses are expected, no insulation is required, as this may provide additional sub-cooling to the refrigerant. When routing the liquid line through high temperature areas, insulation of the line is appropriate to avoid loss of sub-cooling. Liquid Line Guidelines: In order to ensure liquid at the TXV, frictional losses must not exceed available sub-cooling. A commonly used guideline to consider is a system design with pressure losses due to friction through the line not to exceed a corresponding 1-2°F change in saturation temperature. If the velocity of refrigerant in the liquid line is too great, it could cause excessive noise or piping erosion. The maximum velocities for liquid lines are 100 fpm from the condenser to a receiver to discourage fluid backup, and 500 fpm from receiver tank to the evaporator (300 fpm if the line includes an electric valve to minimize valve induced liquid hammer). Liquid Line Accessories: Liquid line accessories including sight glasses and filter driers are available and factory installed. The total length equivalent of pressure losses through valves, elbows and fittings must be considered when adding additional components in the field. It is a good practice to utilize the fewest elbows that will allow the mating units to be successfully joined. Suction Line Sizing: The suction line is more critical than the liquid line from a design and construction standpoint. More care must be taken to ensure that adequate velocity is achieved to return oil to the compressor at minimum loading conditions. However, reducing the piping diameter to increase the velocity at minimal load can result in excessive pressure losses, capacity reduction, and noise at full load. Suction Line Routing: For cooling only systems, pitch the suction line in the direction of flow (about 1 inch per 20 feet of

compressor, and keep it from flooding back into the evaporator. Crankcase heaters are provided to keep any condensed refrigerant that collects in the compressor from causing damage or wear. Make sure to provide support to maintain suction line positioning, and insulate completely between the evaporator and condensing unit. 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. The double suction riser consists of a small diameter riser in parallel with a larger diameter riser, and a trap at the base of the large riser. At minimum capacity, refrigerant velocity is not sufficient to carry oil up both risers, and it collects in the trap, effectively closing off the larger diameter riser, and diverting refrigerant up the small riser where velocity of the refrigerant is sufficient to maintain oil flow. At full load, the mass flow clears the trap of oil, and refrigerant is carried through both risers. Size the smaller diameter pipe to return oil at minimum load, and size the larger diameter pipe for acceptable pressure drop at full load. Figure 8 - Double Suction Riser Suction Line Traps: Include a trap immediately after the evaporator coil outlet to protect the TXV bulb from liquid refrigerant. Include traps every 20 feet in vertical riser sections. Suction Line Insulation: Insulate the entire suction line with a minimum 1 inch thick Armaflex insulation. This prevents condensation from forming on the line, and reduces any potential loss in capacity associated with heat gain placing additional load on the system. Suction Line Guidelines: For proper performance, keep suction line velocities less than a 4000 fpm. The minimum velocity required to return oil is dependent on the pipe diameter, however a general guideline of 1000 fpm minimum may be applied. Tandem compressors must be considered for full load operation (both compressors operating) and at partial load (only one compressor operating). When suction flow is up, the velocity at partial load must be greater than the minimum velocity required to return oil. In a fashion similar to the liquid line, a common guideline to consider is a system design with pressure losses due to friction through the line not to exceed a corresponding 1-2°F change in saturation temperature. At points where small pipe size can be used to provide sufficient velocity to return oil in vertical risers at part loads, greater pressure losses are incurred at full loads. This can be compensated for by over sizing the horizontal and vertical drop SUCTION RISER TRAPS Circuits require suction riser traps every 20 feet. CAUTION

refrigerant charge. Suction Line Accessories: If the job requirements specify suction accumulators, they must be separately purchased and installed. Hot Gas Bypass Line: Hot Gas Bypass is available for use with DX systems that may experience low suction pressure during the operating cycle. This may be due to varying load conditions associated with VAV applications or units supplying a large percentage of outside air. The system is designed to divert refrigerant from the compressor discharge to the low pressure side of the system in order to keep the evaporator from freezing and to maintain adequate refrigerant velocity for oil return at minimum load. Hot discharge gas is redirected to the evaporator inlet via an auxiliary side connector (ASC) to false load the evaporator when reduced suction pressure is sensed. Field piping between the condensing unit and the evaporator is required. See Figure 10 and Figure 11 for hot gas bypass piping configurations. Hot Gas Bypass Piping Considerations for Evaporator Above Condensing Unit: Pitch the hot gas bypass line downward in the direction of refrigerant flow, toward the evaporator. When installing vertical hot gas bypass lines, an oil drip line must be provided at the lowest point in the system. The oil drip line must be vertical, its diameter must be the same as the diameter of the riser, and a maximum of 10” long. Install a sight glass in the oil drip line for observation. Run an oil return line, using 1/8 inch capillary tube, 10 feet in length, from the hot gas bypass line oil drip line to the suction line. Connect the oil return line below the sight glass and 1 inch above the bottom of the oil drip line. Figure 9 - Oil Return Piping HGBP valves are adjustable. Factory HGBP valve settings will be sufficient for most applications, but may require slight adjustments for some make up air or other process cooling applications. Insulate the entire length of the HGBP line with a minimum 1 inch thick Armaflex insulation. Refer to Figure 10 for piping diagram. Hot Gas Bypass Piping Considerations for Evaporator Below Condensing Unit: The line must slope downward from the hot gas bypass valve toward the evaporator. Refer to Figure 11 for piping diagram Hot Gas Bypass Line Guidelines: Choose a small size line to ensure oil return, and minimize refrigerant charge. Maintain velocities below a maximum of 3500 fpm. A general minimum velocity guideline to use is approximately 2000 fpm. Hot Gas Reheat Line: The AAON modulating hot gas reheat system diverts hot discharge gas from the condenser to the air handling unit through the hot gas line. Field piping between the condensing unit and the air handler is required. The line delivers the hot discharge gas to the reheat coil and/or the hot gas bypass valve, so it is sized as a discharge line.

velocity of refrigerant to ensure oil return, avoid excessive noise associated with velocities that are too high, and to minimize efficiency losses associated with friction. Pitch the hot gas line in the direction of flow for oil return. When installing vertical hot gas reheat lines, an oil drip line must be provided at the lowest point in the system. The oil drip line must be vertical, its diameter must be the same as the diameter of the riser, and a maximum of 10” long. Run an oil return line, using 1/8 inch capillary tube, 10 feet in length, from the hot gas reheat line oil drip line to the suction line. Connect the oil return line below the sight glass and 1 inch above the bottom of the oil drip line. Insulate the entire length of the hot gas line with a minimum 1 inch thick Armaflex insulation. Refer to Figure 12 through Figure 19 for piping diagrams. Hot Gas Reheat Line Guidelines: Maintain velocities below a maximum of 3500 fpm. A general minimum velocity guideline is 2000 fpm.

Note: Components shown within air handler and condensing unit are factory installed; all other components are field installed.

Note: Components shown within air handler and condensing unit are factory installed; all other components are field installed.

Note: Components shown within air handler and condensing unit are factory installed; all other components are field installed.

Note: Components shown within air handler and condensing unit are factory installed; all other components are field installed.

line accumulator Note: Components shown within air handler and condensing unit are factory installed; all other components are field installed. TO BE INSTALLED IN FIELD

line accumulator Note: Components shown within air handler and condensing unit are factory installed; all other components are field installed. TO BE INSTALLED IN FIELD

Note: Components shown within air handler and condensing unit are factory installed; all other components are field installed.

Note: Components shown within air handler and condensing unit are factory installed; all other components are field installed.

installed suction line accumulator Note: Components shown within air handler and condensing unit are factory installed; all other components are field installed. TO BE INSTALLED IN FIELD TO BE INSTALLED IN FIELD

suction line accumulator Note: Components shown within air handler and condensing unit are factory installed; all other components are field installed. TO BE INSTALLED IN FIELD

DATE:___________________ JOB NAME:_________________________________________________________________________________________ ADDRESS:_________________________________________________________________ MODEL No:______________ CITY, STATE:______________________________________________________________ SERIAL No:______________ START-UP CONTRACTOR:___________________________________________________ TAG:____________________ PRE START-UP CHECKLIST Installing contractor shall verify the following items (cross out items that do not apply). 1. Is there any visible shipping damage?__________________________________________________ Yes No 2. Is the unit installation level?__________________________________________________________ Yes No 3. Are the unit clearances adequate for service and operation?_________________________________ Yes No 4. Do all access doors open freely and are the handles operational?_____________________________ Yes No 5. Have all shipping braces been removed?________________________________________________ Yes No 6. Have all electrical connections been tested for tightness?___________________________________ Yes No 7. Does the electrical service correspond to the unit nameplate?________________________________ Yes No 8. Has the overcurrent protection been installed to match unit nameplate requirement?______________ Yes No 9. Have all set screws on fans been tightened?______________________________________________ Yes No 10. Do all fans and pumps rotate freely?___________________________________________________ Yes No UNIT CONFIGURATION AIR COOLED__________ EVAPORATIVE COOLED _____ NO WATER LEAKS ___ CONDENSER SAFETY CHECK_______ COOLING TEST COMPRESSORS CRANKCASE NUMBER MODEL # AMPS HEATER L1 Volts/Amps L2 Volts/Amps L3 Volts/Amps AMPS 1 2 3 4 5 6 7 8 AMBIENT TEMPERATURE AMBIENT DRY BULB TEMP_______________°F AMBIENT WET BULB TEMP_______________°F

REFRIGERATION SYSTEM #1 PRESSURE SATURATED LINE SUB-COOLING SUPERHEAT TEMPERATURE TEMPERATURE DISCHARGE SUCTION LIQUID REFRIGERATION SYSTEM #2 PRESSURE SATURATED LINE SUB-COOLING SUPERHEAT TEMPERATURE TEMPERATURE DISCHARGE SUCTION LIQUID REFRIGERATION SYSTEM #3 PRESSURE SATURATED LINE SUB-COOLING SUPERHEAT TEMPERATURE TEMPERATURE DISCHARGE SUCTION LIQUID REFRIGERATION SYSTEM #4 PRESSURE SATURATED LINE SUB-COOLING SUPERHEAT TEMPERATURE TEMPERATURE DISCHARGE SUCTION LIQUID CONDENSER FAN AMPS ALIGNMENT________ CHECK ROTATION__________ NAMEPLATE AMPS________ NUMBER HP L1 Volts/Amps L2 Volts/Amps L3 Volts/Amps 1 2 3 4 5 6 CONDENSER PUMP AMPS CHECK ROTATION______________ NUMBER HP L1 Volts/Amps L2 Volts/Amps L3 Volts/Amps 1 2

July 2015 Added Features and Options section. Updated Service Information section. August 2016 Added a warning to empty the evaporative condenser tank before lifting. October 2017 CL units are now shipped with a 400 psi nitrogen holding charge. Updated Table 2 - Acceptable Refrigerant Circuit Values sub-cooling values. Added a note that reverse osmosis and deionized water cannot be used in the evaporative cooled condensing units. Added suction line filter removal instructions. May 2018 Updated technical support contact information. June 2018 Added E-coated coil cleaning procedure. Added split system evacuation procedure for low ambient and modulating hot gas reheat. January 2019 Removed section on OROA and ORI/ORD valves. Updated special low ambient option charging instructions. Corrected the nitrogen holding charge to 100 psi. May 2019 Added the minimum/maximum voltage range table in the Electrical section. July 2019 Removed most references to PVE oils except in the caution boxes. September 2020 Revised compressor cycling to 3 minute minimum off time. Revised measurement of suction line temperature and pressure to be taken at the evaporator. Revised wording for oil return line. Updated the Nameplate Voltage Markings and Tolerance table. Added phase imbalance example. Revised the e-coated coil cleaning section. Added Voltage check to the startup form. Added the AAON E-Coated Coil Maintenance Record.

Tulsa, OK 74107-2728 www.AAON.com CL Series Installation, Operation & Maintenance R10110 · Rev. C · 200910 Factory Technical Support: 918-382-6450 Note: Before calling Technical Support, please have the model and serial number of the unit available. Parts: For replacement parts, please contact your local AAON Representative. It is the intent of AAON to provide accurate and current product information. However, in the interest of product improvement, AAON reserves the right to change pricing, specifications, and/or design of its product without notice, obligation, or liability. Copyright © AAON, all rights reserved throughout the world. AAON® and AAONAIRE® are registered trademarks of AAON, Inc., Tulsa, OK.