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AAON WHA-060 User Manual

AAON WHA-060
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 WHA-060 Specifications

General IconGeneral
Model NumberWHA-060
CategoryHeat Pump
Cooling Capacity60, 000 BTU/h
Heating Capacity60, 000 BTU/h
Coefficient of Performance (COP)3.5
Refrigerant TypeR-410A
Sound Level68 dBA

Summary

AAON WH Series Features Overview

Energy Efficiency Features

Details features contributing to energy efficiency in the WH Series units.

Indoor Air Quality Features

Highlights features that enhance indoor air quality.

Humidity Control Features

Describes the unit's capabilities for humidity control.

System Integration and Environmental Features

Covers system integration aspects and environmentally friendly attributes.

Safety Guidelines and Warnings

General Safety Notes and Definitions

Clarifies notes and defines caution/warning statements.

Compressor and Fan Rotation Safety

Details safety checks required for motor and compressor rotation.

Chemical Coil Cleaner Safety

Warns against specific chemical cleaners and outlines safe usage.

Operational Safety Precautions

PVC/CPVC Piping Chemical Compatibility

Warns about chemical compatibility issues with PVC/CPVC piping.

Open Loop Applications Warranty Exclusion

Excludes corrosion damage in open loop systems from warranty coverage.

Unit Handling and Electrical Safety

Covers safe unit handling and electrical hazards during service.

System Specific Safety Requirements

Grounding and Rotating Components Safety

Ensures proper grounding and safe operation around moving parts.

Live Electrical Component and Water Freezing Safety

Safety measures for live electrical components and water freezing hazards.

Water Pressure Safety

Precautions related to water pressure and relief valves.

General Operating Instructions

Manual and Technician Requirements

Outlines the importance of reading the manual and using trained technicians.

Unit Nameplate Information

Emphasizes referring to the unit nameplate for specifications.

WSHP Series Feature String Nomenclature

Model Options and Unit Configuration

Explains the structure of the model number and unit configuration.

Unit Size and Series Codes

Details the codes for unit size and cabinet series.

Voltage and Efficiency Level Codes

Defines the codes for voltage and efficiency levels.

Compressor, Loop Type, and Coil Type Codes

Explains the codes for compressor, loop type, and coil type.

Heat Type, Staging, and Orientation Codes

Details the codes for heat type, staging, and unit orientation.

WSHP Series Feature String - Options

Filter Rack and Filter Options

Describes the available filter rack and filter options.

Dehumidification and Service Disconnect Options

Covers dehumidification features and service disconnect options.

Control Sequence and Cabinet Options

Details control sequences and cabinet options.

WSE and Code Options

Explains Waterside Economizer (WSE) and code compliance options.

Shipping, Cabinet Access, and Cabinet Options

Covers shipping, cabinet access, and cabinet construction options.

General Information and Codes

Unit Description and Certifications

Provides a description of the unit and its certifications.

Prohibition of Construction Heater Use

Warns against using the unit as a construction heater.

Applicable Codes and Ordinances

Lists codes and ordinances that installation must conform to.

Refrigerant Handling Compliance

Mentions compliance with refrigerant handling regulations.

Unit Receiving and Storage

Receiving Unit Damage Inspection

Instructions for inspecting units for transit damage.

Model and Voltage Verification

Procedure for verifying unit model and voltage against nameplate.

Repair and Warranty Claims Procedures

Steps for handling repairs and warranty claims for damaged goods.

Proper Unit Storage Guidelines

Guidelines for storing the unit before installation.

Direct Expansion (DX) Systems

DX System Components

Lists the standard components included in DX systems.

Unit Control Method

Specifies how the unit should be controlled.

Installation Procedures

Blower Assembly Check and Shipping Block Removal

Checking the blower assembly and removing shipping blocks.

Unit Placement and Duct Connection

Considerations for unit placement and connecting ductwork.

Foundation Support and Mounting Requirements

Ensuring adequate support and proper mounting.

Mounting and Condensate Piping

Vibration Grommet Installation Details

Details on installing vibration grommets for mounting.

Threaded Rod Sizing and Ductwork Support

Sizing threaded rods and supporting ductwork independently.

Service Clearances and Piping Access

Requirements for service clearances and piping access.

Condensate Drain Piping Installation

Instructions for installing condensate drain piping with p-traps.

Floor Mounted Units and Drain Pan Recommendation

Mounting for floor units and recommendations for drain pans.

Condensate Drain Trap Requirements

Drain Trap Operation Importance

Explains the necessity of drain traps to prevent overflow.

Drain Trap Dimensions and Configuration

Specifies the required dimensions and configuration of drain traps.

WH Series Unit Clearances

Minimum Clearances Required Table

Table detailing minimum required clearances for unit operation.

Unit Orientation and Clearance Diagrams

Diagrams illustrating unit orientations and associated clearances.

Blower Assembly Removal – Side Access

Step 1: Remove Shipping Screw

Instruction to remove the shipping screw on the unit's side.

Step 2: Remove Access Panel

Instruction to remove the side blower access panel.

Step 3: Pull Blower Panel Out

Instruction to pull the bottom of the blower panel outwards.

Step 4: Grip and Lift Blower Assembly

Instruction to grip and lift the blower assembly.

Blower Removal and Discharge Modification

Step 5-7: Angle Blower Mount and Remove Assembly

Steps to angle the blower mount and remove the assembly.

Discharge Direction Selection and Modification

How to select or modify the unit's discharge direction.

Modification Safety and WH-006 Steps

Safety notes for modifications and specific steps for WH-006.

A Cabinet Discharge Modification and Unit Lifting

A Cabinet Discharge Modification Steps

Specific steps for modifying discharge on A Cabinet models.

Lifting and Handling the Unit Procedure

Procedure for safely lifting and handling the unit.

Remove Shipping Material and Use Pallet Jack

Ensuring removal of shipping materials and using a pallet jack.

Unit Handling and Bottom Access

Incorrect Lifting Warning

Warning about the consequences of incorrect lifting practices.

Horizontal Unit Bottom Access Components

Lists components accessible through the bottom access panel.

Bottom Access Panel Removal Procedure

Detailed steps for removing the bottom access panel.

Blower Assembly Removal – Bottom Access

Step 1: Remove Shipping Screw

Instruction to remove the shipping screw for bottom access removal.

Step 2: Open Bottom Access Panel

Instruction to open the bottom access panel.

Step 3: Remove Spade Connectors

Instruction to disconnect spade connectors from the blower motor.

Step 4-5: Grip and Pull Blower Assembly

Instructions to grip, push, and pull the blower assembly.

Blower Motor and Heat Exchanger Access

Step 2-4: Pull Motor and Separate Blower

Steps to pull the motor and separate the blower assembly.

Blower Motor and Fan Access Procedure

General procedure for accessing the blower motor and fan.

Refrigerant-to-Water Heat Exchanger Corrosion Warning

Warning about corrosion in open loop heat exchangers.

Heat Exchanger Water System Concerns

Chemical Corrosion Exclusion for Open Loops

Warranty exclusion for chemical corrosion damage in open loop systems.

Chlorides in Water and Corrosion Risk

Identifies common forms of chlorides and their corrosion risk.

Cupronickel Heat Exchanger Requirement

Specifies the use of cupronickel heat exchangers for open loop applications.

Freezing Water in Heat Exchanger Damage

Explains the potential damage caused by freezing water in heat exchangers.

Water Freezing Prevention and Water Piping

Freezing Damage Warranty Exclusion

Excludes damage from water freezing in heat exchangers from warranty.

Entering Water Temperature Limits

Details the operating limits for Entering Water Temperatures (EWT).

Glycol Percentage and Freeze Point Data

Provides data on glycol concentration and corresponding freezing points.

Water Piping Insulation and Freezing Prevention

Recommendations for insulating water piping to prevent freezing.

Water Pressure Warning

Warns about verifying water pressure and installing relief valves.

Water System Connections and Flushing

PVC/CPVC Piping Chemical Vulnerability

Highlights the vulnerability of PVC/CPVC piping to certain chemicals.

Water Connection Sizes Table

Table specifying supply and return water connection sizes.

Water Pump and System Sizing Guidelines

Guidelines for sizing water pumps and system components.

Water System Flushing and Strainer Requirements

Procedures for flushing the water system and installing strainers.

Water Treatment and Mineral Content Control

Importance of water treatment and controlling mineral content.

Electrical System Requirements

Water Treatment Program Compatibility

Ensuring water treatment programs are compatible with unit materials.

Nameplate Voltage Markings Table

Table correlating voltage features to nameplate markings.

Transformer Configuration Check

Instructions for checking transformer configuration before service.

Electrical Service Warning

Critical warning about disconnecting all electrical power before servicing.

Electrical Protection and Wiring Requirements

Requirements for electrical protection and wiring.

Electrical Connection and Voltage Guidelines

Maximum Overcurrent Protection (MOP)

Guidance on Maximum Overcurrent Protection (MOP) requirements.

Disconnect Switch and Entry Locations

Requirements for disconnect switches and electrical entry points.

Supply Conductor Sizing and Protection

Guidelines for sizing supply conductors and protecting branch circuits.

Voltage Imbalance Caution

Caution regarding the effects of voltage imbalance on motors.

Connecting to WH Series Disconnects

30 Amp Disconnect Procedure

Step-by-step instructions for connecting a 30 amp disconnect.

Motor Rotation and Amperage Checks

Checks required for motor rotation and amperage during installation.

Control Wiring and Factory Wiring Replacement

Guidelines for control wiring and replacing factory wiring.

Scroll Compressor Direction Caution

Warning about potential damage from incorrect scroll compressor rotation.

30 Amp and 60 Amp Disconnect Installation

30 Amp Disconnect Terminal Connections

Connecting field wires to the 30 amp disconnect terminals.

60 Amp Disconnect Faceplate and Terminal Removal

Steps to remove the faceplate and switch terminal block for 60A disconnect.

60 Amp Disconnect Terminal Connections

Connecting field wires to the 60 amp disconnect terminals.

Thermostat Control Wiring

Thermostat Location and Voltage Requirements

Recommended thermostat placement and minimum control voltage.

Allowable Wiring Distances Table

Table showing allowable wiring distances based on wire size.

Wiring Distance Calculation Example

Example calculation for determining wire size based on distance.

Filter Access Doors Description

Description and illustration of filter access doors.

Filter Pull Setup and Operation

Filter Operation Without Filters Warning

Warning against operating the unit without filters installed.

Filter Access Options and Clip Handling

Details on side vs. bottom access and handling filter rack clips.

Filter Pull Location and Usage Procedure

Instructions for locating and using the filter pull.

Duct Connection and Waterside Economizer

Ductwork Attachment and Sizing Standards

Guidance on connecting ductwork and duct sizing standards.

Waterside Economizer Coil and Valve

Description of the waterside economizer coil and its valve.

Economizer Operating Modes and Condensate

Details economizer operating modes and condensate drainage.

Water Mineral Content and Treatment

Importance of controlling water mineral content and treatment.

Economizer Control Configuration

Configuration settings for the waterside economizer control.

Startup Procedures and Fan Adjustments

Startup Operation Limits and Warnings

Covers operating limits and safety warnings for startup.

Routine Startup Checks

Essential checks to perform during unit startup.

Supply Fan Description

Description of the direct drive supply fans used in the units.

Fan Air Flow Adjustment Methods

Methods for adjusting fan air flow using motor speed taps.

Fan Speed and Refrigerant Charge Adjustment

Motor Tap RPMs and Speed Selection

Table of motor tap RPMs and notes on speed selection.

Filter Operation Warning

Warning regarding the operation of the unit without filters.

Refrigerant Charge Adjustment Importance

Emphasizes the critical nature of refrigerant charge adjustment.

Pre-Charging Steps and System Stabilization

Steps before charging and system stabilization time.

Liquid Sub-Cooling Measurement Procedure

Procedure for measuring liquid sub-cooling.

Refrigerant Charge Adjustment Details

Evaporator Superheat Measurement Procedure

Procedure for measuring evaporator superheat.

Overcharge Warning and Correction

Warning about overcharging and how to correct it.

Undercharge Correction and TXV Adjustment

How to correct undercharging and adjust the TXV.

R-410A Refrigerant Temperature-Pressure Chart

Temperature-Pressure Data Table

Table providing R-410A refrigerant temperature and pressure data.

Unit Operation and Controller Overview

Unit Control Methods

Specifies how unit operations must be controlled.

AAON WSHP Pioneer Silver Controller Description

Describes the functionality of the Pioneer Silver Controller.

Controller Specifications and Terminal Block H2

Covers controller specifications and details of Terminal Block H2.

Controller Terminal and Wiring Details

Controller Terminal Block H5 and H1

Details for Terminal Blocks H5 and H1 on the controller.

Quick Disconnect and Wiring Harness Details

Descriptions of quick disconnects and wiring harnesses.

Alarm and Relay Status LEDs

Explanation of alarm and relay status LEDs.

Dip Switch SW1 Reference

Reference to Dip Switch SW1 for glycol percentage setpoints.

Sequences of Operation - Fan and Compressor

Supply Fan Operation Logic

Details the logic for supply fan operation.

Compressor Operation Logic

Explains the logic governing compressor operation.

Sequences of Operation - Valve, Delay, and Test Mode

Reversing Valve Operation Logic

Details the logic for reversing valve operation.

Random Start Delay Conditions

Conditions under which a random start delay is initiated.

Building Occupancy and Night Setback Modes

Operation modes based on building occupancy and night setback.

Test Mode Operation Procedure

Procedure for enabling and operating the unit in test mode.

Alarms: LED Fault Codes Description

Explanation of LED fault codes indicating alarm conditions.

Controller Alarms and Fault Codes

LED Diagnostic Codes Table

Table mapping LED flash counts to specific fault codes.

Automatic Reset Alarms Explained

Description of alarms that reset automatically when faults clear.

Low and High Control Voltage Alarms

Details on low and high control voltage alarms and their effects.

Leaving Water Temperature Alarm Details

Explanation of the leaving water temperature alarm.

Controller Alarms and Settings

Glycol Percentage Setpoints Table

Table for setting glycol percentage for freeze protection.

Air Coil Temperature Alarm

Details the air coil low temperature alarm.

Entering Water Temperature Alarm

Explains the entering water temperature alarm for economizer protection.

Emergency Shutdown Alarm

Details the emergency shutdown alarm and its function.

Lock Out Alarms Clearing Procedure

Procedure for clearing lock-out alarms.

Auxiliary Input and Condensate Level Alarms

Details on auxiliary input and high condensate level alarms.

Controller Alarms - Pressure and Suction

High Discharge Pressure Alarm

Details the high discharge pressure alarm.

Low Suction Pressure Alarm

Explains the low suction pressure alarm.

AAON WSHP Pioneer Silver Expansion Board

Expansion Board Description and Connection Note

Describes the expansion board and its connection to the controller.

Expansion Board Specifications

Covers electrical, input, output, environmental, and dimensional specs.

Expansion Board Terminal Block H4

Details for Terminal Block H4 on the expansion board.

Expansion Board Terminal Block H1

Details for Terminal Block H1 on the expansion board.

Expansion Board Terminal Connections

Quick Disconnect Terminals P1-P11

Descriptions for Quick Disconnect terminals P1 through P11.

Quick Disconnect Terminals P12-P21

Descriptions for Quick Disconnect terminals P12 through P21.

Dip Switch Settings for Operation

Dip Switch SW1: Fan-Speed Dehumidification

Settings for fan-speed dehumidification using Dip Switch SW1.

Dip Switch SW2: Waterside Economizer Enable

Settings to enable the waterside economizer using Dip Switch SW2.

SW2: Economizer Temperature Setpoint Selection

Selection of economizer temperature setpoints via Dip Switch SW2.

Additional Sequences of Operation

Supply Fan Operation Details with ECM

Further details on supply fan operation with ECM motors.

Compressor Operation Logic Details

Additional details on compressor operation logic and delays.

Maintenance and Operational Checks

Annual Service Technician Checks

Recommended annual checks by a qualified service technician.

Monthly Inspections and Maintenance Warning

Monthly inspections and a warning about improper maintenance.

DX Cooling Operational Checks

Checks to perform during DX cooling mode operation.

Condensate Drain Pan Cleaning

Importance and procedure for cleaning condensate drain pans.

Supply Fan and Coil Cleaning Procedures

Blower Wheel Inspection Caution

Cautionary note regarding inspection and cleaning of blower wheels.

Microchannel Coil Cleaning Frequency

Recommended frequency and procedure for cleaning microchannel coils.

Allowed Chemical Cleaners and Procedures

Lists AAON-recommended chemicals and procedures for coil cleaning.

Water Pressure for Coil Cleaning

Specifies water pressure limits for coil cleaning.

Simple Green Coil Cleaning Procedure

Detailed procedure for cleaning microchannel coils with Simple Green.

Coil Cleaning and Filter Replacement

Water Flush Coil Cleaning Procedure

Procedure for cleaning microchannel coils using a water flush.

Other Coil Cleaners Approval Requirement

Requirement for AAON approval before using unapproved coil cleaners.

Filter Replacement Importance

Highlights the importance of regular filter replacement for efficiency.

Filter Media Replacement Recommendation

Recommendation for monthly replacement of filter media.

Replacement Parts and Filter Information

Obtaining Replacement Parts and Information Needed

Guidance on obtaining replacement parts and required information.

Table 10: WH Unit Series Filters (A Cabinet)

Table listing filter quantities, sizes, and types for A cabinets.

Table 11: WH Unit Series Filters (B & C Cabinet)

Table listing filter quantities, sizes, and types for B & C cabinets.

Filter Information Tables

Table 12: WH Series Unit Filters (D Cabinet)

Table listing filter quantities, sizes, and types for D cabinets.

Table 13: WH Series Unit Filters (E Cabinet)

Table listing filter quantities, sizes, and types for E cabinets.

Table 14: WH Series Unit Filters (F Cabinet)

Table listing filter quantities, sizes, and types for F cabinets.

Table 15: WH Series Unit Filters (G Cabinet)

Table listing filter quantities, sizes, and types for G cabinets.

Appendix A: Heat Exchanger Corrosion Resistance

Scaling Potential and pH Range

Details potential scaling issues based on chemical conditions and pH.

Corrosion Potential and Water Velocity

Covers corrosion potential related to chemicals and water velocity.

Biological Growth and Erosion Potential

Information on biological growth and erosion potentials.

Heat Exchanger Notes

Notes regarding heat exchanger applications and limitations.

WH Series Startup Form

Job Information Fields

Fields for recording job and unit identification information.

Pre Startup Checklist Items

Checklist for contractors to verify installation readiness.

Ambient Temperature Recording

Fields for recording ambient dry bulb and wet bulb temperatures.

Startup Form - Assembly and System Checks

Supply Fan Assembly Checks

Checks for supply fan alignment, rotation, and amperage.

Compressors/DX Cooling Checks

Checks for compressor rotation and pressure readings.

Refrigeration System Data Recording

Fields for recording pressure, temperature, sub-cooling, and superheat data.

Unit Configuration Checks

Checks for water leaks and water flow rates.

Startup Form - Water/Glycol System and Maintenance Log

Water/Glycol System Checklist

Checklist for verifying the water/glycol system.

Maintenance Log Purpose and Fields

Explanation of the maintenance log and its entry fields.

Literature Change History

2017 Literature Updates

Summary of literature updates made in 2017.

2018 Literature Updates

Summary of literature updates made in 2018.

2019 Literature Updates

Summary of literature updates made in 2019.

2020 Literature Updates

Summary of literature updates made in 2020.

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