Aaon M2-036 User Manual

Modular Indoor Air Handling Units, Modular Outdoor Air Handling Units, Self Contained Units & Packaged Rooftop Units Installation, Op

10 Do not clean DX refrigerant coils with hot water or

AAON 2425 South Yukon Ave. Tulsa, OK 74107-2728 Phone: 918-583-2266 Fax: 918-583-6094 www.aaon.com M2 Series Installation, Operation & Ma

11 1. Use only with type of the gas approved for the furnace. Refer to the furnace ra

12 conditions including input rate, temperature rise and ESP. 6. Every unit has a unique equipment nameplate with electrical, operational, and unit

13 Model Number Nomenclature Base Model Number Individual Module Model Numbers Identifies the main unit features and options. Identifies module c

14 M2 Base Model Description M2 - H - 011 - R - 2 - A - A - 0 - C - 0 Series and Generation Type Unit Size Supply Airflow Voltage Assembly Wiring P

15 Fan Module Description SFA - 103 - F - B 0 - A 00 0C - 0 0000 - 0 - 0 Module ID Position Motor Size Blower Isolation Motor Type Blank Pulleys S

16 Filter Module Description FTA - 102 - P - A0 - 0 0000 - 0 00 00 - 0 - 0 Module ID Position Filter Type Filters Safety Control Blank Second Fil

17 Mixing Box Module Description MBH - 101 - A - 00 - 0 0000 - 0 0000 - 0 - 0 Module ID Position Position Filters Safety Control Blank Bypass Open

18 Heat Module Description PHA - 101 - H - 00 - 0 00 0 0 - E 02 00 - 0 - 0 Module ID Position Function Filters Rows FPI Circuiting Coating kW

19 Blank Module Description BBA - 101 - 0 - AR - 0 0000 - 0 0000 - 0 - 0 Module ID Position Drain Pan Type Airway Type Safety Control Blank Bypass

20 Coil Module Description CBL - 101 - C - 0 0 - 0 00 0 0 - 4 10 F 0 - S - 0 Module ID Position Cooling Type kW Stages Rows FPI Circuiting Coa

21 Control Panel Module Description TRA - 101 - 0 - 00 - 0 0000 - 00000 - 0 - 0 Module ID Position Blank Blank Safety Options Blank Blank Blank Typ

22 Energy Recovery Module Description HRA - 101 - A - 00 - 00000 - 00000 - 0 - 0 Module ID Position Wheel Size Blank Blank Blank Blank Type MOD

23 Condenser Module Description WCC - 101 - A - 06 - A 000 A - A 0000 - 0 - 0 Module ID Position Compressor Type Tonnage Heat Exchanger Type Blank

24 M2 Series Typical Configurations M2 Series units have been designed as practical, high performance alternative to expensive custom air handling

25 Unit Orientation Determine left hand or right hand orientation/connections: Figure 2 - Unit Orientation Consider the airflow to be hitting

26 General Information M2 Series modular indoor air handling units, modular outdoor air handling units, self contained units and packaged rooftop un

27 c. Certified for installation on a combustible roof with a minimum of 12” high curb. Certification of Cooling Models a. Certified as a commerci

28 all doors with locks or nuts and bolts to prevent unauthorized access. Figure 3 - Lockable Handle The warranty card must be completed in full a

29 to the compressor. As the liquid concentration builds up, oil is washed out of the compressor, leaving it starved for lubrication. The compressor

3 Table of Contents Safety ...

30 Installation AAON equipment has been designed for quick and easy installation. Locating Units Verify rooftop, foundation or mountin

31 Local codes may supersede or further place restrictions on vent termination locations. Figure 4 - Service Access Clearance

32 Figure 5 - M2 Series Unit Four Point Lifting

33 Figure 6 - M2 Series Unit Eight Point Lifting

34 Indoor Floor Mounted Units Indoor M2 Series units can be floor mounted. Dual path units, self contained units and units over size M2-014 must be

35 Module Assembly Although M2 Series modular units are shipped factory assembled as standard, they may be ordered unassembled for certain applicatio

36 Figure 8 - Module Assembly Schematic Configuration Schematic can be found in unit literature packet C

37 2. Apply Bulb Gasket The bulb gasket material creates an airtight seal between adjacent modules after connection. The adhesive backing is initia

38 TopStrap AngleStrap AngleStrap SideStrap Figure 13 - Bar Clamp You should now have a fully gasketed, airtight joint that needs to be perm

39 Figure 17 - Strap Installation 5. Run Power and Control Wiring M2 Series units are equipped with an internal wiring

4 Gas Fired Duct Furnace ... 57 Duct Furnac

40 Only clean ACR tubing should be used. Piping should conform to generally accepted practices and codes. The air handling unit coils

41 Minimizing the refrigerant line size is favorable from an economic perspective, reducing installation costs, and reducing the potential for leakag

42 may provide additional sub-cooling to the refrigerant. When routing the liquid line through high temperature areas, insulation of the line is appr

43 risers. The smaller diameter pipe should be sized to return oil at minimum load, while the larger diameter pipe should be sized so that flow throu

44 Insulate the entire length of the HGB line with a minimum 1 inch thick Armaflex insulation. Hot Gas Bypass Piping Considerations for Evaporator

45 3. Disinfection the water loop with solutions containing sodium hypochlorite. Chlorides will result in a premature failure of the condenser. Fai

46 need for head pressure control. If the EWT is expected to be lower than 50°F or more stable operation is desired, a field provided water regulatin

47 Before connection to the unit the condenser water system should be flushed to remove foreign material that could ca

48 Table 3 - Freezing Points % Glycol Ethylene Glycol Propylene Glycol 20 18°F 19°F 30 7°F 9°F 40 -7°F -6°F 50 -28°F -27°F Pipi

49 Table 5 - Brazed Plate Heat Exchanger Pressure Drops (WCC- & WHP-) -003 -004 -005 -006 gpm psi gpm psi gpm psi gpm psi 7.9 2.89 10.0 4.41 12.

5 Index of Tables and Figures Tables: Table 1 - Minimum Clearances ...

50 A single point connection to a terminal block is provided. Split units may require connection between the units. High voltage conductors should en

51voltages from the average divided by the average voltage. Example: (221V+230V+227V)/3 = 226V, then 100*(226V-221V)/226V = 2.2%, which exceeds th

52 All external devices must be powered via a separate external power supply. Example: A total of 8 wires must be pulled 75ft to a control the unit.

53Draw-Through Drain Pan Pressure Trap Dimensions Negative Static X X/2 (inches of water) (inch) (inch) -0.50 1.50 0.75 -1.00 2.00 1.00 -1.50 2

54 Air Adjustment In the event that reduced air volume is required, an air volume band can be installed within the blower wheel to reduce the amount

55 Figure 20 - Supply Fan Banding Waterside Economizer Pre-cooling waterside economizer coil is supplied without water piping. A kit to pi

56 An aquastat is included with the field installed water piping kit and is used to modulate water flow through the economizer coil. The controller i

57required heat. The indoor fan motor will energize at the same time as the heaters. Wiring to the air handling unit must be done in accordance with

58 minimize the number of elbows or turns in vent pipe. Gas Supply, Piping and Connections Gas piping must be installed in accordance with local cod

59Duct Furnace Component Identification Figure 22 - Horizontal Configuration Horizontal Airflow Configuration 1. Airflow may be from either right

6 Figures: Figure 1 - Typical Configurations ... 24 Fig

60 Input The correct heat capacity of the furnace is controlled by the burner orifices and the gas manifold pressure. The manifold pressure is factor

61For On-Off units the manifold pressure should be 3.5” w.c. Failure to Ignite 1. For the initial start-up, or after unit has been off long periods

62 burner and manifold pipe, or debris in the main burner orifice. Soft brush or vacuum clean affected areas after performing Shutdown procedure. 2.

63Air Pressure Switch An air pressure switch is provided as part of the control system to verify airflow through draft inducer by monitoring the diff

64 Table 9 - Gas Heater Troubleshooting LED Code System Description Actions None No Power to T1 On call for heat nothing happens

65Table 10 - Gas Heater Troubleshooting Continued LED Code System Description Actions 2 Flash Flame F

66 Operating Control Systems Two Stage (TN) - Low / High Fire / High Speed Inducer Only Modulating (MD) - Modulating (25 to 100%) / 2 Speed Draft In

672. Check for proper start-up and ignition as outlined in Start-Up section. 3. Check the appearance of the burner flame. 4. Check that the circula

68 Startup (See back of the manual for startup form) During startup, it is necessary to perform routine checks on the performance of

697. Check all high and low voltage wiring connections for correctness and tightness. 8. Check unit for correct incoming voltage per the data plat

7 Safety ELECTRIC SHOCK, FIRE OR EXPLOSION HAZARD Failure

70 Air Balancing High performance systems commonly have complex air distribution and fan systems. Unqualified personnel should not attempt to adjust

71Checking Liquid Sub-Cooling Measure the temperature of the liquid line as it leaves the condenser. Read the gauge pressure at the liquid line clos

72 temperature range as shown in the table above (high superheat results in increased sub-cooling). Correct an overcharged system by reducing the am

73Table 14 - R-410A Refrigerant Temperature-Pressure Chart °F PSIG °F PSIG °F PSIG °F PSIG °F PSIG 20 78.3 47 134.7 74 213.7 101 321.0 128 463.2 21

74 Maintenance (See back of the manual for maintenance log.) One week after start-up: − Check operating pressures. − Adjust belt tension on all fa

75Table 15 - Bearing Setscrew Torque Recommendations Shaft Size (inches) Setscrew Locking Thread Torque (in-lbs.) 1 1/4 - 28 66 - 85 1 3/16 1/4 -

76 Indoor Coils Indoor cooling/evaporator coils must be cleaned regularly to maintain unit efficiency and operation. Dirty evaporator coils will eve

77 For routine quarterly cleaning, first clean the coil with the below approved coil cleaner. After cleaning the coils with the approved

78 Cleaning The need for cleaning of the wheel will be determined by the operating schedule, climate and regular contaminants of the conditioned spac

79 Electric Heating Set thermostat in the heat mode; call for heat to engage all electric heat strips. Check blower for proper rotation and voltage.

8 Electric shock hazard. Before servicing, shut off al

80 Replacement Parts Parts for AAON equipment may be obtained from AAON at www.aaonparts.com. When ordering parts, reference the unit serial number a

81Table 19 - M2-018 and M2-022 Filters Filter Type (Quantity) Size M2-018 M2-022 2” Pleated - 30% Eff, MERV 8 (8) 20” x 20” 4” Pleated - 30% Eff (MER

82 Appendix A - Heat Exchanger Corrosion Resistance Corrosion Resistance of Copper and Stainless Steel in Brazed Plate Heat Exchangers - Points to

83Water Containing Concentration (mg/l or ppm) Time Limits - Analyze Before AISI 316 SMO 254 Copper Alloy Nickel Alloy Total Hardness (°dH) 4.0-8.5

84 Refrigerant Piping Diagrams Figure 32 - Standard Split System Piping

85 Figure 33 - Modulating Hot Gas Reheat with Hot Gas Bypass Split System Piping Note: When installing hog gas bypass risers, an oil drip line must

86 Figure 34 - Hot Gas Bypass Split System Piping Note: When installing hog gas bypass risers, an oil drip line must be provided at the lowest poi

87 Figure 35 - Modulating Hot Gas Reheat Split System Piping

88 Figure 36 - Heat Pump Split System Piping

89 Figure 37 - Heat Pump with Factory Installed Modulating Hot Gas Reheat Split System Piping Note: When installing hog gas bypass risers, an oil

9 Electric motor over-current protection and overload

90 Figure 38 - Heat Pump with Field Installed Modulating Hot Gas Reheat Split System Piping Note: When installing hog gas bypass risers, an oil dr

91M2 Series Startup Form Job Name:_______________________________________________ Date:______________ Address:_________________________________

92 Supply Fan Assembly Alignment Check Rotation Nameplate Amps________ Number hp L1 L2 L3 1 2 Band Size_____________________ VAV

93Outside Air/Economizer Dampers OA Operation Check Damper Wiring Check Gears Check RA Operation Check Damper Wiring Check Gears Che

94 Refrigeration System 2 - Cooling Mode Pressure Saturated Temperature Line Temperature Sub-cooling Superheat Discharge N/A N/A Suction

95Refrigeration System 4 - Heating Mode (Heat Pump Only) Pressure Saturated Temperature Line Temperature Sub-cooling Superheat Discharge N/

96 Electric Heating Stages__________ Limit Lockout Aux. Limit Lockout Stage Amps Stage Amps 1 5 2 6 3 7 4 8

97Maintenance Log This log must be kept with the unit. It is the responsibility of the owner and/or maintenance/service contractor to document any s

98 Literature Change History March 2010 Update of IOM adding gas heater, self contained unit and packaged rooftop unit information. July 2010 Upda