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AAON WH Series User Manual

AAON WH Series
60 pages
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WH Series
Horizontal Water-Source Heat Pump Unit
Installation, Operation
& Maintenance
If the information in this manual is not
followed exactly, a fire 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. Startup
and service must be performed by a
Factory Trained Service Technician.
Keep a copy of this IOM with the unit.
WARNING

Table of Contents

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AAON WH Series Specifications

General IconGeneral
CategoryHeat Pump
RefrigerantR-410A
SeriesWH Series
Voltage208/230V, 460V, 575V
Unit WeightVaries with model
DimensionsVaries with model

Summary

AAON WH Series Features and Options Introduction

Energy Efficiency Features

Details key efficiency features of the WH Series units.

Indoor Air Quality Features

Highlights features contributing to improved indoor air quality.

Humidity Control Features

Describes humidity control capabilities.

Control Features

Lists control features and options.

System Integration and Environmental Aspects

Covers system integration, environmental friendliness, and extended life.

Reduced Sound Features

Explains features for reduced sound operation.

General Safety Guidelines

Caution and Warning Statement Definitions

Clarifies definitions of CAUTION and WARNING statements.

Motor and Fan Rotation Safety

Ensures proper motor and compressor rotation checks.

Chemical Coil Cleaner Safety

Warns against using certain chemical coil cleaners.

Heat Exchanger Chemical Damage Safety

Warns about chemicals damaging the heat exchanger.

Unit Handling and Electrical Safety

PVC Pipe Compatibility Warning

Warns about PVC pipe vulnerability to specific chemicals.

Unit Handling and Lifting Safety

Provides guidelines for safe unit lifting and testing.

Electrical Shock and Fire Hazard Warning

Highlights electrical dangers and service precautions.

System Safety Requirements

Grounding Requirements

Emphasizes mandatory unit grounding.

Rotating Components Hazard

Warns about injury risks from moving fan parts.

Water Freezing Hazard

Details risks of heat exchanger damage from water freezing.

Water Pressure Safety

Advises on water pressure verification and safety measures.

Essential Startup and Service Safety

Manual Reading and Qualified Service

Recommends reading manual, qualified service, and nameplate reference.

WSHP Series Feature String Nomenclature

Model Options and Unit Sizing

Details model options including generation, orientation, unit size, series, and voltage.

Configuration Codes

Defines codes for efficiency, compressor, loop type, coil, and heat type.

Unit Orientation and Supply Fan

Describes unit orientation and supply fan options.

WSHP Series Feature String Nomenclature

Filter Rack and Filter Options

Details filter rack and filter type/size options.

Refrigeration, Dehumidification, and Service Disconnect Options

Specifies options for refrigeration, dehumidification, and service disconnects.

Control Sequence, Cabinet, and Economizer Options

Details control sequences, cabinet options, and waterside economizer.

Code, Shipping, and Cabinet Access Options

Lists code compliance, shipping, and cabinet access options.

General Unit Information

Unit Description and Certifications

Describes the unit and its cooling model certifications.

Codes and Ordinances Compliance

Details compliance with industry codes and standards.

Installation and Operational Cautions

Advises against construction heater use and warns about sharp edges.

Refrigerant Venting Regulations

Reminds about EPA regulations on refrigerant venting.

Receiving and Storing the Unit

Unit Inspection and Verification

Instructions for inspecting for damage and verifying nameplate information.

Storage Recommendations

Guidance for storing the unit before installation.

Repair and Warranty Procedures

Procedures for handling damaged goods and warranty claims.

Direct Expansion (DX) Systems Overview

DX System Components

Lists components included in DX systems.

Unit Control Guidelines

Provides guidance on controlling the unit.

Unit Installation Procedures

Blower Assembly and Shipping Block Check

Check blower assembly and remove shipping block.

Horizontal Unit Mounting

Details methods for mounting the horizontal WSHP unit.

Unit Location and Duct Connection

Placement and Utility Considerations

Guidance on unit placement relative to utilities and ductwork.

Ductwork Sizing and Installation

Instructions for connecting supply and return air ducts.

Mounting Surface and Vibration Isolation

Ensuring support and installing vibration grommets.

Condensate Drain Piping Installation

Emergency Drain Pan Recommendation

Recommends emergency drain pans for water damage prevention.

Floor Mounted Unit Mounting

Specific mounting instructions for floor-mounted units.

Drain Line and P-Trap Requirements

Details requirements for p-trap and drain line installation.

Condensate Drain Piping Details

Drain Trap Installation Specifications

Provides specific dimensions for drain trap installation.

Drain Seal Maintenance During Startup

Explains how to maintain the drain seal during startup.

Unit Clearances and Orientation

Minimum Clearances Table

Table detailing minimum clearance requirements for unit access and airflow.

Unit Orientation Illustrations

Illustrates different unit orientations for airflow and connections.

Blower Assembly Removal – Side Access

Shipping Screw and Panel Removal

Steps to remove shipping screw and side access panel.

Blower Panel and Mount Handling

Procedure for pulling, lifting, and adjusting the blower panel and mount.

Discharge Modification Procedures

Blower Assembly Removal and Rotation

Final steps to remove and rotate the blower assembly.

Field Discharge Direction Modification

Instructions for modifying the discharge direction.

Lifting and Handling the Unit

Shipping Material Removal for Lifting

Ensuring all shipping material is removed before lifting.

Unit Lifting with Pallet Jack

Guidance on lifting the unit with a pallet jack.

Blower Panel Reinstallation Note

Note on correct panel installation to avoid damage.

Horizontal Unit Bottom Access

Accessible Components via Bottom Panel

Lists components accessible through the bottom access panel.

Bottom Access Panel Removal and Reattachment

Steps for removing and reattaching the bottom access panel.

Blower Assembly Removal – Bottom Access

Shipping Screw and Bottom Panel Access

Steps to remove shipping screw and open bottom panel.

Motor Spade Connectors and Blower Handling

Disconnecting motor connectors and handling the blower assembly.

Blower Motor and Fan Access

Motor and Blower Assembly Separation

Procedure to separate motor from blower assembly.

Motor and Blower Removal Steps

Steps to pull the motor and blower assembly out.

Refrigerant-to-Water Heat Exchanger Piping

Open Loop Corrosion Warning

Notes on corrosion risks for open loop systems.

Heat Exchanger Water Piping Safety

Chemical Corrosion Warning

Warns about chemical corrosion in open loop systems and warranty exclusion.

Chlorides in Water Warning

Advises against allowing chlorides into the heat exchanger.

Harsh Chemical Caution

Warns about harsh chemicals damaging the heat exchanger.

Water Freezing Hazard in Heat Exchanger

Explains freezing risks and damage to the refrigerant circuit.

Water Piping and Freeze Protection

Water Freezing Prevention

Reiterates warnings about water freezing and damage.

Glycol Concentration for Freeze Protection

Provides guidance on glycol concentration for freeze protection.

Water Loop Insulation and Operating Limits

Recommends insulation and details operating limits.

Water Pressure Safety Requirements

Advises on water pressure limits and safety measures.

Water Piping Installation Requirements

PVC Pipe Compatibility and Material Approval

Warns about PVC pipe and specifies approved materials.

Water Connection Sizes

Table specifying water connection sizes for different models.

Contractor Installation Responsibilities

Outlines contractor duties for sizing, installation, and system flushing.

Water System Flushing and Mineral Content Management

Instructions for flushing, strainers, and managing mineral content.

Electrical Connection and Safety

Water Treatment and Piping Recommendations

Requirements for water treatment and piping configuration.

Fluid Velocity and Electrical Verification

Specifies fluid velocity and nameplate verification.

Electrical Entry and Wiring Diagram Location

Details entry points and location of wiring diagrams.

Electrical Shock Hazard Warning

Critical warning about disconnecting power before servicing.

Voltage Imbalance Effects on Motors

Explains voltage imbalance and its effects on motors.

Electrical Connection and Safety

Overcurrent Protection and Disconnect Switches

Guidance on MOP and disconnect switch requirements.

Electrical Entry Sealing and Conductor Sizing

Details entry points and instructions for sizing supply conductors.

Branch Circuit Protection and Voltage Imbalance Caution

Requirements for circuit protection and voltage imbalance.

Connecting to WH Series Disconnect

30 Amp Disconnect Terminal Block Release

Procedure to release the terminal block from the rotary switch.

Compressor Rotation Safety Caution

Caution regarding compressor rotation direction.

WH Series Disconnect Connection Procedures

30 Amp Disconnect Power and Terminal Reinstallation

Connecting power and reinstalling terminal block.

60 Amp Disconnect Procedures

Steps for removing faceplate, terminal block, connecting power, and reinstalling.

Thermostat Control Wiring

Thermostat Placement Guidelines

Recommendations for thermostat location.

Control Voltage and Wiring Distance

Specifies minimum control voltage and allowable wiring distances.

Wire Size Calculation Example

Example for determining wire size for control wiring.

External Device Power Supply

Requirement for external devices to use a separate power supply.

Filter Pull Setup and Operation

Filter Operation Without Filters Warning

Do not operate the unit without filters.

Filter Pull Access and Removal

Steps for accessing and removing the filter pull based on access type.

Filter Rack Clip Adjustment

Instructions for opening clips on 4-sided filter racks.

Duct Connection Procedures

Duct Attachment and Sealing

Instructions for attaching ducts and installer sealing responsibility.

Duct Transition Sizing and Standards

Use of transitions, sizing standards, and flexible connectors.

Waterside Economizer Operation

Economizer Coil and Circuit Modes

Details the optional economizer coil and operation modes.

Economizer Control Configuration

Controller settings for waterside economizer operation.

Water Treatment for Economizer

Reiterates water treatment compatibility for economizer systems.

Unit Startup Procedures

Operating Limits Table

Table of minimum and maximum operating limits for cooling and heating.

Startup Safety Warnings

Warnings about hazards during startup and electrical shock.

Essential Startup Checks

Lists critical checks for air flow, filters, and water flow.

Supply Fan and Air Flow Adjustment

Supply Fan Overview

Describes direct drive supply fans and air volume.

Fan Air Flow Adjustment Methods

Details motor speed tap adjustments for PSC and ECM motors.

Cabinet Specific Fan Adjustments

Describes adjustments for A cabinet units.

Fan Air Flow Adjustment and Motor Taps

High Fan Speed Connection

Connecting thermostat Y to Y2 for higher fan speed.

Motor Tap RPMs Table

Table showing motor tap speeds and corresponding RPMs.

Adjusting Refrigerant Charge

Charge Adjustment Precautions

Emphasizes charge criticality and necessity of adjustment.

Sub-Cooling and Superheat Measurement

Procedures to measure liquid line temperature/pressure and suction line.

Filter Installation Requirement

Do not operate the unit without filters.

Startup Observation Caution

Observe operation to verify component function.

Refrigerant Charge Adjustment Details

Sub-Cooling Calculation and Comparison

Calculating and comparing sub-cooling to acceptable values.

Superheat Calculation and Comparison

Calculating and comparing evaporator superheat.

Overcharge and Expansion Valve Warnings

Warnings against overcharging and caution on expansion valve adjustment.

Correcting System Charge Imbalances

Guidance on correcting overcharged and undercharged systems.

Unit Operation and Controller

Control Method and Thermostat Upgrade

Units controlled by thermostat; recommends electronic thermostat upgrade.

Pioneer Silver Controller Specifications

Lists electrical, environmental, mounting, and dimension specifications.

Controller Inputs and Outputs (H2)

Details terminal block H2 functions for alarms, common, shutdown, and compressor.

Pioneer Silver Controller Inputs and Wiring

Controller Inputs and Outputs (H5)

Details terminal block H5 functions for thermostat, override, and alarm.

Network and Shield Terminals (H1)

Details network terminal block H1 functions for communication.

Quick Disconnect Terminals and Wiring Harnesses

Describes quick disconnect terminals and sensor/output wiring harnesses.

Controller Status Indicators

Lists alarm status LED and relay status LEDs.

Sequences of Operation

Supply Fan Operation Logic

Details how the supply fan operates and is controlled.

Compressor Operation Logic

Describes conditions for compressor enabling and delays.

Alarms Affecting Fan Operation

Lists alarms that prevent fan operation.

Sequences of Operation and Alarms

Reversing Valve Operation Logic

Details conditions for reversing valve activation.

Random Start Delay and Occupancy Modes

Explains random start delay and occupancy modes.

Test Mode Operation

Procedure for enabling and operating in test mode.

LED Fault Code Diagnostics

Introduces LED fault codes for diagnostics.

Alarms and Diagnostic Codes

LED Diagnostic Code Table

Table correlating LED flashes to specific fault codes.

Automatic Reset Alarms

Describes alarms that reset automatically.

Control Voltage Alarms

Details low and high control voltage alarms.

Leaving Water Temperature Alarm

Explains the alarm for preventing heat exchanger freezing.

Alarms and Freeze Protection Settings

Glycol Percentage Setpoint Configuration

Explains dip switch settings for glycol percentage.

Air Coil and Water Temperature Alarms

Describes alarms for air coil temperature and waterside economizer freeze protection.

Emergency Shutdown and Lock Out Alarms

Details emergency shutdown and non-resetting alarms.

Auxiliary Input and Condensate Alarms

Describes auxiliary input and high condensate level alarms.

System Alarms and Faults

High Discharge Pressure Alarm

Explains the alarm for high discharge pressure.

Low Suction Pressure Alarm

Describes the alarm for low suction pressure.

AAON WSHP Pioneer Silver Expansion Board

Expansion Board Description and Compatibility

Details the board's purpose and compatibility notes.

Expansion Board Specifications

Lists electrical, environmental, and mounting specifications.

Expansion Board Inputs and Outputs (H4)

Details terminal block H4 functions for thermostat inputs.

Expansion Board Network Terminals (H1)

Details network terminal block H1 functions for communication.

Pioneer Silver Expansion Board Layout

Expansion Board Quick Disconnect Terminals

Lists functions of quick disconnect terminals (P1-P21).

Expansion Board Dip Switches and LEDs

Identifies dip switches and relay status LEDs.

Expansion Board Dip Switch Settings

Fan-Speed Dehumidification Settings

Explains dip switch settings for fan-speed dehumidification.

Waterside Economizer Enable and Setpoints

Details dip switch settings for enabling and configuring the economizer.

Expansion Board Relay Status LEDs

Lists relay status LEDs and their functions.

Additional Sequences of Operation

Supply Fan Operation with ECM Motors

Details supply fan operation with ECM motors and speed selection.

Compressor Operation Logic and Delays

Describes compressor operation with alarms and delays.

Auxiliary Heating and Dehumidification Modes

Explains auxiliary heating and fan speed dehumidification.

Unit Maintenance Procedures

Annual Service and Monthly Inspections

Recommends annual service and monthly inspections of components.

Maintenance Safety Warning

Warning about hazards during maintenance.

DX Cooling Checks

Cooling Mode Setup and Fan Checks

Setting controls to cooling mode and checking fans.

Component Operational Checks

Instructions for checking compressor, voltage, and reversing valve.

Condensate Drain Pan Maintenance

Drain Pan Cleaning Importance

Importance of periodic cleaning to prevent microbial growth and blockages.

Qualified Personnel for Cleaning

Cleaning must be done by qualified personnel.

Supply Fan Maintenance

Dust Buildup Caution

Warns about dust buildup on blower wheels causing vibration.

Electric Shock Hazard Warning

Warning about electrical shock hazard.

Fan Motor Lubrication

Supply fan motors are permanently lubricated.

Microchannel Coil Cleaning Procedures

Coil Cleaning Frequency and Technique

Coils require cleaning annually; improper technique can cause damage.

Recommended Chemicals and Procedures

Recommends specific chemicals and procedures warranted by AAON.

Chemical Warning and Water Pressure Limits

Warns about chemicals and specifies water pressure/distance for cleaning.

Simple Green Cleaning Procedure

Detailed steps for cleaning with Simple Green.

Microchannel Coil Cleaning and Filter Replacement

Simple Green Application and Water Flush

Spraying, soaking instructions for Simple Green and water flush procedure.

Pressurized Water Caution

Caution on water pressure and nozzle angle during cleaning.

Other Coil Cleaners and pH Requirement

Requires approval for cleaners; neutral pH (6-8) needed.

Foaming Cleaner Warning

Warns against foaming cleaners.

Filter Replacement Recommendation

Recommends monthly filter inspection and replacement.

Filter Replacement Electrical Hazard

Warning about electrical shock hazard during filter replacement.

Replacement Parts Information

Obtaining and Ordering Parts

Contacting representative and required information for ordering.

Warranty End Date and Contact Details

Finding warranty date and department contact information.

Filter Information Tables

Filters for A Cabinet Models

Details filters for A cabinet models.

Filters for B & C Cabinet Models

Details filters for B & C cabinet models.

Filter Information Tables

Filters for D Cabinet Models

Details filters for D cabinet models.

Filters for E Cabinet Models

Details filters for E cabinet models.

Filters for F Cabinet Models

Details filters for F cabinet models.

Filters for G Cabinet Models

Details filters for G cabinet models.

Appendix A - Heat Exchanger Corrosion Resistance

Corrosion Resistance Parameters for Copper Exchangers

Specifies chemical limits for copper heat exchangers.

Corrosion Resistance Parameters for Cupro-Nickel Exchangers

Specifies chemical limits for cupro-nickel heat exchangers.

Corrosion, Growth, and Erosion Factors

Outlines factors affecting heat exchanger longevity.

Application Notes for Heat Exchangers

Includes notes on harness, pool, and saltwater applications.

WH Series Startup Form

Pre Startup Installation Checklist

List of items for contractor to verify before startup.

Ambient Temperature Recording

Section to record ambient temperature readings.

WH Series Startup Form - Operational Checks

Supply Fan Assembly Checks

Checks for fan alignment, rotation, and amperage.

Compressor and DX Cooling Checks

Checks for compressor rotation, pressure, sub-cooling, and superheat.

Refrigeration System Mode Data

Fields for recording cooling and heating mode data.

Unit Configuration and Water Flow Data

Checks for water leaks and records water flow and temperature.

WH Series Startup Form - Water System and Maintenance

Water/Glycol System Verification Checks

Checks for system flushing, fluid fill, glycol, and insulation.

Maintenance Log Entry

Section to document service, repair, or adjustments.

Literature Change History

April 2017 Updates

Records changes made in April 2017.

May 2017 Updates

Records changes made in May 2017.

August 2017 Updates

Records changes made in August 2017.

January 2018 Updates

Records changes made in January 2018.

April 2018 Updates

Records changes made in April 2018.

July 2018 Updates

Records changes made in July 2018.

January 2019 Updates

Records changes made in January 2019.

April 2019 Updates

Records changes made in April 2019.

August 2019 Updates

Records changes made in August 2019.

April 2020 Updates

Records changes made in April 2020.

July 2020 Updates

Records changes made in July 2020.

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