Celebrity1 Modular Air Handlers Installation and Operation Manual October 2004 AAON ® Think Ahead.
Since the inception of AAON® in 1988, we have maintained our commitment to design, develop, manufacture, and deliver heating and cooling products to perform beyond all expectations and to demonstrate their daily value to our customers. AAON utilizes extensive product knowledge and state of the art manufacturing to continuously provide practical HVAC products to the dynamic marketplace. Our objective remains the same: Meet the customer specific requirement at a reasonable first cost.
Owner should pay particular attention to the words: NOTE, CAUTION, and WARNING. NOTES are intended to clarify or make the installation easier. CAUTIONS are given to prevent equipment damage. WARNINGS are given to alert owner that personal injury and/or equipment damage may result if installation procedure is not handled properly. Celebrity1 Modular Air Handler Installation and Operation Manual October 2004 1. Description ……………………….. 4 6. Important Safety Information Unit Data Unit Orientation 2.
1. Description WARNING RISK OF ELECTRICAL SHOCK - Important Safety Information Before attempting to perform any service or maintenance, turn the electrical power to the unit OFF at disconnect switch(es). Unit may have multiple power supplies. ONLY QUALIFIED PERSONNEL SHOULD PERFORM INSTALLATION, OPERATION, AND MAINTENANCE OF EQUIPMENT DESCRIBED IN THIS MANUAL.
Unit Data Table 1.1, Unit Data Features CFM RANGE COOLING COIL SELECTION DX Single Circuit 4 Row 6 Row 8 Row DX Cooling DX Double Circuit 4 Row 6 Row 8 Row 4 Row Chilled Water 6 Row Cooling 8 Row 1 Row *Hot Water 2 Row Heating 2 Row Hot Gas Reheat Model Cabinet Size 11 05 08 1,000 to 2,700 2,000 to 4,400 3,100 to 6,000 14 18 5,000 to 7,700 6,000 to 10,300 Face Area Sq. Ft. 4.7 4.7 4.7 7.7 7.7 7.7 10.5 10.5 10.5 13.5 13.5 13.5 18.0 18.0 18.0 4.7 4.7 4.7 4.7 4.7 4.7 4.7 4.7 4.7 5.3 / 21.
Unit Orientation Figure 1.1, Unit Orientation Supply Air When determining unit orientation (or Supply Air Flow as it is identified in the base model number below), consider the air to be “hitting you in the back of the head” when you are facing the return air end of the unit. A I R F L O W Left Hand Side If you have a “Left Hand” unit, then all connections will be on the left hand side of the unit. Air will flow from right to left as you look at the left side.
Base Model Number MAIN FEATURES M1 TYPE SIZE SUPPLY AIR FLOW - - VOLTAGE - ASSEMBLY - WIRING - TYPE H= V= Horizontal Vertical SIZE 005 = 008 = 011 = 014 = 018 = 5 8 11 14 18 SUPPLY AIR FLOW L= R= Left Hand Right Hand VOLTAGE 1= 2= 3= 4= 8= 9= 230V/1Ø/60HZ 230V/3Ø/60HZ 460V/3Ø/60HZ 575V/3Ø/60HZ 208V/3Ø/60HZ 208V/1Ø/60HZ ASSEMBLY A = Factory Assembled B = Loose Boxes WIRING 0= A= B= C= D= E= No Factory Wiring Control Panel in Fan Box Control Panel in Control Box Loose Control Panel Contro
Individual Module Numbers HEAT MODULE MODULE ID POSITION FUNCTION - - MODULE ID PHA = PHB = RHC = PHC = PHD = E-Heat Heat HGRH Heat / Filter E-Heat / Filter FILTERS Heating Dehumidification Heating & Dehum. - FILTERS 00 = A0 = B0 = C0 = D0 = E0 = FILTER OPTIONS ELECTRIC HEAT - - FUNCTION H= D= B= HEATING COIL 0 0 - TYPE - FILTER OPTIONS 0= A= B= C= None 2” 30% Std. 4” 30% Std. 4” 65% Std. 4” 85% Std. 4” 95% Std.
COIL MODULE MODULE ID POSITION - MODULE ID CLB = CLC = CLD = CLE = CLF = CLG = CLH = CLI = CLJ = CLK = CLL = COOLING TYPE - ELECTRIC HEAT HEATING COIL - COOLING TYPE - 0 0 COATING 0= P= S= H= Standard Phenolic Coating Stainless Steel Casing Stainless Steel Casing & Copper Fin CIRCUITING ELECTRIC HEAT F= H= S= I= HEATING COIL Single Serpentine Half Serpentine DX Single Circuit DX Interlaced (Dual) STAGES 01 = 02 = 03 = 04 = 1 Stage 2 Stage 3 Stage 4 Stage FPI COATING 0= P= S= H= KW A= B= C
FILTER MODULE MODULE ID POSITION FILTER TYPE - - MODULE ID FTA = FTF = FTC = FTD = FILTERS - - FILTER TYPE P= C= B= Flat Filter, Small Flat Filter, Large Cartridge Filter Bag Filter 0 0 0 CARTRIDGE C0 = D0 = E0 = - 0 0 0 0 0 0= A= B= C= B0 = C0 = D0 = E0 = TYPE None Magnehelic Gauge Clogged Filter Switch Magnehelic Gauge & Clogged Filter Switch TYPE BAG 65% Eff. 85% Eff. 95% Eff.
FAN MODULE MODULE ID MOTOR SIZE POSITION - - - 0 0 - X X 0 BLOWER Power Exhaust Return Fan Supply Fan Supply Fan, Vertical Supply Fan, Top Discharge Exhaust Fan, Top Discharge 0= A= B= C= D= 0 0 SAFETY CONTROL 0= A= None 15” 18.5” 22.5” 27” 0= A= B= MOTOR TYPE 0 0 X X None 1 HP 2 HP 3 HP 5 HP 7.
AAONAIRE HEAT RECOVERY WHEEL MODULE MODULE ID POSITION - WHEEL SIZE - 0 0 BLANK - 0 0 0 BLANK 0 0 - 0 0 0 BLANK 0 AAONAIRE Heat Wheel A= B= 0 - 0 TYPE - TYPE WHEEL SIZE* MODULE ID HRA = - BLANK 0= X= Standard Optional None Special (SPA Req’d.) *Optional wheel size (selection ‘B’) available only in size 5, 8, and 11 units.
3. Delivery ALL SHIPMENTS ARE F.O.B. THE FACTORY. IT IS THE RESPONSIBILITY OF THE RECEIVING PARTY TO INSPECT THE EQUIPMENT UPON ARRIVAL. Receipt & Inspection The air handler should be inspected for damage that may have occurred in transit. Do the following upon receipt: 1. Inspect all items for internal, external, and concealed damage before accepting 2. Assure carrier is in compliance with Bill of Lading instructions If damage is found: 1.
Handling 4. Installation Be aware of what is contained in the equipment! General Dependent upon the optional accessories that were ordered, this equipment may contain fragile components and delicate electronics. Although the unit is constructed of sturdy materials, avoid impacts and handling methods that may damage internal apparatus and structure, or the exterior surfaces of the unit.
Coil & AAONAIRE Heat Wheel Modules Mounting & Suspension Coils and heat wheels slide out for easier servicing. There should be enough clearance left on one side of the unit (usually the piping connection side) to completely remove the coils and heat wheel for maintenance or replacement. CelebrityTM air handlers can be designed for horizontal or vertical airflow applications, and can be floor mounted or suspended.
Modules present may include any or all of the following depending on the equipment ordered and the application: Figure 4.2, Suspended Modular Air Handler Suspension lines − Overhead Support Structure − − − − − − − − Fan Module – includes the plenum fan and blower motor Coil Module – contains heating and/or cooling and/or re-heat coils. May contain electric heat. AAONAIRE Heat Wheel Module – module has heat wheel installed. Air Mixing Module – module where outside air combines with return air.
Figure 4.3, Module Configuration Schematic Base model number. CONFIGURATION: M1-H-011-R-2-A-A-0-A-0 FTF-101-P-A0-00000-00000-0-0 HRA-102-A-00-00000-00000-0-0 CLF-103-C-00-210F0-610F0-S-0 SFA-104-K-C0-A0000-00000-0-0 PEC-201-K-B0-A0000-00000-0-0 FTD-203-B-B0-00000-00000-0-0 Configuration Schematic can be found in unit literature packet. Module configuration numbers. Arrows indicate airflow. Table provides required service access clearances for applicable modules.
module top, and should be used if present). Align modules, and insert bolts through the bolt holes of two adjacent modules, and secure with nuts to pull the two modules together tightly. Every bolt hole must be used to ensure a tight seal between modules, and a structurally stable assembly. Note that a heat wheel module will have a 100 series number identifying it, but will span both tiers also utilizing a 200 series space, and effectively “skipping” one of the top-tiered numbers.
− − − − − − − Air Handler Equipped with Electric Heating Piping from the condensing unit to the indoor air handler is the responsibility of the installing contractor. Only clean “ACR” tubing should be used. Piping should conform to generally accepted practices and codes. Care must be taken not to cross the circuits on multiple circuit systems. Once piped, the interconnecting piping and air handler MUST BE evacuated to 50 microns or less; leak checked and charged with refrigerant.
If the control wires are to run inside the same conduit, use 600-volt wire or as required by applicable codes. Acceptable system design and installation will include consideration as follows. The units must be electrically grounded in accordance with the National Electric Code, ANSI / UL 1995 when installed if an external source is utilized; in Canada use current C.S.A. Standard C22.2, No. 236, Canadian Electric Code Part 1. General Power wiring is to the unit terminal block.
the liquid lines, the overall efficiency is reduced, and the system may malfunction. 5.1, a double suction riser may be required in order to return oil at partial load. A pressure loss of 3 psi in the liquid line results in a 1°F loss of sub-cooling temperature with R-22. Figure 5.1, Double Suction Riser Example Table 5.1, R-22 Liquid Line Capacity w/ 3 PSI (1°F) Pressure Loss per 100 Feet at 100°F Liquid Evaporator Line Size (In.) 1/2 5/8 7/8 Max. Tons 4.0 7.6 19.
1. Avoid trapping oil at part-load operation, and 2. prevent condensed refrigerant and oil in the line from draining back to the head of the compressor, and 3. avoid developing excessive noise from either hot-gas pulsations, compressor vibrations, or both. Minimum Gas Velocities for Oil Transport in Risers On multiple compressor installations, the lowest possible system loading should be calculated with a riser size selected to give at least the minimum capacity for successful oil transport.
This float prevents excessive liquid buildup in the trap, and reduces the potential for “liquid hammer” when the compressor is restarted. Table 5.5, Fitting Losses in Equivalent Feet of Straight Copper Tubing Tubing Size (In.) 1/2 5/8 7/8 1 1/8 1 3/8 1 5/8 In order to prevent gas from active compressors from condensing on the heads of idle compressors in multiple compressor arrangements, each discharge line should have a check valve.
access panels. Air handlers should not be operated without proper ductwork and access panels installed, except as required during start-up and air balancing. 6. Start-Up General 1. Check all electrical connections to be sure they are tight. 2. Open all access panels, and remove all shipping screws, or restraints. 3. Clean out any debris that may have been left. 4. Check belt alignment, and tightness of fan drives. 5. Check bearing locking collars, and fan wheel set screws for tightness. 6.
2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 6. Install filter of the proper size and type. 7. Ensure that drain P-trap is installed. 8. Check all terminal blocks, fuses, fuse blocks, and contactors for correctness. 9. Check all high, and low voltage wiring connections for tightness. Check unit for correct incoming voltage per the data plate. 10. Check the security of the locking system on all blower bearings 11. Turn the unit power on. 12.
Commissioning 7. Operation & Maintenance The commissioning of an air conditioning system is the process of achieving, verifying, and documenting the performance of that system to meet the operational needs of the building. This may not be a formal process in smaller structures, such as a normal residence, but some form of owner acceptance will occur. Adjustments made during the commissioning phase may include air, or water balancing, or configuration of controls, and operational sequences.
− − − Belts Clean the drain line, “P” trap, and condensate pan. Check refrigerant pressures, and temperatures every Spring, and correct unusual operation. Check heating section every Fall. Check all electrical connections for tightness, and check heater elements for indications of overheating. Determine cause and replace elements if necessary. Belt drive misalignment is one of the most common causes of premature belt failure.
Figure 7.3, Belt Deflection Refrigeration Cycle Satisfactory performance of the refrigeration cycle can be determined by measuring suction line superheat. In order to determine if refrigerant flowing from the evaporator is dry, ensure that the system has enough refrigerant to produce liquid line subcooling, but not so much to cause abnormally high condensing temperatures (and pressures).
5. If the discharge superheat measured does not agree with the values in Table 7.2, then adjust the charge (see heading “Charging” in this section). you must have a refrigerant scale in order to charge during cold weather, and if you are complying with all of the U.S. Environmental Protection Agency’s laws governing the use of refrigerants, then you will have a refrigerant scale available to use. If the superheat is 5°F higher than shown, then the system is undercharged.
capacity of only .25 ounces. Added grease should be limited to .09 ounces. Heating Electric DO NOT OVER LUBRICATE! Set thermostat in the heat mode; call for heat to engage all electric heat strips. Check blower for proper rotation and voltage. Measure the amperage and voltage. Compare them to the nameplate data. If applicable, check remote heat pump condenser as per the manufacturer’s recommendations. Recommended greases are: − − − Steam or Hot Water Set thermostat in the heat mode.
8. Hot Gas Bypass Figure 8.1, Components of Hot Gas Bypass The purpose of (external) hot gas bypass (HGBP) is to prevent coil freeze-up and compressor damage from liquid slugging during periods of low airflow operation, or with low entering air temperatures. HGBP is useful when the air conditioning system is subject to variations in load caused by varying air volume or large proportions of outside air.
9. Hot Gas Reheat Figure 8.3, HGBP Connection to Evaporator & ASC Fitting Air Handling Unit Although the evaporator reduces moisture content from warm, moist air being conditioned, the space thermostat is a dry bulb device and will not call for refrigeration if outdoor and space temperatures are mild but very humid and the space temperature is satisfied. However, the humidity level may cause the space to be uncomfortable. A reheat system is used to correct this condition.
The only additional work required is to run the valve control wires to the outdoor unit. The factory setting can be overridden by connection to a 0 to 10 VDC signal from another control system. After the room temperature thermostat is satisfied and the humidistat continues to call for moisture removal, the modulating valve will allow a controlled amount of hot gas to enter the reheat coil. A discharge air temperature sensor mounted within the air handling unit provides input to an electronic control board.
Figure 10.2, HGRH with External HGBP Piping 2nd Stage Condenser Coil 2nd Stage Comp. 1st Stage Comp. 1st Stage Condenser Coil HGBP line connects to ASC fitting between TXV and distributor 1st Stage Evaporator Coil TXV TXV Reheat Coil HGRH Valve Check Valve Filter Drier HGBP Valves Filter Drier 2nd Stage Evaporator Coil Isolation Valves Factory Piping Field Piping HGBP Lines 11.
Figure 11.1, AAONAIRE® “Total Energy” Heat Wheel Motor Side “Pulley Side” View Pulley Side Rim Diameter Seal Outdoor Air Fresh Air Supply Rotation Bearing Access Cover Exhaust Air Indoor Air Capacitor P.C.S.
12. Troubleshooting Common Problems Table 12.
No Cooling – Compressor Will Not Run Control Panel Not Set for Cooling Thermostat Not Calling for Cooling Low Pressure Switch Open No Power to Contactor Power to Unit Check Unit Fuses and Windings No Power Unit Check Circuit Breaker at Power Distribution Panel High Pressure Switch Open Compressor Low Ambient Lockout Open (Temperature Outside Below 55°F) Transformer Open Broken or Loose Control No 24 Volt Power to Holding Coil Contactor Open Holding Coil Burned Out 24 Volt Power to Holding Coil Re
13. Factory Start-Up Form The factory start-up form is provided for the convenience of the installing contractor, and is not required for return to the factory for any reason. However, it is advisable to complete a start-up form to file with the unit records. The form on the back of this page may be completed and sent to the factory for archiving.
14.
Table Index: 1.1 4.1 5.1 5.2 5.3 5.4 5.5 7.1 7.2 7.3 7.4 12.1 Unit Data Module Code Chart R-22 Liquid Line Capacity Min. Capacity to Carry Oil Up Suc. Riser R-22 Suction Line Capacity R-22 Hot Gas Bypass Line Capacity Fitting Losses Bearing Setscrew Torque Discharge Superheat Temp Weight of R-22 Bearing Lubrication Schedule Troubleshooting Pressure – Temperature Chart (Inside Back Cover) Figure Index: 1.1 1.2 4.1 4.2 4.3 4.4 5.1 5.2 7.1 7.2 7.3 8.1 8.2 8.3 8.4 9.1 10.1 10.2 11.
Pressure – Temperature Chart, R-410A & R-22 PSIG PSIG PSIG PSIG PSIG PSIG PSIG (°F) R-410A R-22 (°F) R-410A R-22 (°F) R-410A R-22 (°F) R-410A R-22 (°F) R-410A R-22 (°F) R-410A R-22 (°F) R-410A R-22 -40 10.8 0.6 -10 36.4 16.5 20 78.3 43.1 50 142.2 84.1 80 234.9 143.6 110 364.1 226.4 140 540.1 337.4 -39 11.5 1.0 -9 37.5 17.2 21 80.0 44.2 51 144.8 85.7 81 238.6 146.0 111 369.1 229.6 141 547.0 341.6 -38 12.1 1.4 -8 38.6 17.9 22 81.
AAON offers the Celebrity 1 modular air handler to accommodate new and remodeled applications. Whether the need be heating, cooling, dehumidification, filtering, or ventilation, the Celebrity 1 product line assures the flexibility to meet your customer’s requirements. AAON Coil Products, Inc. 203 Gum Springs Road Longview, Texas 75602 Tel 903-236-4403 Fax 903-236-4463 www.aaon.com It is the intent of AAON to provide accurate and current specification information.
