AAON CF Series Owner's manual

CF Series
Condenser and Condensing 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.
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
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

2
Table of Contents
AAON CF Series Features and Options Introduction..................................................................... 5
Safety .............................................................................................................................................. 6
CF Series Feature String Nomenclature ....................................................................................... 11
General Information...................................................................................................................... 14
Codes and Ordinances............................................................................................................... 14
Receiving Unit........................................................................................................................... 14
Storage....................................................................................................................................... 15
Wiring Diagrams....................................................................................................................... 16
General Maintenance................................................................................................................. 16
Installation..................................................................................................................................... 17
Forklifting the Unit.................................................................................................................... 17
Lifting the Unit.......................................................................................................................... 18
Locating the Unit....................................................................................................................... 18
Mounting Isolation.................................................................................................................... 19
Access Doors............................................................................................................................. 19
Low Ambient Operation............................................................................................................ 19
Fan Cycling Low Ambient........................................................................................................ 20
Variable Speed Low Ambient................................................................................................... 20
Flooded Condenser Low Ambient ............................................................................................ 20
LAC Valve ................................................................................................................................ 20
Condenser Flooding .................................................................................................................. 21
Refrigerant Piping ..................................................................................................................... 22
Determining Refrigerant Line Size........................................................................................ 22
Liquid Line ............................................................................................................................ 23
Suction Line........................................................................................................................... 24
Discharge Line....................................................................................................................... 26
Hot Gas Bypass Line............................................................................................................. 28
Hot Gas Reheat...................................................................................................................... 29
Electrical.................................................................................................................................... 30
Startup........................................................................................................................................... 32
Compressor Operation............................................................................................................... 32
Variable Capacity Compressor Controller................................................................................ 33
Low Voltage Terminals............................................................................................................. 33
High Voltage Terminals............................................................................................................ 33
Compressor Lockouts................................................................................................................ 35
Maintenance.................................................................................................................................. 36
General ...................................................................................................................................... 36
Compressors.............................................................................................................................. 36
Refrigerant Filter Driers............................................................................................................ 36
Adjusting Refrigerant Charge ................................................................................................... 36
Lubrication ................................................................................................................................ 40
Condenser Tube Inspection....................................................................................................... 40
Maintenance Recommendations ............................................................................................... 40
E-Coated Coil Cleaning ............................................................................................................ 41
Service....................................................................................................................................... 43

3
Warranties ................................................................................................................................. 43
Replacement Parts..................................................................................................................... 43
AAON - Longview Warranty, Service, and Parts Department................................................. 43
Split System Refrigerant Piping Diagrams................................................................................... 44
Index of Tables and Figures
Tables:
Table 1 –Clearances for Proper Operation.................................................................................... 18
Table 2 –Clearances for Coil Pull................................................................................................ 18
Table 3 - Condenser Flooding....................................................................................................... 21
Table 4 - Demand Signal vs. Compressor Capacity Modulation.................................................. 34
Table 5 - Thermistor Temperature vs. Resistance Values............................................................ 35
Table 6 - Max Filter Drier Pressure Drops ................................................................................... 36
Table 7 - Acceptable Refrigeration Circuit Values....................................................................... 37
Table 8 - R-410A Refrigerant Temperature-Pressure Chart......................................................... 40
Figures:
Figure 1 - Forklifting a CF Series A Cabinet................................................................................ 17
Figure 2 - Forklifting a CF Series B and C Cabinet ..................................................................... 17
Figure 3 –Lifting Details and Orientation of a CF Series 9-70 ton Condensing Unit................. 18
Figure 4 - Orientation of Series 2-7 ton Condensing Unit............................................................ 18
Figure 5 - Adjustable Fan Cycling Switch.................................................................................... 20
Figure 6 - Piping Schematic of Example System using the LAC Valve ...................................... 21
Figure 7 - Double Suction Riser Construction.............................................................................. 25
Figure 8 –Heat Pump Piping Schematic of Suction Vapor Flow Down in Double Riser ........... 27
Figure 9 –Heat Pump Piping Schematic of Discharge Vapor Flow Up in Double Riser............ 27
Figure 10 –Oil Return Line.......................................................................................................... 29
Figure 11 - Variable Capacity Compressor Controller................................................................. 33
Figure 12 - Compressor Controller Flash Code Details................................................................ 34
Figure 13 - Adjustable compressor lockout.................................................................................. 35
Figure 14 - Ambient sensor cover................................................................................................. 35
Figure 15 - A/C Split System Piping, Suction Down ................................................................... 44
Figure 16 - A/C Split System Piping, Suction Up........................................................................ 45
Figure 17 - A/C with LAC Split System Piping, Suction Down .................................................. 46
Figure 18 - A/C with LAC Split System Piping, Suction Up....................................................... 47
Figure 19 - A/C with Modulating Hot Gas Reheat Split System Piping, Suction Down............. 48
Figure 20 - A/C with Modulating Hot Gas Reheat Split System Piping, Suction Up.................. 49
Figure 21 - A/C with Modulating Hot Gas Reheat Split + LAC System Piping, Suction Down. 50
Figure 22 - A/C with Modulating Hot Gas Reheat Split + LAC System Piping, Suction Up...... 51
Figure 23 - A/C with Hot Gas Bypass Split System Piping, Suction Down ................................ 52
Figure 24 - A/C with Hot Gas Bypass Split System Piping, Suction Up ..................................... 53
Figure 25 - A/C with Hot Gas Bypass + LAC Split System Piping, Suction Down.................... 54
Figure 26 - A/C with Hot Gas Bypass + LAC Split System Piping, Suction Up......................... 55

4
Figure 27 - A/C with Modulating Hot Gas Reheat and Hot Gas Bypass Split System Piping,
Suction Down................................................................................................................................ 56
Figure 28 - A/C with Modulating Hot Gas Reheat and Hot Gas Bypass Split System Piping,
Suction Up .................................................................................................................................... 57
Figure 29 - A/C with Modulating Hot Gas Reheat and Hot Gas Bypass + LAC Split System
Piping, Suction Down................................................................................................................... 58
Figure 30 - A/C with Modulating Hot Gas Reheat and Hot Gas Bypass + LAC Split System
Piping, Suction Up........................................................................................................................ 59
Figure 31 - Heat Pump Split System Piping, Suction Down........................................................ 60
Figure 32 - Heat Pump Split System Piping, Suction Up............................................................. 61
Figure 33 - Heat Pump with Modulating Hot Gas Reheat Split System Piping, Suction Down.. 62
Figure 34 - Heat Pump with Modulating Hot Gas Reheat Split System Piping, Suction Up....... 63
Figure 35 - Heat Pump with Hot Gas Bypass Split System Piping, Suction Down..................... 64
Figure 36 - Heat Pump with Hot Gas Bypass Split System Piping, Suction Up.......................... 65
Figure 37 –Heat Pump with Modulating Hot Gas Reheat and Hot Gas Bypass Split System
Piping, Suction Down................................................................................................................... 66
Figure 38 –Heat Pump with Modulating Hot Gas Reheat and Hot Gas Bypass Split System
Piping, Suction Up........................................................................................................................ 67
V45040 · Rev. A · 180319
(ACP J00424)

5
AAON CF Series Features and Options Introduction
Energy Efficiency
•Staged, Two-Step, 10-100% Variable
Capacity, or Tandem R-410A Scroll
Compressors
•Air-Source Heat Pump
•VFD Controlled or ECM Driven
Condenser Fans
Humidity Control
•Modulating Hot Gas Reheat
Safety
•Phase and Brownout Protection
•Adjustable Compressor Lockout
Installation and Maintenance
•Isolated Controls and Compressor
Compartment
•Access Doors with Full Length Stainless
Steel Piano Hinges
•Molded Lockable Handles
•Run Test Report and Installation Manual
Included in Controls Compartment
•Color-Coded Wiring and Wiring
Diagrams
•Factory Installed Convenience Outlet
•Service Access Lights
•Remote Start/Stop Terminals
•Liquid Line Sight Glass
•Compressor Isolation Valves
System Integration
•Complete Split System with AAON DX
Air Handling Units
•Single Point Non-Fused Disconnect
Power Switch
•Labeled Split System Piping Stub Outs
with Shut-Off Valves
•Flooded Condenser 0°F Low Ambient
Controls
•Terminal Block for Thermostat with
Isolation Relays
•Constant Air Volume (CAV), Makeup
Air (MUA), Variable Air Volume
(VAV), and Single Zone Variable Air
Volume (SZ VAV)
Environmentally Friendly
•R-410A Refrigerant
Extended Life
•Optional 5 Year Compressor Warranty
•G90 Galvanized Steel Construction
•2,500 Hour Salt Spray Tested Exterior
Corrosion Protection
•6,000 Hour Salt Spray Tested Polymer
E-Coated Condenser Coils
•Copper Fin and Stainless Steel Casing
Coils
•Condenser Coil Guards

6
ELECTRIC SHOCK
Electric shock hazard. Before
servicing, shut off all electrical power
to the unit, including remote
disconnects, to avoid shock hazard
or injury from rotating parts. Follow
proper Lockout-Tagout procedures.
WARNING
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.
QUALIFIED INSTALLER
Improper installation, adjustment,
alteration, service or maintenance
can cause property damage,
personal injury or loss of life. Startup
and service must be performed by a
Factory Trained Service Technician.
A copy of this IOM should be kept
with the unit.
WARNING
ELECTRIC SHOCK, FIRE OR
EXPLOSION HAZARD
Failure to follow safety warnings
exactly could result in dangerous
operation, serious injury, death or
property damage.
Improper servicing could result in
dangerous operation, serious injury,
death, or property damage.

When servicing controls, label all
wires prior to disconnecting.
Reconnect wires correctly.

Verify proper operation after
servicing. Secure all doors with
key-lock or nut and bolt.
WARNING

7
ROTATING COMPONENTS
Unit contains fans with moving parts
that can cause serious injury. Do not
remove grill containing fans until the
power to the unit has been
disconnected and fan has stopped
rotating.
WARNING
LIVE ELECTRICAL
During installation, testing, servicing,
and troubleshooting of the equipment
it may be necessary to work with live
electrical components. Only a
qualified licensed electrician or
individual properly trained in handling
live electrical components shall
perform these tasks.
Standard NFPA-70E, an OSHA
regulation requiring an Arc Flash
Boundary to be field established and
marked for identification of where
appropriate Personal Protective
Equipment (PPE) be worn, should be
followed.
WARNING
FIRE, EXPLOSION OR CARBON
MONOXIDE POISONING HAZARD
Failure to replace proper controls
could result in fire, explosion or
carbon monoxide poisoning. Failure
to follow safety warnings exactly
could result in serious injury, death or
property damage. Do not store or use
gasoline or other flammable vapors
and liquids in the vicinity of this
appliance.
WARNING
GROUNDING REQUIRED
All field installed wiring must be
completed by qualified personnel.
Field installed wiring must comply
with NEC/CEC, local and state
electrical code requirements. Failure
to follow code requirements could
result in serious injury or death.
Provide proper unit ground in
accordance with these code
requirements.
WARNING
VARIABLE FREQUENCY DRIVES
Do not leave VFDs unattended in
hand mode or manual bypass.
Damage to personnel or equipment
can occur if left unattended. When in
hand mode or manual bypass mode
VFDs will not respond to controls or
alarms.
WARNING

8
LEAK TESTING
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
VARIABLE FREQUENCY DRIVES
Electric motor over-current protection
and overload protection may be a
function of the Variable Frequency
Drive to which the motors are wired.
Never defeat the VFD motor overload
feature. The overload ampere setting
must not exceed 115% of the electric
motors FLA rating as shown on the
motor nameplate.
CAUTION
PVC PIPING
PVC (Polyvinyl Chloride) and CPVC
(Chlorinated Polyvinyl Chloride) are
vulnerable to attack by certain
chemicals. Polyolester (POE) oils
used with R-410A and other
refrigerants, even in trace amounts,
in a PVC or CPVC piping system will
result in stress cracking of the piping
and fittings and complete piping
system failure.
CAUTION
3-PHASE ROTATION
Rotation must be checked on all
MOTORS AND COMPRESSORS of
3 phase units at startup by a qualified
service technician. Scroll
compressors are directional and can
be damaged if rotated in the wrong
direction. Compressor rotation must
be checked using suction and
discharge gauges. Fan motor rotation
should be checked for proper
operation. Alterations should only be
made at the unit power connection
CAUTION
UNIT HANDLING
To prevent injury or death lifting
equipment capacity shall exceed unit
weight by an adequate safety factor.
Always test-lift unit not more than 24
inches high to verify proper center of
gravity lift point to avoid unit damage,
injury or death.
WARNING
DOOR LATCHES
Door compartments containing
hazardous voltage or rotating parts
are equipped with door latches that
allow locks. Door latches are shipped
with a nut and bolt requiring tooled
access. If the shipping hardware is
not replaced with a pad lock, always
re-install the nut and bolt after closing
the door to maintain tooled access.
CAUTION

9
ENCLOSED AREA
Do not work in an enclosed area
where refrigerant or nitrogen gases
may be leaking. A sufficient quantity
of vapors may be present and cause
injury or death.
WARNING
COMPRESSOR LUBRICANT
Polyolester (POE) and Polyvinylether
(PVE) oils are two types of lubricants
used in hydrofluorocarbon (HFC)
refrigeration systems. Refer to the
compressor label for the proper
compressor lubricant type.
CAUTION
COIL CLEANERS
To prevent damage to the unit, do not
use acidic chemical coil cleaners. Do
not use alkaline chemical coil
cleaners with a pH value greater than
8.5, after mixing, without first using
an aluminum corrosion inhibitor in the
cleaning solution.
CAUTION
COIL CLEANERS
Some chemical coil cleaning
compounds are caustic or toxic.
Use
these substances only in accordance
with the manufacturer’s usage
instructions. Failure to follow
instructions may result in equipment
damage, injury or death.
WARNING
COIL CLEANING
Do not clean DX refrigerant coils with
hot water or steam. The use of hot
water or steam on refrigerant coils
will cause high pressure inside the
coil tubing and damage to the coil.
CAUTION
CONVENIENCE OUTLETS
Factory installed convenience outlets
are not intended for use while the unit
is operating.
WARNING

10
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. Every unit has a unique equipment
nameplate with electrical, operational,
and unit clearance specifications.
Always refer to the unit nameplate for
specific ratings unique to the model
purchased.
4. READ THE ENTIRE INSTALLATION,
OPERATION AND MAINTENANCE
MANUAL. OTHER IMPORTANT
SAFETY PRECAUTIONS ARE
PROVIDED THROUGHOUT THIS
MANUAL.
5. Keep this manual and all literature
safeguarded near or on the unit.
COMPRESSOR CYCLING
5 MINUTE MINIMUM OFF TIME
To prevent motor overheating
compressors must cycle off for a
minimum of 5 minutes.
5 MINUTE MINIMUM ON TIME
To maintain the proper oil level
compressors must cycle on for a
minimum of 5 minutes.
The cycle rate must not exceed 6
starts per hour.
WARNING