AAON RQ SERIES Owner's manual

RQ SERIES
Packaged Rooftop Units, Heat Pumps,
& Outdoor Air Handling Units
Installation, Operation,
& Maintenance
oDo not store gasoline or other flammable
vapors and liquids in the vicinity of this or any
other appliance
oWHAT TO DO IF YOU SMELL GAS
Do not try to light any appliance.

Do not touch any electrical switch; do not
use any phone in your building.
Leave the building immediately.

Immediately call your gas supplier from a
phone remote from the building. Follow the
gas supplier’s instructions.

If you cannot reach your gas supplier, call
the fire department.
o
Startup and service must be performed by a
Factory Trained Service Technician.
WARNING
FIRE OR EXPLOSION HAZARD
Failure to follow safety warnings
exactly could result in serious
injury, death or property damage.
Be sure to read and understand
the installation, operation and
service instructions in this manual.
Improper installation, adjustment,
alteration, service or maintenance
can cause serious injury, death or
property damage.
A copy of this IOM should be kept
with the unit.
WARNING

3
Table of Contents
AAON® RQ Series Features and Options Introduction................................................................. 7
Safety .............................................................................................................................................. 8
RQ Series Feature String Nomenclature....................................................................................... 13
General Information...................................................................................................................... 22
Codes and Ordinances .............................................................................................................. 22
Receiving Unit.......................................................................................................................... 23
Packaged Direct Expansion (DX) Units................................................................................... 24
Gas or Electric Heating............................................................................................................. 25
Wiring Diagrams....................................................................................................................... 26
Condensate Drain Pan............................................................................................................... 26
Installation..................................................................................................................................... 27
Unit Location............................................................................................................................ 27
Setting the Curb........................................................................................................................ 27
Forklifting the Unit................................................................................................................... 30
Lifting the Unit ......................................................................................................................... 31
Vertical Duct Connection ......................................................................................................... 32
Seismic Curb Installation.......................................................................................................... 33
Horizontal Duct Connection..................................................................................................... 35
Outside Air Rain Hood............................................................................................................. 35
Metal Mesh Filters.................................................................................................................... 36
Electrical................................................................................................................................... 37
Variable Speed Compressors................................................................................................ 39
Thermostat Control Wiring................................................................................................... 39
Gas Heating............................................................................................................................... 40
Maximum Piping Capacities................................................................................................. 40
Piping Sizing Examples........................................................................................................ 41
Inlet and Manifold Pressures ................................................................................................ 41
Gas Pressure Regulator & Overpressure Protection Device................................................. 42
Additional Gas Piping Considerations.................................................................................. 42
Leak Testing.......................................................................................................................... 44
Refrigerant-to-Water Heat Exchanger...................................................................................... 44
Water-Source Heat Pump Applications................................................................................ 44
Open Loop Applications....................................................................................................... 45
Freezing Water in the Heat Exchanger................................................................................. 45
Water Piping ......................................................................................................................... 46
Condensate Drain Piping.......................................................................................................... 48
Discharge and Suction Line Piping .......................................................................................... 48
Heating Coils ............................................................................................................................ 51
Chilled Water Coil.................................................................................................................... 51
Electric Preheat......................................................................................................................... 52
Status Display Screens.......................................................................................................... 52
System Setting Screens......................................................................................................... 53
LED Flash Alarm Codes....................................................................................................... 55
Operation............................................................................................................................... 55
Energy Recovery Units............................................................................................................. 56

4
Startup........................................................................................................................................... 64
Filters........................................................................................................................................ 64
Adjusting Refrigerant Charge................................................................................................... 64
Checking Liquid Sub-Cooling.............................................................................................. 65
Checking Evaporator Superheat............................................................................................ 65
Adjusting Sub-Cooling and Superheat Temperatures........................................................... 65
Gas Heater Instructions............................................................................................................. 67
Freeze Stat Startup.................................................................................................................... 68
Supply Fan EC Motor Startup .................................................................................................. 68
Condenser Fan EC Motor Startup............................................................................................. 69
Adjustable Fan Cycling Switch Procedure............................................................................... 71
Operation....................................................................................................................................... 73
Thermostat Operation............................................................................................................... 73
Packaged DX Cooling Operation and Control ......................................................................... 73
Gas Heater Operation................................................................................................................ 73
Electric Heating Operation ....................................................................................................... 74
Steam or Hot Water Preheating and Heating Operation........................................................... 74
Modulating Electric Preheat ..................................................................................................... 74
Chilled Water or Non-Compressorized DX Cooling Operation............................................... 74
Maintenance.................................................................................................................................. 74
Gas Heating............................................................................................................................... 74
Gas Heat Exchanger Removal.................................................................................................. 75
DX Cooling............................................................................................................................... 76
Condenser Fan .......................................................................................................................... 76
Condensate Drain Pans............................................................................................................. 76
Evaporator Coil......................................................................................................................... 77
E-Coated Coil Cleaning............................................................................................................ 77
Microchannel Coil Cleaning..................................................................................................... 79
Supply Fan................................................................................................................................ 81
Variable Capacity Compressor Controller................................................................................ 84
Filter Replacement.................................................................................................................... 85
Replacement Parts..................................................................................................................... 86
Appendix A - Heat Exchanger Corrosion Resistance................................................................... 87
Appendix B - Thermistor Temperature vs. Resistance Values..................................................... 89
RQ Series Startup Form................................................................................................................ 90
Maintenance Log .......................................................................................................................... 94
Literature Change History............................................................................................................. 95
R94490 · Rev. F · 170925

5
Index of Tables and Figures
Tables:
Table 1 - Electric and Gas Heating Capacities ............................................................................. 25
Table 2 - Auxiliary Electric Heating Capacities........................................................................... 26
Table 3 - Unit Clearances ............................................................................................................. 27
Table 4 - Single Circuited Variable Speed Compressor Frequency Range.................................. 39
Table 5 - Control Wiring............................................................................................................... 39
Table 6 - 2-6 ton Gas Connections ............................................................................................... 40
Table 7 - Natural Gas (ft3/hr)........................................................................................................ 40
Table 8 - Propane (kBtu/hr).......................................................................................................... 41
Table 9 - Gas Piping Supports...................................................................................................... 42
Table 10 - Glycol Freezing Points................................................................................................ 46
Table 11 - Condenser Water Connections.................................................................................... 46
Table 12 - Hot Water Coil Connection Sizes................................................................................ 51
Table 13 - Steam Coil Connection Sizes ...................................................................................... 51
Table 14 - Chilled Water Coil Connection Sizes.......................................................................... 51
Table 15 - Stages of Electric Preheat............................................................................................ 54
Table 16 - Acceptable Refrigeration Circuit Values..................................................................... 65
Table 17 - R-410A Refrigerant Temperature-Pressure Chart....................................................... 66
Table 18 - EC Condenser Fan Cycling Options............................................................................ 70
Table 19 - Demand Signal vs. Compressor Capacity Modulation................................................ 84
Table 20 - RQ Series 2-6 ton Pre Filters....................................................................................... 85
Table 21 - RQ Series 2-6 ton Unit Filters..................................................................................... 86
Table 22 - RQ Series 2-6 ton Energy Recovery Wheel Filters..................................................... 86

6
Figures:
Figure 1 - Lockable Handle .......................................................................................................... 23
Figure 2 - RQ Series Orientation.................................................................................................. 27
Figure 3 - RQ Cabinet Standard and Power Exhaust Gasket Locations....................................... 29
Figure 4 - Forklifting an RQ Series Unit from the Side ............................................................... 30
Figure 5 - Forklifting an RQ Series Unit from the Front.............................................................. 30
Figure 6 - Lifting Details of a 2-6 ton Standard or Power Exhaust Unit...................................... 31
Figure 7 - Lifting Details of a 2-6 ton Energy Recovery Wheel Unit .......................................... 31
Figure 8 - Vertical Duct Connection............................................................................................. 32
Figure 9 - Solid Bottom Seismic Curb with Filters ...................................................................... 33
Figure 10 - Seismic Solid Bottom Curb without Filters Cross Section........................................ 34
Figure 11 - Seismic Solid Bottom Curb without Filters Detail A................................................. 34
Figure 12 - Seismic Solid Bottom Curb without Filters Detail B................................................. 34
Figure 13 - Seismic Rigid Mount Curb Cross Section ................................................................. 35
Figure 14 - Horizontal duct connections....................................................................................... 35
Figure 15 - RQ Series unit Closed Rain Hood.............................................................................. 36
Figure 16 - RQ Series unit Open Rain Hood................................................................................ 36
Figure 17 - Rain Hood with Metal Mesh Filter Rack Installation................................................ 36
Figure 18 - Unit Base Utility Entry............................................................................................... 37
Figure 19 - Back View of Power Switch from Control Compartment......................................... 37
Figure 20 - RQ Series Gas Heat Exchanger.................................................................................. 40
Figure 21 - Example 2-6 ton through the Base Gas Piping .......................................................... 43
Figure 22 - Post Corner Hole Location......................................................................................... 49
Figure 23 - Post Back Hole Location............................................................................................ 49
Figure 24 - Post Corner Hole Piping............................................................................................. 50
Figure 25 - Post Back Hole Piping ............................................................................................... 50
Figure 26 - Preheat Controller ...................................................................................................... 52
Figure 27 - Gas Heater Instructions.............................................................................................. 67
Figure 28 - PIN Connectors on EC Supply Fan Motor Electronics.............................................. 68
Figure 29 - Gas Heat Exchanger................................................................................................... 76
Figure 30 - Removal of a Condenser Fan Assembly.................................................................... 76
Figure 31 - Evaporator Coil Access.............................................................................................. 77
Figure 32 - 2-6 ton Supply Fan..................................................................................................... 81
Figure 33 - RQ Supply Fan Removal Bolts.................................................................................. 81
Figure 34 - RQ Supply Fan Removal Slide.................................................................................. 82
Figure 35 - Variable Capacity Compressor Controller................................................................. 84
Figure 36 - Compressor Controller Flash Code Details................................................................ 85
Figure 37 - RQ Series 2-6 ton Standard Filter Layout.................................................................. 86

7
AAON® RQ Series Features and Options Introduction
Energy Efficiency
Direct Drive Backward Curved Plenum
Supply Fans
Variable Capacity R-410A Scroll
Compressors
Airside Economizers
Factory Installed AAONAIRE®Energy
Recovery Wheels
Double Wall Rigid Polyurethane Foam
Panel Construction, R-13 Insulation
Modulating Natural Gas Heaters
Modulating/SCR Electric Heaters
Premium Efficiency Motors
Variable Speed Supply/ Exhaust Fans
Air-Source, Water-Source and
Geothermal Heat Pumps
Indoor Air Quality
100% Outside Air
Constant Volume Outside Air Control
Economizer CO2Override
High Efficiency Filtration
Double Wall Rigid Polyurethane Foam
Panel Construction, R-13 Insulation
Interior Corrosion Protection
Humidity Control
High Capacity Cooling Coils
Variable Capacity Compressors
Factory Installed AAONAIRE Total
Energy Recovery Wheels
Modulating Hot Gas Reheat
Safety
Burglar Bars
Freeze Stats
Hot Water/Steam Preheat Coils
Electric Preheat
Phase and Brown Out Protection
Supply/Return Smoke Detectors
Supply/Return Firestats
Installation and Maintenance
Clogged Filter Switch
Color Coded Wiring Diagram
Compressors in Isolated Compartment
Compressor Isolation Valves
Convenience Outlet
Direct Drive Supply Fans
Hinged Access Doors with Lockable
Handles
Magnehelic Gauge
Service Lights
Sight Glass
System Integration
Chilled Water Cooling Coils
Controls by Others
Electric/Natural Gas/LP Heating
Hot Water/Steam Heating Coil
Non-Compressorized DX Coils
Environmentally Friendly
Airside Economizers
Factory Installed AAONAIRE Energy
Recovery Wheels
R-410A Refrigerant
Extended Life
5 Year Compressor Warranty
15 Year Aluminized Steel Heat
Exchanger Warranty
25 Year Stainless Steel Heat Exchanger
Warranty
Interior Corrosion Protection
Polymer E-Coated Coils - 5 Year
Warranty
Stainless Steel Coil Casing
Stainless Steel Drain Pans

8
Safety
Attention should be paid to the following statements:
NOTE - Notes are intended to clarify the unit installation, operation and maintenance.
CAUTION - Caution statements are given to prevent actions that may result in
equipment damage, property damage, or personal injury.
WARNING - Warning statements are given to prevent actions that could result in
equipment damage, property damage, personal injury or death.
DANGER - Danger statements are given to prevent actions that will result in equipment
damage, property damage, severe personal injury or death.
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.

Before servicing, disconnect all
electrical power to the furnace.
More than one disconnect may be
provided.

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
WHAT TO DO IF YOU SMELL GAS
Do not try to turn on unit.
Shut off main gas supply.
Do not touch any electric switch.

Do not use any phone in the
building.

Never test for gas leaks with an
open flame.

Use a gas detection soap solution
and check all gas connections
and shut off valves.
CAUTION
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

9
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
ROTATING COMPONENTS
Unit contains fans with moving parts
that can cause serious injury. Do not
open door containing fans until the
power to the unit has been
disconnected and fan wheel has
stopped rotating.
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
During installation, testing, servicing
and troubleshooting of the equipment
it may be necessary to work with live
electrical components. Only a
qualified licensed electrician or
individual properly trained in handling
live electrical components shall
perform these tasks.
Standard NFPA-70E, an OSHA
regulation requiring an Arc Flash
Boundary to be field established and
marked for identification of where
appropriate Personal Protective
Equipment (PPE) be worn, should be
followed.
WARNING
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
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

10
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
Failure to properly drain and vent
coils when not in use during freezing
temperature may result in coil and
equipment damage.
CAUTION
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
should be checked for proper
operation. Alterations should only be
made at the unit power connection
CAUTION
Do not use oxygen, acetylene or air
in place of refrigerant and dry
nitrogen for leak testing. A violent
explosion may result causing injury or
death.
WARNING
WATER PRESSURE
Prior to connection of condensing
water supply, verify water pressure is
less than maximum pressure shown
on unit nameplate. To prevent injury
or death due to instantaneous
release of high pressure water, relief
valves should be field supplied on
system water piping.
WARNING
Always use a pressure regulator,
valves and gauges to control
incoming pressures when pressure
testing a system. Excessive pressure
may cause line ruptures, equipment
damage or an explosion which may
result in injury or death.
WARNING
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
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