AAON F1-060 Instruction manual

F1 Series
Indoor Air Handing Units
Installation, Operation
& Maintenance
If the information in this manual is not
followed exactly, a fire or explosion
may result causing property damage,
personal injury or loss of life.
FOR YOUR SAFETY
Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of this or any other appliance.
WARNING
WARNING
QUALIFIED INSTALLER
Improper installation, adjustment,
alteration, service or maintenance
can cause property damage,
personal injury or loss of life.
Installation and service must be
performed by a trained, qualified
installer. A copy of this IOM should
be kept with the unit.
WARNING
These instructions are addressed
primarily to the installer; however,
useful maintenance information is
included. This manual should be kept
with the unit for future reference.
NOTICE

Table of Contents
Safety .............................................................................................................................................. 5
F1 Series Feature String Nomenclature .......................................................................................... 9
General Information...................................................................................................................... 10
Codes and Ordinances............................................................................................................... 10
Receiving Units......................................................................................................................... 11
Before Installation..................................................................................................................... 12
Storage....................................................................................................................................... 12
Direct Expansion (DX) Systems ............................................................................................... 13
Wiring Diagrams....................................................................................................................... 13
Condensate Drain Pans.............................................................................................................. 13
Installation..................................................................................................................................... 14
General ...................................................................................................................................... 14
Locating the Unit....................................................................................................................... 14
Service and Installation Clearance............................................................................................ 14
Floor Mounted Units................................................................................................................. 14
Suspended.................................................................................................................................. 15
Lifting and Handling the Unit................................................................................................... 16
Sealing....................................................................................................................................... 16
Cooling Equipment ................................................................................................................... 16
Heating Equipment.................................................................................................................... 16
Field Wiring - MCA and MOP ................................................................................................. 17
Heat Pump................................................................................................................................. 17
ECM Driven Fan....................................................................................................................... 18
Reheat Coil Refrigerant Piping ................................................................................................. 19
Condensate Drain Piping........................................................................................................... 20
Electrical.................................................................................................................................... 21
Thermostat................................................................................................................................. 22
Filters......................................................................................................................................... 22
Charging Refrigerant................................................................................................................. 22
Evaporator Coil ......................................................................................................................... 24
Startup........................................................................................................................................... 26
General ...................................................................................................................................... 26
Check-Out ................................................................................................................................. 26
Procedures................................................................................................................................. 26
Electric Heat Section Procedures.............................................................................................. 27
Refrigerant Cooling Section Procedures................................................................................... 27
Optional Equipment Procedures................................................................................................ 28
Commissioning.......................................................................................................................... 28
Air Balancing ............................................................................................................................ 28
Water Balancing........................................................................................................................ 28
Controls..................................................................................................................................... 28
Operation and Maintenance.......................................................................................................... 28
General ...................................................................................................................................... 28
Maintenance Schedule............................................................................................................... 28

3
Lubrication ................................................................................................................................ 29
Blower Assembly...................................................................................................................... 29
Coils .......................................................................................................................................... 29
Heating ...................................................................................................................................... 29
Filters......................................................................................................................................... 29
Replacement Parts..................................................................................................................... 30
AAON-Longview Product Support........................................................................................... 30
Refrigerant Piping Diagrams ........................................................................................................ 32
Thermostat Installation and Wiring.............................................................................................. 40
F1 Series Startup Form ................................................................................................................. 50
Maintenance Log .......................................................................................................................... 53
Literature Change History............................................................................................................. 54
R58420 · Rev. B · 171016
(ACP 29902)

Index of Table and Figures
Tables:
Table 1 - Electric Heat Minimum Circuit Ampacity.................................................................... 17
Table 2 - Electric Heat Maximum Overcurrent Protection........................................................... 17
Table 3 - Factory Preset Air Flow................................................................................................. 18
Table 4 - Cooling Fan Speed Tap Settings ................................................................................... 18
Table 5 - Climate Settings............................................................................................................. 18
Table 6 - Heating Fan Speed Tap Settings.................................................................................... 19
Table 7 - Acceptable Air-Cooled Refrigeration Circuit Values ....Error! Bookmark not defined.
Figures:
Figure 1 - Typical Vertical and Horizontal Unit Installation Methods......................................... 15
Figure 2 - Example Configuration of ECM Fan Taps .................................................................. 18
Figure 3 - TXV Bulb Position....................................................................................................... 30
Figure 4 - Modulating Hot Gas Reheat Piping Diagram with Air Handling Unit above
Condensing Unit. .......................................................................................................................... 32
Figure 5 - Modulating Hot Gas Reheat Piping Diagram with Air Handling Unit below
Condensing Unit ........................................................................................................................... 33
Figure 6 - Modulating Hot Gas Reheat Piping Diagram with Air Handling Unit above
Condensing Unit with Optional Accumulator .............................................................................. 34
Figure 7 - Modulating Hot Gas Reheat Piping Diagram with Air Handling Unit below
Condensing Unit with Optional Accumulator .............................................................................. 35
Figure 8 - Heat Pump Piping Diagram with Indoor Unit above Outdoor Unit............................. 36
Figure 9 - Heat Pump Piping Diagram with Outdoor Unit above Indoor Unit............................. 37
Figure 10 - Heat Pump Piping Diagram with Modulating Hot Gas Reheat and Indoor Unit above
Outdoor Unit................................................................................................................................. 38
Figure 11 - Heat Pump Piping with Modulating Hot Gas Reheat and Outdoor Unit above Indoor
Unit ............................................................................................................................................... 39
Figure 12 - 2 Stage Cooling with Electric Heat............................................................................ 40
Figure 13 - 2 Stage Cooling with Heat Pump and Electric Heat.................................................. 41
Figure 14 - 2 Stage Cooling and Electric Heat with Hot Gas Reheat and Humidistat ................. 42
Figure 15 - Main Control Board for Units Equipped with Modulating Hot Gas Reheat.............. 43
Figure 16 - Field Wiring Connections for an F1 Series Air Handling Unit. ................................ 44
Figure 17 - 5kW Electric Heat..................................................................................................... 45
Figure 18 - 10 kW Electric Heat.................................................................................................. 46
Figure 19 - 15 kW Electric Heat.................................................................................................. 47
Figure 20 - 20 kW Electric Heat................................................................................................. 48
Figure 21 - 25 kW Electric Heat................................................................................................. 49

5
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 unit. 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
Electric shock hazard. Before
servicing, disconnect all electrical
power to the unit, including remote
disconnects, to avoid shock hazard
or injury from rotating parts. Follow
proper Lockout-Tagout procedures.
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

6
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
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
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
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

7
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.
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
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
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
Always use a pressure regulator,
valves and gauges to control
incoming pressures when pressure
testing a system. Excessive pressure
may cause line ruptures, equipment
damage or an explosion which may
result in injury or death.
WARNING
Do not work in a closed area where
refrigerant or nitrogen gases may be
leaking. A sufficient quantity of
vapors may be present and cause
injury or death.
WARNING
Risk of injury from hot parts –
Disconnect all power, close all
isolation valves and allow equipment
to cool before servicing equipment
with heating coils. Hot water will
circulated even after the power is off.
WARNING

8
1. Startup and service must be performed
by a Factory Trained Service
Technician.
2. The unit is for indoor use only. See
General Information section for more
unit 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 you
have 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.
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

9
F1 Series Feature String Nomenclature
F1
-
B
-
060
-
1
-
M
-
C
:
C
0
0
0
C
000
0
0
Series and
Generation
Rev.
Unit
Size
Voltage
App.
Heat
Mtrs
Filters
Cntls
Blank
Refri.
Blank
Cabinet
Special
BASE MODEL
SERIES AND GENERATION
F1
REVISION
B = Design Sequence
UNIT SIZE
024 = 24 MBH (2 ton)
036 = 36 MBH (3 ton)
048 = 48 MBH (4 ton)
060 = 60 MBH (5 ton)
VOLTAGE
1 = 208-230V/1Φ/60Hz
APPLICATION
V = Vertical Position (Up-flow)
M = Multi-Position (Up-flow or Horizontal)
HEATING
0 = No Heat
A = 5 kW
B = 10 kW
C = 15 kW
D = 20 kW
E = 25 kW
G = Hot Water Heating
FEATURE 1: MOTORS
A = ECM - 1/2 hp
B = ECM - 3/4 hp
C = ECM - 1.0 hp
FEATURE 2: FILTERS
0 = Standard - 1”
FEATURE 3: CONTROLS
0 = Standard - Terminal Block
FEATURE 4: BLANK
0 = Standard
FEATURE 5: REFRIGERATION
0 = Standard - Split System Air Conditioner
C = Split System Heat Pump
D = Split System Air Conditioner + Modulating Hot
Gas Reheat
F = Split System Heat Pump + Modulating Hot Gas
Reheat
FEATURE 6: BLANK
0 = Standard
FEATURE 7: BLANK
0 = Standard
FEATURE 8: BLANK
0 = Standard
FEATURE 9: CABINET
0 = Standard - Embossed Galvanized Steel
A = Painted Cabinet Exterior
FEATURE 10: SPECIAL
0 = Standard
X = Special Price Authorization
Model/Feature Number

10
General Information
F1 Series air handling units are designed for
safe operation when installed, operated and
maintained within design specifications and
the instructions set forth in this manual. It is
necessary to follow these instructions to
avoid personal injury or damage to
equipment or property during equipment
installation, operation, start-up and
maintenance.
Certification of Cooling Models
a. Certified for use with a R-410A
condensing unit with a scroll
compressor.
b. Certified for indoor installation only
Certification of Cooling and Reheat
Models
a. Certified for use with a R-410A
condensing unit with a scroll compressor
and hot gas dehumidification
capabilities.
b. Certified for indoor installation only
Certification of Electric Heat Models
a. Certified as an electric heating air
handling unit with a cooling coil.
b. Certified for indoor installation only.
Codes and Ordinances
F1 Series units have been tested and
certified, by ETL, in accordance with UL
Safety Standard 1995/CSA C22.2 No. 236.
System should be sized in accordance with
the American Society of Heating,
Refrigeration and Air Conditioning
Engineers Handbook.
Installation of F1 Series units must conform
to the ICC standards of the International
Mechanical Code, the International Building
Code, Installation of Air Conditioning and
Ventilating Systems Standard, NFPA 90A,
and local building, plumbing and waste
water codes. All appliances 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.
Important: The United States
Environmental Protection Agency (EPA)
has issued various regulations regarding the
introduction and disposal of refrigerants in
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. A
copy of this IOM should be kept with
the unit.
WARNING
This equipment is protected by a
standard limited warranty under the
condition that initial startup and
maintenance is performed according
to the instructions set forth in this
manual. This manual should be read
in its entirety prior to installation and
before performing any service or
maintenance work.
WARNING
These units must not be used as a
“construction heater” at anytime
during any phase of construction.
Very low return air temperatures,
harmful vapors, and misplacement of
the filters will damage the unit and its
efficiency.
CAUTION