AAON RQ NextGen Series Owner's manual

RQ
NextGen
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.
oStartup 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.
Keep a copy of this IOM with the
unit.
WARNING
UL-60335

3
Table of Contents
AAON®RQ Series Features and Options Introduction.................................................................. 7
Safety .............................................................................................................................................. 8
RQ Series Unified Feature String Nomenclature .................................................................... 14
General Information...................................................................................................................... 22
Codes and Ordinances .............................................................................................................. 22
Receiving Unit .......................................................................................................................... 23
Storage ...................................................................................................................................... 24
Wiring Diagrams....................................................................................................................... 24
Installation..................................................................................................................................... 24
Unit Location ............................................................................................................................ 24
Setting the Curb ........................................................................................................................ 25
Forklifting the Unit ................................................................................................................... 27
Lifting the Unit ......................................................................................................................... 28
Vertical Duct Connection ......................................................................................................... 29
Seismic Curb Installation.......................................................................................................... 30
Horizontal Duct Connection ..................................................................................................... 32
Outside Air Rain Hood ............................................................................................................. 32
Metal Mesh Filters .................................................................................................................... 33
Electrical ................................................................................................................................... 34
Variable Speed Compressors ................................................................................................ 36
Thermostat Control Wiring................................................................................................... 37
Condensate Drain Piping .......................................................................................................... 37
Draw-Through Coils ................................................................................................................. 38
Non-Compressorized Liquid and Suction Line Piping............................................................. 39
Startup........................................................................................................................................... 41
Filters ........................................................................................................................................ 41
Supply Fan EC Motor Startup .................................................................................................. 42
Adjusting Refrigerant Charge................................................................................................... 43
Checking Liquid Sub-Cooling .............................................................................................. 43
Checking Evaporator Superheat............................................................................................ 44
Adjusting Sub-cooling and Superheat Temperatures............................................................ 45
Freeze Stat Startup .................................................................................................................... 50
Condenser Fan EC Motor Startup............................................................................................. 50
Adjustable Fan Cycling Switch Procedure ............................................................................... 51
Operation....................................................................................................................................... 53
Thermostat Operation ............................................................................................................... 53
Packaged DX Cooling Operation and Control ......................................................................... 53
Gas Heater Operation................................................................................................................ 53
Electric Heating Operation ....................................................................................................... 54
Steam or Hot Water Preheating and Heating Operation........................................................... 54
Modulating Electric Preheat ..................................................................................................... 54
Chilled Water or Non-Compressorized DX Cooling Operation............................................... 54
Maintenance.................................................................................................................................. 54
Supply Fan ................................................................................................................................ 54
DX Cooling............................................................................................................................... 55
Condensate Drain Pans ............................................................................................................. 55

4
E-Coated Coil Cleaning ............................................................................................................ 56
Microchannel Coil Cleaning..................................................................................................... 57
Options.......................................................................................................................................... 59
Heating Coils ............................................................................................................................ 59
Chilled Water Coil .................................................................................................................... 59
Packaged Direct Expansion (DX) Units ................................................................................... 60
Variable Capacity Compressor Controller................................................................................ 61
Evaporator Coil......................................................................................................................... 63
Condenser Fan .......................................................................................................................... 63
Refrigerant-to-Water Heat Exchanger ...................................................................................... 64
Water-Source Heat Pump Applications ................................................................................ 64
Open Loop Applications ....................................................................................................... 64
Freezing Water in the Heat Exchanger ................................................................................. 65
Water Piping ......................................................................................................................... 66
Energy Recovery Units............................................................................................................. 68
Energy Recovery Wheel General Cleaning .......................................................................... 71
Gas or Electric Heating............................................................................................................. 77
Electric Preheat ......................................................................................................................... 78
Status Display Screens .......................................................................................................... 78
System Setting Screens ......................................................................................................... 79
LED Flash Alarm Codes ....................................................................................................... 80
Operation............................................................................................................................... 81
Gas Heating............................................................................................................................... 81
Piping Sizing Examples ........................................................................................................ 83
Inlet and Manifold Pressures ................................................................................................ 83
Gas Pressure Regulator & Overpressure Protection Device................................................. 84
Piping Supports..................................................................................................................... 84
Additional Gas Piping Considerations.................................................................................. 84
Leak Testing ........................................................................................................................ 87
Gas Heater Operating Instructions........................................................................................ 88
Gas Heating Maintenance ..................................................................................................... 89
Gas Heat Exchanger Removal .............................................................................................. 90
Phase and Brownout Protection Module .................................................................................. 91
Filter Replacement .................................................................................................................... 93
Replacement Parts..................................................................................................................... 94
Appendix A - Heat Exchanger Corrosion Resistance................................................................... 97
Appendix B - Thermistor Temperature vs. Resistance Values..................................................... 99
RQ Series Startup Form .............................................................................................................. 100
Maintenance Log ........................................................................................................................ 104
Maintenance Log (E-Coated Coil).............................................................................................. 105
Literature Change History........................................................................................................... 106
G149150 · Rev. A · 231127

5
Index of Tables and Figures
Tables:
Table 1 - Unit Clearances ............................................................................................................. 24
Table 2 - Nameplate Voltage Markings & Tolerances ................................................................. 34
Table 3 – 35 KAIC Fuse Sizing.................................................................................................... 36
Table 4 – 65 KAIC Fuse Sizing.................................................................................................... 36
Table 5 - Single Circuited Variable Speed Compressor Frequency Range .................................. 37
Table 6 - Control Wiring............................................................................................................... 37
Table 7 - Draw-Through Drain Trap Dimensions (Metric).......................................................... 38
Table 8 - Draw-Through Drain Trap Dimensions (Imperial) ....................................................... 38
Table 9 - Acceptable Refrigeration Circuit Values (Metric) ........................................................ 44
Table 10 – Acceptable Refrigeration Circuit Values (Imperial)................................................... 44
Table 11 - Acceptable Microchannel Air-Cooled Condenser Coil Liquid Sub-Cooling Values
(Metric) ......................................................................................................................................... 44
Table 12 - Acceptable Microchannel Air-Cooled Condenser Coil Liquid Sub-Cooling Values
(Imperial) ...................................................................................................................................... 45
Table 13 - R-410A Refrigerant Temperature-Pressure Chart (Metric) ........................................ 46
Table 14 - R-410A Refrigerant Temperature-Pressure Chart (Imperial)...................................... 47
Table 15 - R-454B Refrigerant Temperature-Pressure Chart (Metric)......................................... 48
Table 16 - R-454B Refrigerant Temperature-Pressure Chart (Imperial)...................................... 49
Table 17 - EC Condenser Fan Cycling Options............................................................................ 50
Table 18 - Hot Water Coil Connection Sizes................................................................................ 59
Table 19 - Steam Coil Connection Sizes ...................................................................................... 59
Table 20 - Chilled Water Coil Connection Sizes.......................................................................... 60
Table 21 – Min and Max Water Pressures and Temps ................................................................. 60
Table 22 - Demand Signal vs. Compressor Capacity Modulation................................................ 62
Table 23 - Glycol Concentration Freezing Points......................................................................... 66
Table 24 - Condenser Water Connections .................................................................................... 66
Table 25 - Electric and Gas Heating Capacities ........................................................................... 77
Table 26 - Auxiliary Electric Heating Capacities......................................................................... 77
Table 27 - Stages of Electric Preheat ............................................................................................ 79
Table 28: 2-6 ton Gas Connections............................................................................................... 82
Table 29 – (Metric) Natural Gas Maximum Piping Capacities (m3/hr)....................................... 82
Table 30 – (Imperial) Natural Gas Maximum Piping Capacities (ft3/hr) .................................... 82
Table 31 – (Metric)Propane (kW) Maximum Piping Capacities................................................ 83
Table 32 – (Imperial)Propane (kBtu/hr) Maximum Piping Capacities ....................................... 83
Table 33 - Gas Piping Supports (Metric)...................................................................................... 84
Table 34 - Gas Piping Supports (Imperial)................................................................................... 84
Table 35 - RQ Series 2-6 ton Pre Filters....................................................................................... 93
Table 36 - RQ Series 2-6 ton Unit Filters ..................................................................................... 93
Table 37 - RQ Series 2-6 ton Energy Recovery Wheel Filters..................................................... 93

6
Figures:
Figure 1 - Lockable Handle .......................................................................................................... 23
Figure 2 - RQ Series Orientation .................................................................................................. 25
Figure 3 - RQ Cabinet Standard and Power Exhaust Gasket Locations....................................... 26
Figure 4 - Forklifting an RQ Series Unit from the Side ............................................................... 27
Figure 5 - Forklifting an RQ Series Unit from the Front.............................................................. 27
Figure 6 - Lifting Details of a 2-6 ton Standard or Power Exhaust Unit ...................................... 28
Figure 7 - Lifting Details of a 2-6 ton Energy Recovery Wheel Unit .......................................... 28
Figure 8 - Vertical Duct Connection............................................................................................. 29
Figure 9 - Solid Bottom Seismic Curb with Filters ...................................................................... 30
Figure 10 - Seismic Solid Bottom Curb without Filters Cross Section ........................................ 31
Figure 11 - Seismic Solid Bottom Curb without Filters Detail A................................................. 31
Figure 12 - Seismic Solid Bottom Curb without Filters Detail B................................................. 31
Figure 13 - Seismic Rigid Mount Curb Cross Section ................................................................. 32
Figure 14 - Horizontal duct connections....................................................................................... 32
Figure 15 - RQ Series unit Closed Rain Hood.............................................................................. 33
Figure 16 - RQ Series unit Open Rain Hood ................................................................................ 33
Figure 17 - Rain Hood with Metal Mesh Filter Rack Installation ................................................ 33
Figure 18 - Unit Base Utility Entry............................................................................................... 34
Figure 19 - Back View of Power Switch from Control Compartment ......................................... 35
Figure 20 - Draw-Through Drain Trap ......................................................................................... 38
Figure 20 - Post Corner Hole Location......................................................................................... 39
Figure 21 - Post Back Hole Location............................................................................................ 39
Figure 22 - Post Corner Hole Piping............................................................................................. 40
Figure 23 - Post Back Hole Piping ............................................................................................... 40
Figure 24 - PIN Connectors on EC Supply Fan Motor Electronics.............................................. 42
Figure 25 - 2-6 ton Supply Fan..................................................................................................... 55
Figure 26 - RQ Supply Fan Removal Bolts.................................................................................. 55
Figure 27 - RQ Supply Fan Removal Slide .................................................................................. 55
Figure 28 - Variable Capacity Compressor Controller ................................................................. 61
Figure 29 - Compressor Controller Flash Code Details................................................................ 62
Figure 30 - Evaporator Coil Access.............................................................................................. 63
Figure 31 - Removal of a Condenser Fan Assembly .................................................................... 64
Figure 32 - Preheat Controller ...................................................................................................... 78
Figure 33 - RQ Series Gas Heat Exchanger.................................................................................. 82
Figure 34 - Example 2-6 ton through the Base Gas Piping Note: RQ units will only contain one
Heat Exchanger............................................................................................................................. 86
Figure 35 - Gas Heater Instructions .............................................................................................. 88
Figure 36 - Gas Heat Exchanger................................................................................................... 90
Figure 37 - RQ Series 2-6 ton Standard Filter Layout.................................................................. 94

7
AAON®RQ Series Features and Options Introduction
Energy Efficiency
•Direct Drive Backward Curved Plenum
Supply Fans
•Two-Stage, Variable Capacity and
Variable Speed 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
•Water-Cooled Condensers
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 Coating
Warranty
•Stainless Steel Coil Casing
•Stainless Steel Drain Pans

8
Safety
Attention must 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
CARBON MONOXIDE POISONING
HAZARD
Failure to follow instructions could
result in severe personal injury or
death due to carbon-monoxide
poisoning, if combustion products
infiltrate into the building.
Check that all openings in the outside
wall around the vent (and air intake)
pipe(s) are sealed to prevent
infiltration of combustion products into
the building.
Check that furnance vent (and air
intake) terminal(s) are not obstructed
in any way during all seasons.
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
This appliance is not intended for use
by persons with reduced physical,
sensory or mental capabilities, or lack
of experience and knowledge, unless
they have been given supervision or
instruction concerning use of the
appliance by a person responsible for
their safety. Children must be
supervised around this appliance.
WARNING
In order to avoid a hazard due to
inadvertent resetting of the THERMAL
CUT-OUT, this appliance must not be
supplied through an external
switching device, such as a timer, or
connected to a circuit that is regularly
switched on and off by the utility.
CAUTION

10
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 must
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
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 th
e 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
UNIT HANDLING
To prevent injury or death lifting
equipment capacity must 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
must be checked for proper operation.
Alterations must 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