CC SERIES Condensers & Condensing Units Installation, Operation & Maintenance WARNING WARNING QUALIFIED INSTALLER FOR YOUR SAFETY 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. Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.
Table of Contents Safety .............................................................................................................................................. 5 General Description ...................................................................................................................... 10 Receiving Unit .............................................................................................................................. 10 Storage ...............................................
Index of Tables and Figures Tables: Table 1 - CC Series Clearances .................................................................................................... 12 Table 2- Recommended Elevation Minimums ............................................................................. 13 Table 3 - Predetermined Line Sizes for R-410A CC Condensing Units ...................................... 22 Table 4 - Sub-cooling and Superheat ............................................................................
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.
WARNING 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 Do not work in a closed area where refrigerant or nitrogen gases may be leaking. A sufficient quantity of vapors may be present and cause injury or death. CAUTION 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 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.
CC Series Feature String Nomenclature 7 6 5 4 2 3 CIRCUITS COMP TYPE VOLTAGE UNIT SIZE MJREV GEN 1 : Unit Feature Options Model Option CC - C - 010 - 3 - D - 2 : B D 0 0 0 A 0 BASE MODEL OPTIONS Series and Generation CC Revision C = Design Sequence Unit Size 002 = 2 Ton Capacity - Horizontal Discharge 003 = 3 Ton Capacity - Horizontal Discharge 004 = 4 Ton Capacity - Horizontal Discharge 005 = 5 Ton Capacity - Horizontal Discharge 006 = 6 Ton Capacity 007 = 7 Ton Capacity 008 = 8 Ton Capacity
CC Series Feature String Nomenclature 7 6 5 4 2 3 CIRCUITS COMP TYPE VOLTAGE UNIT SIZE MJREV GEN 1 : Unit Feature Options Model Option CC - C - 010 - 3 - D - 2 : B D 0 0 0 A 0 Feature 4: Coil Protection 0 = Standard, A = Polymer E-Coated Coil Feature 5: Cabinet Options 0 = Standard B = Compressor Sound Blanket D = Exterior Corrosion Protection E = Options B + D R = California OSHPD Certified S = Shake Table Cert.
General Description AAON CC Series air-cooled condensers and condensing units have been designed for outdoor installation only. Startup and service must be performed by a Factory Trained Service Technician. WARNING Coils and sheet metal surfaces present sharp edges and care must be taken when working with equipment. WARNING Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life.
Direct Expansion (DX) Condensing Units Condensing units are factory assembled and wired, including a holding charge of refrigerant. Refrigeration systems include factory provided liquid line filter driers and fully hermetic scroll compressors with a positive pressure forced lubrication system. CAUTION CRANKCASE HEATER OPERATION Units are equipped with compressor crankcase heaters, which should be energized at least 24 hours prior to cooling operation, to clear any liquid refrigerant from the compressors.
Installation AAON equipment has been designed for quick and easy installation. Locating Unit CC Series units are designed for outdoor application and placement at ground level or on a rooftop. Units must be placed on a level and solid foundation that can support the unit’s weight. Figure 1 - Vertical Air Discharge CC Series Orientation When rooftop mounted, a steel frame must be provided that will support the unit above the roof itself for load distribution.
2-5 ton units are horizontal discharge and must have no obstruction on the discharge side of the unit. Unit should not be installed in an enclosure or pit. Placement relative to the building or other structures must be carefully selected. Consider the effects of outdoor fan noise on any adjacent occupied space. It is recommended that the unit be placed so that air does not discharge toward windows on intakes less than 25 feet away.
Route power and control wiring through the utility entries on the sides of the unit. It is recommended not to run power and control signal wires in the same conduit. If the control wires are run inside the same conduit as the power wiring use 600 volt wire, or as required by applicable codes. Size supply conductors based on the unit MCA rating. Supply conductors must be rated a minimum of 75°C. Protect the branch circuit in accordance with code requirements.
CAUTION Scroll compressors are directional and will be damaged by operation in the wrong direction. High pressure switches on compressors have been disconnected after factory testing. Rotation should be checked by a qualified service technician at startup using suction and discharge pressure gauges and any wiring alteration should only be made at the unit power connection.
Determining Refrigerant Line Size CAUTION Line sizes must be selected to meet actual installation conditions, not simply based on the connection sizes at the condensing unit or air handling unit. The piping between the condenser and low side must ensure: 1. Minimum pressure drop, and 2. Continuous oil return, and 3.
Liquid Line Routing Care should be taken with vertical risers. When the system is shut down, gravity will pull liquid down the vertical column, and back to the condenser when it is below the evaporator. This could potentially result in compressor flooding. A check valve can be installed in the liquid line where the liquid column rises above the condenser to prevent this. The liquid line is typically pitched along with the suction line, or hot gas line, to minimize the complexity of the configuration.
A double suction riser can be applied to the situation of part load operation with a suction riser. A double suction riser is designed to return oil at minimum load while not incurring excessive frictional losses at full load. A double suction riser consists of a small diameter riser in parallel with a larger diameter riser, and a trap at the base of the large riser.
When installing hot gas bypass risers, an oil drip line must be provided at the lowest point in the system. The oil drip line must be vertical, its diameter should be the same as the diameter of the riser, and it should be 1 foot long. Install a sight glass in the oil drip line for observation. Run an oil return line, using 1/8 inch capillary tube, 10 feet in length, from the oil drip line to the suction line.
The liquid lines have been chosen to maintain velocities between 100 and 350 fpm. The suction line diameters are selected to limit velocities to a 4,000 fpm maximum, while a minimum velocity restriction is imposed by the ability to entrain oil up vertical suction risers (ASHRAE Handbook - Refrigeration). Acceptable pressure loss criteria are applied to each of the lines: The total equivalent length of the liquid line available is determined such that 3°F of liquid subcooling remain at the TXV.
Note: CC-006, CC-007, CC-008, and CC010 HGB line sizes are based on four stage cooling operation condensing units, with two step compressors. CC-031, CC-034, CC-040, CC-045, CC-050, CC-055, and CC-063 HGB line sizes are based on four stage cooling operation condensing units, with tandem compressors. With HGB, four stage cooling is recommended on these sizes of units. Two stage cooling operation condensing units in these sizes with HGB may need larger HGB line sizes.
Table 3 - Predetermined Line Sizes for R-410A CC Condensing Units Connection Size Suction HGB* Model Circuit CC-002 1 3/8'' 3/4'' CC-003 1 3/8'' CC-004 1 CC-005 Predetermined Line Size Suction HGB* HGR** HGR** Liquid 3/8'' 1/2'' 3/8'' 3/4'' 3/8'' 1/2'' 3/4'' 1/2'' 1/2'' 3/8'' 3/4'' 1/2'' 1/2'' 1/2'' 7/8'' 1/2'' 5/8'' 1/2'' 7/8'' 1/2'' 5/8” 1 1/2'' 7/8'' 1/2'' 5/8'' 1/2'' 7/8'' 1/2'' 5/8'' CC-006 2 3/8'' 7/8'' 3/8'' 1/2'' 3/8'' 7/8'' 3/8'' 1/2'' CC-007
Startup (See back of the manual for startup form.) WARNING 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. WARNING Electric shock hazard. Shut off all electrical power to the unit to avoid shock hazard or injury from rotating parts.
Units equipped with hot gas reheat must be charged with the hot gas valves closed while the unit is in cooling mode. After charging, unit should be operated in reheat (dehumidification) mode to check for correct operation. Checking Evaporator Superheat Measure the temperature of the suction line close to the compressor. After adding or removing charge the system must be allowed to stabilize, typically 10-15 minutes, before making any other adjustments.
CAUTION If the sub-cooling is correct and the superheat is too high, the TXV may need adjustment to correct the superheat. DO NOT OVERCHARGE! Refrigerant overcharging leads to excess refrigerant in the condenser coils resulting in elevated compressor discharge pressure. The system is undercharged if the superheat is too high and the sub-cooling is too low. Correct an undercharged system by adding refrigerant to the system to reduce superheat and raise sub-cooling.
°F 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 26 PSIG 78.3 80.0 81.8 83.6 85.4 87.2 89.1 91.0 92.9 94.9 96.8 98.8 100.9 102.9 105.0 107.1 109.2 111.4 113.6 115.8 118.1 120.3 122.7 125.0 127.4 129.8 132.2 Table 5 - R-410A Refrigerant Temperature-Pressure Chart PSIG PSIG PSIG °F °F °F 134.7 213.7 321.0 47 74 101 137.2 217.1 325.6 48 75 102 139.7 220.6 330.2 49 76 103 142.2 224.1 334.9 50 77 104 144.8 227.7 339.6 51 78 105 147.4 231.3 344.4 52 79 106 150.1 234.9 349.
Operation Unit operations should be controlled with thermostat, or unit controller, never at the main power supply, except for emergency, servicing, or complete shutdown of the unit. Thermostat Operation Heating Thermostat system switch - "Heat" Thermostat fan switch - "Auto" or "On" Thermostat temperature set to desired point. Cooling Thermostat system switch - "Cool" Thermostat fan switch - "Auto" or "On" Thermostat temperature set to desired point.
High Voltage Terminals A1 & A2 Alarm Relay Out M1 & M2 Contactor L1 Control Voltage N L2 Control Voltage L U1 & U2 Digital Unloader Solenoid V1 & V2 Vapor Injection Solenoid WARNING Figure 4 - Variable Capacity Compressor Controller Low Voltage Terminals 24COM Module Common 24VAC Module Power C1 & C2 Demand Input P1 Pressure Common P2 Pressure Input P3 Pressure Power 5VDC P4 Pressure Shield P5 & P6 Pressure Output T1 & T2 Discharge Temperature Sensor To avoid damaging the compressor controller, DO NOT con
Figure 5 - Compressor Controller Flash Code Details °C -40 -35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 Table 7 - Thermistor Temperature vs. Resistance Values °F kΩ °C °F -40 2889.60 75 167 -31 2087.22 80 176 -22 1522.20 85 185 -13 1121.44 90 194 -4 834.72 95 203 5 627.28 100 212 14 475.74 105 221 23 363.99 110 230 32 280.82 115 239 41 218.41 120 248 50 171.17 125 257 59 135.14 130 266 68 107.44 135 275 77 86.00 140 284 86 69.28 145 293 95 56.16 150 302 104 45.81 155 311 113 37.
Low Ambient Options Adjustable fan cycling is a low ambient head pressure control option that cycles the condenser fans to maintain refrigerant circuit head pressures at acceptable levels during cooling operation. The head pressure set point (100-470 psi) and pressure differential (35-200 psi) are field adjustable.
cleaner. If a vacuum cleaner is not available, a soft non-metallic bristle brush may be used. In either case, the tool should be applied in the direction of the fins. Coil surfaces can be easily damaged (fin edges bent over) if the tool is applied across the fins. Use of a water stream, such as a garden hose, against a surface loaded coil will drive the fibers and dirt into the coil. This will make cleaning efforts more difficult.
use of this product, the product must be able to come in contact with the salts. These salts may be beneath any soils, grease or dirt; therefore, these barriers must be removed prior to application of this product. As in all surface preparation, the best work yields the best results. Apply CHLOR*RID DTS - Apply directly onto the substrate. Sufficient product must be applied uniformly across the substrate to thoroughly wet out surface, with no areas missed.
Refrigerant Piping Diagrams Figure 6 - A/C Only Piping, AHU Above CU 33
Figure 7 - A/C Only Piping, AHU Below CU 34
Figure 8 - Modulating Hot Gas Reheat Piping, AHU Above CU 35
Figure 9 - Modulating Hot Gas Reheat Piping, AHU Below CU 36
Figure 10 - Hot Gas Bypass Piping, AHU Above CU 37
Figure 11 - Hot Gas Bypass Piping, AHU Below CU 38
Figure 12 - Modulating Hot Gas Reheat with Hot Gas Bypass Piping, AHU Above CU 39
Figure 13 - Modulating Hot Gas Reheat with Hot Gas Bypass Piping, AHU Below CU 40
Figure 14 - Heat Pump Piping, AHU Above CU 41
Figure 15 - Heat Pump Piping, AHU Below CU 42
Figure 16 - Heat Pump with Modulating Hot Gas Reheat Piping, AHU Above CU 43
Figure 17 - Heat Pump with Modulating Hot Gas Reheat, AHU Below CU 44
CC Series Startup Form Date:______________ Job Name:_____________________________________________________________________ Address:______________________________________________________________________ Model Number:_________________________________________________________________ ______________________________________________________________________________ Serial Number:_____________________________________________ Tag:_______________ Startup Contractor:______________________________________________________
Refrigeration System 1 - Cooling Mode Saturated Pressure Temperature Discharge Suction Liquid Refrigeration System 2 - Cooling Mode Saturated Pressure Temperature Discharge Suction Liquid Refrigeration System 3 - Cooling Mode Saturated Pressure Temperature Discharge Suction Liquid Refrigeration System 4 - Cooling Mode Saturated Pressure Temperature Discharge Suction Liquid 46 Line Temperature Sub-cooling Superheat N/A N/A N/A N/A Line Temperature Sub-cooling Superheat N/A N/A N/A N/A Line Temper
Refrigeration System 1 - Heating Mode (Heat Pump Only) Saturated Line Pressure Temperature Temperature Discharge Suction Liquid Refrigeration System 2 - Heating Mode (Heat Pump Only) Saturated Line Pressure Temperature Temperature Discharge Suction Liquid Refrigeration System 3 - Heating Mode (Heat Pump Only) Saturated Line Pressure Temperature Temperature Discharge Suction Liquid Refrigeration System 4 - Heating Mode (Heat Pump Only) Saturated Line Pressure Temperature Temperature Discharge Suction Liquid
Maintenance Log This log must be kept with the unit. It is the responsibility of the owner and/or maintenance/service contractor to document any service, repair or adjustments. AAON Service and Warranty Departments are available to advise and provide phone help for proper operation and replacement parts. The responsibility for proper start-up, maintenance and servicing of the equipment falls to the owner and qualified licensed technician. Entry Date 48 Action Taken Name/Tel.
Literature Change History March 2009 Update of IOM revising the model numbers, manual format, and piping diagrams to show factory installed liquid line receiver tank. November 2009 Update of IOM adding variable capacity scroll compressor information September 2010 Update of IOM to include water cooled condenser options and updated model and feature options. Text size in piping diagrams was increased for readability. March 2012 Update of piping diagrams P1, P3, P4, and P6 and addition of piping diagram P7.
AAON 203 Gum Springs Rd. Longview, TX 75602-1721 Phone: 903-236-4403 Fax: 903-236-4463 www.aaon.com CC Series Installation, Operation & Maintenance R59081 · Rev. A · 140305 (ACP J00186) It is the intent of AAON, Inc. to provide accurate and current specification information. However, in the interest of product improvement, AAON, Inc. reserves the right to change pricing, specifications, and/or design of its products without notice, obligation or liability Copyright © AAON, Inc.
