AAON CF Series Owner's manual

CF Series
Condenser and Condensing Units
Installation, Operation,
& Maintenance
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
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
UL-60335

2
Table of Contents
i
Index of Tables and Figures
Tables:
Table 1 - Clearances for Proper Operation ................................................................................... 18
Table 2 - Clearances for Coil Pull................................................................................................. 18
Table 3 - Acceptable Fin & Tube Refrigeration Circuit Values................................................... 23
Table 4 - Acceptable Microchannel Air-Cooled Condenser Coil Liquid Sub-Cooling Values
(Metric) ......................................................................................................................................... 24
Table 5 - Acceptable Microchannel Air-Cooled Condenser Coil Liquid Sub-Cooling Values
(Imperial) ...................................................................................................................................... 24
Table 6 - R-410A Refrigerant Temperature-Pressure Chart (Metric) .......................................... 26
Table 7 - R-410A Refrigerant Temperature-Pressure Chart (Imperial)........................................ 27
Table 8 - R-454B Refrigerant Temperature-Pressure Chart (Metric)........................................... 28
Table 9 - R-454B Refrigerant Temperature-Pressure Chart (Imperial)........................................ 29
Table 10 - Estimated R410A Refrigerant Charge per 5 ft at SCT = 115oF & Subcooling = 10oF,
SST = 45oF & Superheat=10oF..................................................................................................... 30
Table 11 - Charge to Flood Fin and Tube Condenser Coil for Ambient Above 21.3°C (70°F).. 31
Table 12 - Charge to Flood Microchannel Condenser Coil for Ambient Above 21.3°C (70°F) .. 31
Table 13 - % Charge to Flood Condenser Coil for Ambient Below 21.3°C (70°F) ..................... 31
Table 14 - Nameplate Voltage Markings & Tolerances ............................................................... 42
Table 15 – 35 KAIC Fuse Sizing.................................................................................................. 44
Table 16 – 65 KAIC Fuse Sizing.................................................................................................. 44
Table 17 - Demand Signal vs. Compressor Capacity Modulation................................................ 46
Table 18 - Thermistor Temperature vs. Resistance Values .......................................................... 47
Table 19 - Max Filter Drier Pressure Drops ................................................................................. 49
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 - CU evacuation connections.......................................................................................... 20
Figure 6 - CU evacuation connections.......................................................................................... 21
Figure 7 - Adjustable Fan Cycling Switch.................................................................................... 32
Figure 8 - LAC Piping Example ................................................................................................... 33
Figure 9 - Double Suction Riser Construction.............................................................................. 36
Figure 10 - Heat Pump Piping Schematic of Cooling Mode in Double Riser.............................. 39
Figure 11 - Heat Pump Piping Schematic of Heating Mode in Double Riser .............................. 39
Figure 12 - Oil Return Line .......................................................................................................... 41
Figure 13 - Variable Capacity Compressor Controller ................................................................. 45
Figure 14 - Compressor Controller Flash Code Details................................................................ 47
Figure 15 - Adjustable compressor lockout .................................................................................. 48

3
Figure 16 - Ambient sensor cover................................................................................................. 48
Figure 17 - A/C Split System Piping, Suction Down ................................................................... 57
Figure 18 - A/C Split System Piping, Suction Up ........................................................................ 58
Figure 19 - A/C with LAC Split System Piping, Suction Down .................................................. 59
Figure 20 - A/C with LAC Split System Piping, Suction Up ....................................................... 60
Figure 21 - A/C with Modulating Hot Gas Reheat Split System Piping, Suction Down ............. 61
Figure 22 - A/C with Modulating Hot Gas Reheat Split System Piping, Suction Up .................. 62
Figure 23 - A/C with Modulating Hot Gas Reheat Split + LAC System Piping, Suction Down. 63
Figure 24 - A/C with Modulating Hot Gas Reheat Split + LAC System Piping, Suction Up...... 64
Figure 25 - A/C with Hot Gas Bypass Split System Piping, Suction Down ................................ 65
Figure 26 - A/C with Hot Gas Bypass Split System Piping, Suction Up ..................................... 66
Figure 27 - A/C with Hot Gas Bypass + LAC Split System Piping, Suction Down .................... 67
Figure 28 - A/C with Hot Gas Bypass + LAC Split System Piping, Suction Up ......................... 68
Figure 29 - A/C with Modulating Hot Gas Reheat and Hot Gas Bypass Split System Piping,
Suction Down................................................................................................................................ 69
Figure 30 - A/C with Modulating Hot Gas Reheat and Hot Gas Bypass Split System Piping,
Suction Up .................................................................................................................................... 70
Figure 31 - A/C with Modulating Hot Gas Reheat and Hot Gas Bypass + LAC Split System
Piping, Suction Down ................................................................................................................... 71
Figure 32 - A/C with Modulating Hot Gas Reheat and Hot Gas Bypass + LAC Split System
Piping, Suction Up........................................................................................................................ 72
Figure 33 - Heat Pump Split System Piping, Suction Down ........................................................ 73
Figure 34 - Heat Pump Split System Piping, Suction Up............................................................. 74
Figure 35 - Heat Pump with Modulating Hot Gas Reheat Split System Piping, Suction Down.. 75
Figure 36 - Heat Pump with Modulating Hot Gas Reheat Split System Piping, Suction Up....... 76
Figure 37 - Heat Pump with Hot Gas Bypass Split System Piping, Suction Down ..................... 77
Figure 38 - Heat Pump with Hot Gas Bypass Split System Piping, Suction Up .......................... 78
Figure 39 - Heat Pump with Modulating Hot Gas Reheat and Hot Gas Bypass Split System
Piping, Suction Down ................................................................................................................... 79
Figure 40 - Heat Pump with Modulating Hot Gas Reheat and Hot Gas Bypass Split System
Piping, Suction Up........................................................................................................................ 80
V04410 · Rev. A · 230927
(ACP J000237 )

4
AAON CF Series Features and Options Introduction
Energy Efficiency
•Two-Stage, 10-100% Variable Capacity,
or Tandem R-410A Scroll Compressors
•Air-Source Heat Pump
•VFD Controlled and ECM Driven
Condenser Fans
Humidity Control
•Modulating Hot Gas Reheat
•Makeup Air Applications up to 100%
Outside Air
Safety
•Phase and Brownout Protection
•Single Point Non-Fused Disconnect
Power Switch
•Automatic Low Pressure and Manual
Reset High Pressure Safety Cut-outs
•Adjustable Compressor Lockout
Installation and Maintenance
•Isolated Controls and Compressor
Compartment
•Access Doors with Full Length Stainless
Steel Piano Hinges
•Molded Lockable Handles
•Color-Coded Wiring Diagrams
•Run Test Report and Installation Manual
Included in Controls Compartment
•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
•Remote Air-Cooled Condenser Option
•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
•10,000 Hour Salt Spray Tested Polymer
E-Coated Condenser Coils
•Condenser Coil Guards
•Custom Color Paint Options

5
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.
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 must be kept with the
unit.
WARNING
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
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
e
lectrical 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

6
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, must 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

7
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 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
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 ro
tation 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
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

8
ENCLOSED AREA
Do not work in an en
closed 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
Unit power supply wire must be only
copper or aluminum.
CAUTION
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

9
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
3 MINUTE MINIMUM OFF TIME
To prevent motor overheating
compressors must cycle off for a
minimum of 3 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 7
starts per hour.
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
thei
r safety. Children must be
supervised to ensure they do not play
with this appliance.
WARNING
Units with VFD driven
motors/compressors have adjustable
overload settings. These are set by
the AAON factory for the protection of
these motors/compressors and must
not be adjusted over this factory
setpoint or bypassed.
WARNING

CF Series Feature String Nomenclature
Model Options
:
Unit Feature Options
GEN
MJREV
SIZE
SERIES
MNREV
VLT A1 A2 A3 A4 A5
1
2A
2B
3A
3B
4
5
6A
6B
6C
7
8A
8B
8C
8D
9
10
11
12
13
14
15
CF
A
-
015
-
A
-
0
-
3
-
D
A
0
0
K
:
0
-
A
0
-
E
0
-
C
0
-
A
J
0
-
D
-
B
A 0 0 - 0 0 A 0 E 0 0
0 0 0 0 0 D B
16
17
18
19
20
21
22
10
CFSeriesFeatureStringNomenclature
MODEL OPTIONS
Series and Generation
CF
Major Revision
A
Unit Size
002 = 2 ton Capacity
003 = 3 ton Capacity
004 = 4 ton Capacity
005 = 5 ton Capacity
006 = 6 ton Capacity (Obsolete)
007 = 7 ton Capacity
009 = 9 ton Capacity
011 = 11 ton Capacity
013 = 13 ton Capacity
015 = 15 ton Capacity
016 = 16 ton Capacity
018 = 18 ton Capacity
020 = 20 ton Capacity
025 = 25 ton Capacity
026 = 26 ton Capacity
030 = 30 ton Capacity
031 = 31 ton Capacity
040 = 40 ton Capacity
050 = 50 ton Capacity
060 = 60 ton Capacity
070 = 70 ton Capacity
Series
A = 2-7 ton units
B = 9-15 ton units
C = 16-25 & 30 ton units
D = 26 & 31-70 ton units
Minor Revision
A
Voltage
1 = 230V/1Φ/60Hz
2 = 230V/3Φ/60Hz
3 = 460V/3Φ/60Hz
4 = 575V/3Φ/60Hz
8 = 208V/3Φ/60Hz
9 = 208V/1Φ/60Hz
A1: Compressor Style
0 = Air-Cooled Condenser - No Compressors
(1 Circuit)
A = R-410A Scroll Compressors
B = R-410A Two-Stage Capacity Scroll Compressors
D = R-410A Variable Capacity Scroll Compressors
E = R-410A Tandem Scroll Compressors
G = R-410A Tandem Variable Capacity Scroll
Compressors
P = Air-Cooled Condenser - No Compressors
(2 Circuits)
Q = Air-Cooled Condenser - No Compressors
(4 Circuits)
A2: Condenser Style
A = Air-Cooled Microchannel Condenser
C = Air-Cooled Condenser (Fin and Tube) (Obsolete)
J = Air-Source Heat Pump (Fin and Tube)
A3: Configuration
0 = Standard
A4: Coating
0 = Standard
E = Polymer E-Coated Condenser Coil
F = Stainless Steel Casing (Obsolete)
G = Copper Fin + Stainless Steel Casing (Obsolete)
H = Option E + F (Obsolete)
A5: Staging
0 = No Cooling
G = 1 On/Off Refrigeration System
H = 1 Variable Capacity Refrigeration System
J = 2 On/Off Refrigeration Systems
K = 1 Variable Capacity Refrigeration System + 1
On/Off Refrigeration System
L = 2 Variable Capacity Refrigeration System
M = 2 Two-Stage Refrigeration System
N = 1 Variable Capacity Refrigeration System + 1
Two-Stage Refrigeration System
R = 4 On/Off Refrigeration Systems
T = 2 Variable Capacity Refrigeration Systems + 2
On/Off Refrigeration Systems
U = 4 Variable Capacity Refrigeration Systems