AAON LF Series Owner's manual

LF Series
Air-Cooled Chillers
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
Factory Trained Service Technician. A
copy of this IOM should be kept with
the unit.
WARNING

2
Table of Contents
AAON LF Series Features and Options Introduction..................................................................... 4
Safety .............................................................................................................................................. 5
LF Series Feature String Nomenclature.......................................................................................... 7
General Description...................................................................................................................... 12
Receiving Unit........................................................................................................................... 12
Chiller........................................................................................................................................ 13
Wiring Diagrams....................................................................................................................... 14
General Maintenance................................................................................................................. 14
Primary Pumping Package ........................................................................................................ 14
Glycol........................................................................................................................................ 15
Compression Tank..................................................................................................................... 15
Pressure Relief Valve................................................................................................................ 15
Manual and Automatic Air Vent............................................................................................... 15
Dual Pumps ............................................................................................................................... 15
Differential Pressure Gauge and Thermometers....................................................................... 16
Pipe Insulation........................................................................................................................... 16
Installation..................................................................................................................................... 16
Forklifting the Unit (4-17, 22 and 24 ton)................................................................................. 16
Lifting the Unit.......................................................................................................................... 17
Locating the Unit....................................................................................................................... 18
Water Connection...................................................................................................................... 18
Mounting Isolation.................................................................................................................... 19
Access Doors............................................................................................................................. 19
Low Ambient Operation............................................................................................................ 19
LAC Valve............................................................................................................................. 20
Condenser Flooding............................................................................................................... 21
Electrical.................................................................................................................................... 21
Startup........................................................................................................................................... 23
Maintenance.................................................................................................................................. 24
General ...................................................................................................................................... 24
Compressors.............................................................................................................................. 24
Refrigerant Filter Driers............................................................................................................ 24
Adjusting Refrigerant Charge ................................................................................................... 24
Lubrication ................................................................................................................................ 26
Service....................................................................................................................................... 27
Warranties ................................................................................................................................. 27
Condenser Tube Inspection....................................................................................................... 27
Pump Operation......................................................................................................................... 27
Access Doors............................................................................................................................. 27
Pump Bearings - Lubrication .................................................................................................... 27
Air Inlet ..................................................................................................................................... 27
Propeller Fans and Motors ........................................................................................................ 28

3
Recommended Annual Inspection ............................................................................................ 28
Air-Cooled Condenser............................................................................................................... 28
E-Coated Coil Cleaning ............................................................................................................ 28
Microchannel Coil Cleaning ..................................................................................................... 30
Replacement Parts..................................................................................................................... 32
AAON Technical Support......................................................................................................... 32
Appendix - Water Piping Component Information ...................................................................... 33
Water Pressure Relief Valve ..................................................................................................... 33
Automatic Air Vent Valves....................................................................................................... 33
Pumps: Installation and Operating Instructions ........................................................................ 34
Dual Pump Specific Information............................................................................................... 39
Valve Operation ........................................................................................................................ 39
Suction Guides .......................................................................................................................... 44
Flo-Trex Combination Valve .................................................................................................... 45
LF Series Startup Form................................................................................................................. 51
Maintenance Log .......................................................................................................................... 54
Literature Change History............................................................................................................. 55
Index of Tables and Figures
Tables:
Table 1 - 4-7 & 9 ton Service Clearances..................................................................................... 18
Table 2 - 8 & 10-13 ton Service Clearances................................................................................. 18
Table 3 - 14-17, 22 & 24 ton Service Clearances......................................................................... 18
Table 4 - 21 & 26-55 ton Service Clearances............................................................................... 18
Table 5 - Water Connection Sizes ................................................................................................ 19
Table 6 - Condenser Flooding....................................................................................................... 21
Table 7 - Nameplate Voltage Markings........................................................................................ 21
Table 8 - Max Filter Drier Pressure Drops ................................................................................... 24
Table 9 - Acceptable Refrigeration Circuit Values....................................................................... 25
Table 10 - R-410A Refrigerant Temperature-Pressure Chart....................................................... 26
Figures:
Figure 1 - Pressure Relief Valve................................................................................................... 15
Figure 2 - Forklifting an LF Series A, B and C Cabinet, 4-17, 22 and 24 tons............................ 16
Figure 3 - Lifting Details of a 4-17, 22 and 24 ton Standard Unit................................................ 17
Figure 4 - Lifting Details of a 21 and 26-55 ton Standard Unit.................................................... 17
Figure 5 - Piping Schematic of Example System using the LAC Valve ...................................... 20
V45070 · Rev. A · 190515
(ACP J00425)

4
AAON LF Series Features and Options Introduction
Energy Efficiency
•Staged or 10-100% Variable Capacity
R-410A Scroll Compressors
•High Efficiency Air-Cooled
Microchannel Condenser Coils
•VFD Controlled Pumping Packages
•VFD Controlled or ECM Condenser Fan
Head Pressure Control
•ECM Low Sound Condenser Fan Head
Pressure Control
•Waterside Economizers
•Factory Installed EXVs
Outdoor Mechanical Room
•Chilled Water Applications up to 55 tons
•Isolated Controls and Compressor
Compartment
•Isolated Evaporator and Pumping
Package Compartment
•Factory Engineered Primary Pumping
Packages
•Brazed Plate or Shell and Tube
Evaporators
Safety
•Phase and Brownout Protection
•Single Point Non-Fused Disconnect
Power Switch
•Waterside Thermometer and Pressure
Gauge
Installation and Maintenance
•Double Wall Rigid Polyurethane Foam
Injected Panel Construction
•Access Doors with Full Length Stainless
Steel Piano Hinges
•Molded Lockable Handles
•Factory Installed Convenience Outlet
•Service Vestibule Heating
•Controls Diagnostics
•Touchscreen Computer Controls
Interface
•Liquid Line Sight Glass
•Compressor Isolation Valves
•Color-Coded Wiring Diagrams
System Integration
•Complete System with AAON Chilled
Water Air Handling Units
•BMS Connectivity
•Grooved End Water Piping Connections
•Custom Order Paint Options
Environmentally Friendly
•R-410A Refrigerant
Extended Life
•5 Year Compressor Warranty
•Condenser Coil Guards
•2,500 Hour Salt Spray Tested Exterior
Corrosion Protection
•10,000 Hour Salt Spray Tested Polymer
E-Coated Condenser Coils

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.

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
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
Electric shock hazard. Shut off all
electrical power to the unit to avoid
shock hazard or injury from rotating
parts.
WARNING

6
1. Startup and service must be performed by
a Factory Trained Service Technician.
2. The unit is for outdoor use only. See
General Information section for more
information.
3. READ THE ENTIRE INSTALLATION,
OPERATION AND MAINTENANCE
MANUAL. OTHER IMPORTANT
SAFETY PRECAUTIONS ARE
PROVIDED THROUGHOUT THIS
MANUAL.
4. Keep this manual and all literature
safeguarded near or on the unit.
COMPRESSOR CYCLING
5 MINUTE MINIMUM OFF TIME
To prevent motor overheating
compressors must cycle off for a
minimum of 5 minutes.
2 MINUTE MINIMUM ON TIME
To maintain the proper oil level
compressors must cycle on for a
minimum of 2 minutes.
The cycle rate must not exceed 6
starts per hour.
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
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

LF Series Feature String Nomenclature
Model Options
:
Unit Feature Options
GEN
MJREV
SIZE
SERIES
MNREV
VLT
A1
A2
A3
A4
A5
B1
B2
B3
B4
1
2
3A
3B
3C
3D
4A
4B
4C
4D
5A
5B
5C
5D
6
7
8A
8B
8C
LF
A
-
031
-
D
-
0
-
3
-
D
A
C
0
E
-
0
0
0
0
:
C
0
-
0
0
0
0
-
0
0
0
0
-
0
0
0
0
-
0
0
-
0
0
0
0
-
0
E
0
0
-
0
0
C
0
0
-
0
A
0
0
0
-
0
0
0
0
0
-
0
0
0
0
0
0
-
0
0
0
0
0
-
0
0
D
B
9
10A
10B
10C
10D
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26A
26B
26C
26D
26E
26F
27
28
29
30
31
32
33
34
35
7
LFSerie s Fea ture Stri ng Nom enclature
MODEL OPTIONS
SERIES AND GENERATION
LF
MAJOR REVISION
A
UNIT SIZE
004 = 4 ton Capacity
005 = 5 ton Capacity
007 = 7 ton Capacity
008 = 8 ton Capacity
009 = 9 ton Capacity
010 = 10 ton Capacity
011 = 11 ton Capacity
013 = 13 ton Capacity
014 = 14 ton Capacity
015 = 15 ton Capacity
017 = 17 ton Capacity
021 = 21 ton Capacity
022 = 22 ton Capacity
024 = 24 ton Capacity
026 = 26 ton Capacity
031 = 31 ton Capacity
042 = 42 ton Capacity
048 = 48 ton Capacity
055 = 55 ton Capacity
SERIES
A = 4-7 and 9 ton units
B = 8 and 10-13 ton unit
C = 14-17, 22 and 24 ton units
D = 21 and 26-55 ton units
MINOR REVISION
A
VOLTAGE
2 = 230V/3Φ/60Hz
3 = 460V/3Φ/60Hz
4 = 575V/3Φ/60Hz
8 = 208V/3Φ/60Hz
A1: COMPRESSOR STYLE
A = R-410A Scroll Compressors
D = R-410A Variable Capacity Scroll Compressors
E = R-410A Tandem Scroll Compressors
G = R-410A Tandem Variable Capacity Scroll
Compressors
A2: CONDENSER STYLE
A = Air-Cooled Microchannel Condenser
A3: EVAPORATOR CONFIGURATION
A = Brazed Plate
B = Oversized Brazed Plate
A4: Coating
0 = Standard
E = Polymer E-Coated Condenser Coil
A5: Staging
0 = Staged On/Off Compressors
E = All Variable Capacity Compressors
G = Half Variable Capacity Compressors
B1: Blank
0 = Standard
B2: Blank
0 = Standard
B3: Blank
0 = Standard
B4: Blank
0 = Standard

LF Series Feature String Nomenclature
Model Options
:
Unit Feature Options
GEN
MJREV
SIZE
SERIES
MNREV
VLT
A1
A2
A3
A4
A5
B1
B2
B3
B4
1
2
3A
3B
3C
3D
4A
4B
4C
4D
5A
5B
5C
5D
6
7
8A
8B
8C
LF
A
-
031
-
D
-
0
-
3
-
D
A
C
0
E
-
0
0
0
0
:
C
0
-
0
0
0
0
-
0
0
0
0
-
0
0
0
0
-
0
0
-
0
0
0
0
-
0
E
0
0
-
0
0
C
0
0
-
0
A
0
0
0
-
0
0
0
0
0
-
0
0
0
0
0
0
-
0
0
0
0
0
-
0
0
D
B
9
10A
10B
10C
10D
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26A
26B
26C
26D
26E
26F
27
28
29
30
31
32
33
34
35
8
UNIT FEATURE OPTIONS
1: Unit Orientation
0 = Standard Access End Water Connections
2: Pumping Style
B = Const. Primary Pumping System Large Pipe Size
D = Var. Primary Pumping System Large Pipe Size
J = No Pumping Package - Piping to Connections at
Wall Cutouts
3A: Building Pump Configuration
0 = No Building Pumps
A = 1 Pump + High Eff Motor
B = 1 Dual Pump + High Eff Motors
D = 1 Pump + VFD + High Eff Motor
E = 1 Dual Pump + 2 VFD's + High Eff Motors
3B: Building Pump Series and RPM
0 = No Building Pumps
A = 4360 (1,170 nominal rpm)
B = 4360 (1,760 nominal rpm)
C = 4360 (3,520 nominal rpm)
D = 4380 (1,170 nominal rpm)
E = 4380 (1,760 nominal rpm)
F = 4380 (3,520 nominal rpm)
K = 4382 (1,170 nominal rpm)
L = 4382 (1,760 nominal rpm)
M = 4382 (3,520 nominal rpm)
3C: Pump Size
0 = No Building Pumps
A = 1.5B
B = 2B
C = 2D
D = 3D
E = 1.5x1.5x6
F = 2x2x6
G = 3x3x6
H = 4x4x6
J = 6x6x6
K = 1.5x1.5x8
L = 2x2x8
M = 3x3x8
N = 4x4x8
P = 5x5x8
Q = 6x6x8
R = 8x8x8
S = 2x2x10
T = 3x3x10
U = 4x4x10
V = 6x6x10
W = 8x8x10
Y = 4x4x11.5
Z = 5x5x11.5
1 = 6x6x11.5
2 = 8x8x11.5
3 = 4x4x13
4 = 6x6x13
5 = 8x8x13

LF Series Feature String Nomenclature
Model Options
:
Unit Feature Options
GEN
MJREV
SIZE
SERIES
MNREV
VLT
A1
A2
A3
A4
A5
B1
B2
B3
B4
1
2
3A
3B
3C
3D
4A
4B
4C
4D
5A
5B
5C
5D
6
7
8A
8B
8C
LF
A
-
031
-
D
-
0
-
3
-
D
A
C
0
E
-
0
0
0
0
:
C
0
-
0
0
0
0
-
0
0
0
0
-
0
0
0
0
-
0
0
-
0
0
0
0
-
0
E
0
0
-
0
0
C
0
0
-
0
A
0
0
0
-
0
0
0
0
0
-
0
0
0
0
0
0
-
0
0
0
0
0
-
0
0
D
B
9
10A
10B
10C
10D
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26A
26B
26C
26D
26E
26F
27
28
29
30
31
32
33
34
35
9
3D: Building Pump Motor Size
0 = No Building Pumps
A = 0.5 hp
B = 0.75 hp
C = 1 hp
D = 1.5 hp
E = 2 hp
F = 3 hp
G = 5 hp
H = 7.5 hp
J = 10 hp
K = 15 hp
L = 20 hp
M = 25 hp
N = 30 hp
P = 40 hp
Q = 50 hp
R = 60 hp
S = 75 hp
4A: Blank
0 = Standard
4B: Blank
0 = Standard
4C: Blank
0 = Standard
4D: Blank
0 = Standard
5A: Blank
0 = Standard
5B: Blank
0 = Standard
5C: Blank
0 = Standard
5D: Blank
0 = Standard
6: Refrigeration Options
0 = None
A = Hot Gas Bypass Non-Variable Capacity
Compressor Circuits
B = Hot Gas Bypass - All Circuits
7: Refrigeration Accessories
0 = Standard
A = Sight Glass
B = Compressor Isolation Valves
C = Option A + B
D = Single Circuit 0°F Low Ambient
E = Option A + D
F = Option B + D
G = Option A + B + D
H = Dual Circuits 0°F Low Ambient
J = Option A + H
K = Option B + H
L = Option A + B + H
8A: Unit Disconnect Type
0 = Standard Single Point Power Block
A = Single Point Power Non-fused Disconnect
8B: Disconnect 1 Size
0 = Power Block
N = 100 amps
R = 150 amps
V = 250 amps
Z = 400 amps
8C: Blank
0 = Standard
9: Accessories
0 = None
B = Phase & Brown Out Protection
E = Compressor Sound Blanket
M = Option B + E
10A: Unit Control Sequence
0 = Standard AAON Controls
10B: Unit Control Supplier
E = MCS Controls

LF Series Feature String Nomenclature
Model Options
:
Unit Feature Options
GEN
MJREV
SIZE
SERIES
MNREV
VLT
A1
A2
A3
A4
A5
B1
B2
B3
B4
1
2
3A
3B
3C
3D
4A
4B
4C
4D
5A
5B
5C
5D
6
7
8A
8B
8C
LF
A
-
031
-
D
-
0
-
3
-
D
A
C
0
E
-
0
0
0
0
:
C
0
-
0
0
0
0
-
0
0
0
0
-
0
0
0
0
-
0
0
-
0
0
0
0
-
0
E
0
0
-
0
0
C
0
0
-
0
A
0
0
0
-
0
0
0
0
0
-
0
0
0
0
0
0
-
0
0
0
0
0
-
0
0
D
B
9
10A
10B
10C
10D
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26A
26B
26C
26D
26E
26F
27
28
29
30
31
32
33
34
35
10
10C: Control Supplier Options
0 = None
C = Modem
10D: BMS Connection & Diagnostics
0 = None
A = BACnet IP
B = BACnet MSTP
C = Modbus IP
D = Modbus RTU
E = LonTalk
H = No BMS Connection with Diagnostics
J = BACnet IP with Diagnostics
K = BACnet MSTP with Diagnostics
L = Modbus IP with Diagnostics
M = Modbus RTU with Diagnostics
N = LonTalk with Diagnostics
11: Blank
0 = Standard
12: Vestibule Accessories
0 = None
C = Vestibule Heating (Electric)
13: Maintenance Accessories
0 = None
A = 115VAC Convenience Outlet Factory Wired
B = 115VAC Convenience Outlet Field Wired
14: Blank
0 = Standard
15: Code Options
0 = Standard ETL U.S.A. Listing
16: Shipping Splits
0 = One Piece Unit
B = Crating
C = Export Crating
17: Air-Cooled Chiller Accessories
0 = Standard
A = Cond Coil Guards
C = ECM Condenser Fan Head Pressure Control
E = VFD Condenser Fan Head Pressure Control
G = Option A + C
J = Option A + E
N = Low Sound ECM Cond Fans –Head Pressure
Control
S = Option A + N
18: Blank
0 = Standard
19: Blank
0 = Standard
20: Blank
0 = Standard
21: Blank
0 = Standard
22: Blank
0 = Standard
23: Blank
0 = Standard
24: Chiller Accessories 1
0 = None
A = Glycol chiller
C = Thermometers & Pressure Gauges
G = Option A + C
25: Blank
0 = Standard
26A: Blank
0 = Standard
26B: Blank
0 = Standard