lz series - aaon · lz series chillers and outdoor mechanical rooms installation, operation, &...

LZ Series

Chillers and Outdoor Mechanical Rooms

Installation, Operation,

& Maintenance

FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exactly could result in serious injury, death or property damage. Be sure to read and understand the installation, operation and service instructions in this manual. Improper installation, adjustment, alteration, service or maintenance can cause serious injury, death or property damage. A copy of this IOM should be kept with the unit.

Do not store gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance. Do not touch any electrical switch. Do not use any phone in your

building. Leave the building immediately. Immediately call you gas supplier

from a phone remote from the building. Follow the gas supplier’s instructions.

If you cannot reach your gas supplier call the fire department.

Startup and service must be performed by a Factory Trained Service Technician.

WARNING WARNING

Table of Contents

Codes and Ordinances ............................................................................................................... 19 Receiving Unit ........................................................................................................................... 19

Storage ....................................................................................................................................... 20 Outdoor Mechanical Room ....................................................................................................... 20 Wiring Diagrams ....................................................................................................................... 21 General Maintenance ................................................................................................................. 21 Chiller Primary Pumping .......................................................................................................... 21

Chiller Primary/Secondary Pumping ........................................................................................ 22 Condensing Boilers ................................................................................................................... 22 Makeup Water ........................................................................................................................... 23 Compression Tank ..................................................................................................................... 23

Pressure Relief Valve ................................................................................................................ 24 Automatic Air Vent ................................................................................................................... 24

Dual Pumps ............................................................................................................................... 24 Pressure Gauges and Thermometers ......................................................................................... 24

Pipe Insulation ........................................................................................................................... 25 Outdoor Mechanical Room Placement...................................................................................... 25 Curb and Steel Mount Installation ............................................................................................ 25

Lifting and Handling ................................................................................................................. 28 Vestibule Exhaust Fan ............................................................................................................... 29

Water Connection ...................................................................................................................... 30 Temporary Drain – Evaporative Condenser .............................................................................. 31 Access Doors ............................................................................................................................. 31

End Flashing Installation ........................................................................................................... 31

Boiler Gas Connection .............................................................................................................. 32 Boiler Air Intake / Vent Piping ................................................................................................. 32 Sidewall Direct Boiler Venting ................................................................................................. 35

Vertical Direct Boiler Venting .................................................................................................. 37 Boiler Condensate Drain ........................................................................................................... 41

Split Unit Assembly .................................................................................................................. 41 Unit Mounting Isolation ............................................................................................................ 41

Low Ambient Operation ............................................................................................................ 41 Electrical .................................................................................................................................... 42 Variable Speed Compressors .................................................................................................... 44 Condenser Fan Pitch Adjustment .............................................................................................. 47 Boiler System Startup ................................................................................................................ 50

Boiler Sequence of Operations .................................................................................................. 51 General ...................................................................................................................................... 51

Refrigerant Suction Line Filter ................................................................................................. 51 Suction Filter Removal Instructions .......................................................................................... 52 Refrigerant Liquid Line Filter Driers ........................................................................................ 52 Evaporator/Heat Exchangers ..................................................................................................... 53 Adjusting Refrigerant Charge ................................................................................................... 53 Lubrication ................................................................................................................................ 57

4

Air-Cooled Condenser ............................................................................................................... 57 E-Coated Coil Cleaning ............................................................................................................ 57 Microchannel Coil Cleaning ..................................................................................................... 59 Evaporative-Condensed Chiller ................................................................................................ 61

Severe Operating Conditions Service .................................................................................... 62 Safety ..................................................................................................................................... 62 Performance ........................................................................................................................... 62 Warranties .............................................................................................................................. 63 Condenser Tube Inspection ................................................................................................... 63

Freeze Protection ................................................................................................................... 63 Recirculating Water System .................................................................................................. 63 Startup .................................................................................................................................... 63 Cleanliness ............................................................................................................................. 63

Storage ................................................................................................................................... 63 Pump Operation ..................................................................................................................... 64

Running.................................................................................................................................. 64 Condenser Fan Motors ........................................................................................................... 64

Water Make Up Valve ........................................................................................................... 64 Water Treatment System ....................................................................................................... 65 Sequence of Operation for LZ Series units without Diagnostics .......................................... 65

Sequence of Operation for LZ Series units with Diagnostics ................................................ 66 Pump Maintenance ................................................................................................................ 67

Fan Motor Maintenance ......................................................................................................... 67 Access Doors ......................................................................................................................... 67 Bearings - Lubrication ........................................................................................................... 68

Recommended Monthly Inspection ....................................................................................... 68

Mist Eliminators .................................................................................................................... 68 Air Inlet .................................................................................................................................. 68 Stainless Steel Base Pan ........................................................................................................ 68

Propeller Fans and Motors ..................................................................................................... 68 Recommended Annual Inspection ......................................................................................... 68

Cleaning ................................................................................................................................. 68 Water Quality ......................................................................................................................... 69

Mechanical Cleaning ............................................................................................................. 70 Service ....................................................................................................................................... 70 Replacement Parts ..................................................................................................................... 70 Water Pressure Reducing Valve ................................................................................................ 71 Water Pressure Relief Valve ..................................................................................................... 73

Automatic Air Vent Valves ....................................................................................................... 73 Pumps - Installation and Operating Instructions ....................................................................... 75

Pump Piping - General .............................................................................................................. 77 Pump Operation ......................................................................................................................... 77 General Care .............................................................................................................................. 78 Dual Pump Specific Information ............................................................................................... 80 Horizontal and Vertical Expansion Tanks ................................................................................ 85 Suction Guides .......................................................................................................................... 86

5

Glycol Auto Fill Unit ................................................................................................................ 87 Flo-Trex Combination Valve .................................................................................................... 89

Index of Tables and Figures

Tables:

Table 1 - Service Clearances......................................................................................................... 25 Table 2 - Unit Gas Pipe Information, Feature B4 = A-J ............................................................... 33

Table 3 - Unit Gas Pipe Information, Feature B4 = K-N.............................................................. 34 Table 4- Tandem Circuited Variable Speed Compressor VFD Frequency Range ....................... 44 Table 5 - Air-Cooled Condenser Fan Pitch................................................................................... 47 Table 6 - Evaporative-Condensed Chiller Fan Pitch .................................................................... 47

Table 7 - Condenser Fan Pin Location (Bushing Mount) ............................................................. 49 Table 8 - Condenser Fan Pin Location (Rotation Direction) ........................................................ 49

Table 9 - Fan Assembly Bushing Torque Specifications.............................................................. 50 Table 10 - Filter Drier Maximum Pressure Drop.......................................................................... 52

Table 11 - Acceptable Refrigeration Circuit Values..................................................................... 54 Table 12 - R-134a Refrigerant Temperature-Pressure Chart ........................................................ 55 Table 13 - R-410A Refrigerant Temperature-Pressure Chart ....................................................... 56

Table 14 - Recirculating Water Quality Guidelines ..................................................................... 69

Figures:

Figure 1 - Backflow Preventer ...................................................................................................... 23

Figure 2 - Pressure Relief Valve ................................................................................................... 24

Figure 3 - Curb Mounting with Dimensions ................................................................................. 26 Figure 4 - Curb End Detail............................................................................................................ 26 Figure 5 - Steel Mounting Rail with Dimensions ......................................................................... 26

Figure 6 - Concrete Pad Mounting with Dimensions ................................................................... 27 Figure 7 - LZ Base ........................................................................................................................ 27

Figure 8 - Lifting Points ................................................................................................................ 28 Figure 9 - LZ Series Example Lifting Detail ................................................................................ 29

Figure 10 - Vestibule Exhaust Fan................................................................................................ 29 Figure 11 - Water Pipe Flashing Installation ................................................................................ 30 Figure 12 – Temporary Drain Components .................................................................................. 31 Figure 14 - Factory Supplied End Flashings................................................................................. 31 Figure 15 - Sidewall Vent Shipping Cover Removal ................................................................... 35

Figure 16 - Sidewall Vent Plate Installation ................................................................................. 35 Figure 17 - Typical Air Intake Piping ........................................................................................... 35

Figure 18 - Typical Flue Vent Piping ........................................................................................... 36 Figure 19 - Sidewall Vent Base .................................................................................................... 37 Figure 20 - Sidewall Vent Cap...................................................................................................... 37 Figure 21 - Roof Air Intake and Vent Piping Shipping Covers .................................................... 37 Figure 22 - Typical Vertical Air Intake Piping ............................................................................. 38 Figure 23 - Correct Joint Connection............................................................................................ 39

6

Figure 24 - Incorrect Joint Connection ......................................................................................... 39 Figure 25 - Typical Vertical Vent Piping ..................................................................................... 40 Figure 26 - Vertical Termination of Air Intake and Vent Piping ................................................. 40 Figure 27 - Evaporative-Condensed Chiller Section Layout ........................................................ 45

Figure 28 - Fan with the HUB on the top and RET on the bottom. .............................................. 48 Figure 29 - Bushing Mount Location............................................................................................ 48 Figure 30 - RET with Pin in Groove 4 .......................................................................................... 48 Figure 31 - Fan HUB and RET Castings ...................................................................................... 48 Figure 32 - Pitch Insert ................................................................................................................. 49

Figure 33 - Replaceable Core Filter Driers ................................................................................... 52 Figure 34 - Proper Unit Location .................................................................................................. 62 Figure 35 - Improper Unit Locations ............................................................................................ 62 Figure 36 - Water Makeup Valve ................................................................................................. 65

Figure 36 – Evaporative condenser access door ........................................................................... 67

V45100 · Rev. A · 190308

7

AAON LZ Series Features and Options Introduction

Energy Efficiency

• Staged or Variable Speed R-410A Scroll Compressors

• Oil-Free Magnetic Bearing R-134a Turbocor Centrifugal Compressors

• High Efficiency Air-Cooled Microchannel Condenser Coils

• AAON Evaporative-Condensed Chiller • VFD Controlled Pumping Packages • VFD Controlled Condenser Fan Head

Pressure Control

• ECM Low Sound Condenser Fan Head Pressure Control

• 98% Thermal Efficiency Boilers • Waterside Economizers • Factory Installed EXVs

Outdoor Mechanical Room • Chilled Water Applications up to

540 tons

• Hot Water Applications up to 6,000 MBH

• Lighted Walk-In Service Vestibule • Factory Engineered Primary or

Primary/Secondary Pumping Packages

• Factory Installed Three Chemical Water Treatment

• Factory Installed Compression Tank • Brazed Plate or Shell and Tube

Evaporators

• Factory Installed Option Boxes for Field Installed Accessories

Safety • Phase and Brownout Protection • Single Point Non-Fused Disconnect

Power Switch

• Factory Installed Refrigerant Leak Detector

• Water Piping Air Separator • Waterside Thermometer and Pressure

Gauge

Installation and Maintenance • Double Wall Rigid Polyurethane Foam

Injected Panel Construction

• Lighted Walk-In Service Vestibule • Access Doors with Full Length Stainless

Steel Piano Hinges

• Zinc Cast Lockable Handles • Factory Installed Convenience Outlet • Service Vestibule Heating and Cooling • Motorized Service Vestibule Fresh Air • Controls Diagnostics • Touchscreen Computer Controls

Interface

• Evaporative-Condensed Chiller De-Superheater

• Evaporative-Condensed Chiller Sump Heaters

• Liquid Line Sight Glass • Compressor Isolation Valves • Auto Glycol Feeder • Color-Coded Wiring Diagrams

System Integration • Complete System with AAON Chilled

Water Air Handling Units

• BMS Connectivity • Grooved End Water Piping Connections • Custom Color Paint Options

Environmentally Friendly • R-410A or R-134a Refrigerant

Extended Life • Optional 5 Year Compressor Warranty • Condenser Coil Guards • 2,500 Hour Salt Spray Tested Exterior

Corrosion Protection

• 6,000 Hour Salt Spray Tested Polymer E-Coated Condenser Coils

•

8

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.

DANGER - Danger statements are given to prevent actions that will result in equipment

damage, property damage, severe personal injury or death.

ELECTRIC SHOCK, FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exactly could result in dangerous operation, serious injury, death or property damage. Improper servicing could result in dangerous operation, serious injury, death, or property damage. Before servicing, disconnect all

electrical power to the unit. More than one disconnect may be provided.

When servicing controls, label all wires prior to disconnecting. Reconnect wires correctly.

Verify proper operation after servicing. Secure all doors with key-lock or nut and bolt.

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. A copy of this IOM should be kept with the unit.

WARNING

WHAT TO DO IF YOU SMELL GAS Do not try to turn on unit. Shut off main gas supply. Do not touch any electric switch. Do not use any phone in the

building. Never test for gas leaks with an

open flame. Use a gas detection soap solution

and check all gas connections and shut off valves.

CAUTION

9

FIRE, EXPLOSION OR CARBON MONOXIDE POISONING HAZARD Failure to replace proper controls could result in fire, explosion or carbon monoxide poisoning. Failure to follow safety warnings exactly could result in serious injury, death or property damage. Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this appliance.

WARNING

Electric shock hazard. Before servicing, shut off all electrical power to the unit, including remote disconnects, to avoid shock hazard or injury from rotating parts. Follow proper Lockout-Tagout procedures.

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

GROUNDING REQUIRED All field installed wiring must be completed by qualified personnel. Field installed wiring must comply with NEC/CEC, local and state electrical code requirements. Failure to follow code requirements could result in serious injury or death. Provide proper unit ground in accordance with these code requirements.

WARNING

VARIABLE FREQUENCY DRIVES

Do not leave VFDs unattended in hand mode or manual bypass. Damage to personnel or equipment can occur if left unattended. When in hand mode or manual bypass mode VFDs will not respond to controls or alarms.

WARNING

Electric motor over-current protection and overload protection may be a function of the Variable Frequency Drive to which the motors are wired. Never defeat the VFD motor overload feature. The overload ampere setting must not exceed 115% of the electric motors FLA rating as shown on the motor nameplate.

CAUTION

10

UNIT HANDLING To prevent injury or death lifting equipment capacity shall exceed unit weight by an adequate safety factor. Always test-lift unit not more than 24 inches high to verify proper center of gravity lift point to avoid unit damage, injury or death.

WARNING

Always use a pressure regulator, valves and gauges to control incoming pressures when pressure testing a system. Excessive pressure may cause line ruptures, equipment damage or an explosion which may result in injury or death.

WARNING

Door compartments containing hazardous voltage or rotating parts are equipped with door latches to allow locks. Door latches are shipped with nut and bolts requiring tooled access. If you do not replace the shipping hardware with a pad lock always re-install the nut & bolt after closing the door.

CAUTION

Do not use oxygen, acetylene or air in place of refrigerant and dry nitrogen for leak testing. A violent explosion may result causing injury or death.

WARNING

PVC (Polyvinyl Chloride) and CPVC (Chlorinated Polyvinyl Chloride) are vulnerable to attack by certain chemicals. Polyolester (POE) oils that are used in R-410A and other refrigerant systems will cause stress cracking of PVC or CPVC piping, even if only present in trace amounts. This will result in complete piping system failure.

CAUTION

COMPRESSOR CYCLING

3 MINUTE MINIMUM OFF TIME To prevent motor overheating compressors must cycle off for a minimum of 3 minutes.

3 MINUTE MINIMUM ON TIME To maintain the proper oil level compressors must cycle on for a minimum of 3 minutes. The cycle rate must not exceed 6 starts per hour.

WARNING

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 8.5, after mixing, without first using an aluminum corrosion inhibitor in the cleaning solution.

CAUTION

11

1. Startup and service must be performed by a Factory Trained Service Technician.

2. The unit is for outdoor use only. See General Information section for more

information.

3. Use only with type of the gas approved for the boiler. Refer to the boiler rating

plate.

4. Provide adequate combustion ventilation air to the boiler.

5. Every unit has a unique equipment nameplate with electrical, operational,

and unit clearance specifications. Always

refer to the unit nameplate for ratings

unique to the model you have purchased.

6. READ THE ENTIRE INSTALLATION, OPERATION AND MAINTENANCE

MANUAL. OTHER IMPORTANT

SAFETY PRECAUTIONS ARE

PROVIDED THROUGHOUT THIS

MANUAL.

7. Keep this manual and all literature safeguarded near or on the unit.

Polyolester (POE) and Polyvinylether (PVE) oils are two types of lubricants used with R-410A and R134a refrigeration systems. Refer to the compressor label for the proper compressor lubricant type.

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

Rotation must be checked on ALL MOTORS AND COMPRESSORS of 3 phase units at startup by a qualified service technician. Scroll compressors are directional and can be damaged if rotated in the wrong direction. Compressor rotation must be checked using suction and discharge gauges. Fan motor rotation should be checked for proper operation. Alterations should only be made at the unit power connection.

CAUTION

Some chemical coil cleaning compounds are caustic or toxic. Use these substances only in accordance with the manufacturer’s usage instructions. Failure to follow instructions may result in equipment damage, injury or death.

WARNING

LZ Series Feature String Nomenclature

Model Options : Unit Feature Options

GE

N

MJ

RE

V

SIZ

E

SE

RIE

S

MN

RE

V

VL

T

A1

A2

A3

A4

A5

B1

B2

B3

B4

1

2

3A

3B

3C

3D

4A

4B

4C

4D

5A

5B

5C

5D

6

7

8A

8B

8C

LZ A - 140 - C - A - 3 - F A C 0 E - 0 0 0 0 : E 0 - 0 0 0 0 - 0 0 0 0 - 0 0 0 0 - 0 0 - 0 0 0 0 - 0 E 0 0 - 0 0 C 0 0 - 0 J 0 0 0 - 0 0 0 0 0 - 0 0 0 0 0 0 - 0 0 0 0 0 - 0 0 D B

9

10

A

10B

10C

10

D

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

A

26B

26C

26

D

26E

26

F

27

28

29

30

31

32

33

34

35

12


MODEL OPTIONS Series and Generation

LZ

Major Revision

A

Unit Size

Air-Cooled Evaporative-Condensed

045 = 45 ton Capacity 053 = 53 ton Capacity












181 = 181 ton Capacity














Series - Scroll Compressor

Air-Cooled

A = 45-60 ton units

B = 75 ton unit

C = 95-140 ton units

D = 170-200 ton units

Evaporative-Condensed

A = 53-69 ton units

B = 78 ton unit

C = 106-161 ton units

D = 193-239 ton units

E = 274-319 ton units

F = 356-401 ton units

G = 441-478 ton units

Series - Turbocor Compressor

Air-Cooled

H = 90-120 ton units

K = 181 ton unit

Evaporative-Condensed

H = 90 & 120 ton units

J = 150 & 180 ton units

K = 181 ton unit

L = 240 ton unit

M = 300 & 360 ton units

N = 450 & 540 ton units

Minor Revision

A

Voltage

2 = 230V/3Φ/60Hz

3 = 460V/3Φ/60Hz

4 = 575V/3Φ/60Hz

8 = 208V/3Φ/60Hz

A1: Compressor Style

F = R-410A Tandem VFD Compatible Scroll

Compressor

H = R-134a Turbocor Centrifugal Compressor

J = R-134a Turbocor Centrifugal Compressor with

Economizer

A2: Condenser Style

A = Air-Cooled Microchannel Condenser

H = Evaporative-Condensed

A3: Evaporator Configuration

A = Brazed Plate

B = Oversized Brazed Plate

C = Shell & Tube

D = Oversized Shell & Tube

A4: Coating

0 = Standard

E = Polymer E-Coated Condenser Coil

A5: Staging

0 = Staged On/Off Compressors

E = All Circuits Variable Capacity Compressors

G = Half Circuits Variable Capacity Compressors



GE

N

MJR

EV

SIZ

E

SE

RIE

S

MN

RE

V

VL

T

A1

A2

A3

A4

A5

B1

B2

B3

B4

1

2

3A

3B

3C

3D

4A

4B

4C

4D

5A

5B

5C

5D

6

7

8A

8B

8C


9

10

A

10B

10C

10

D

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

A

26B

26C

26

D

26E

26

F

27

28

29

30

31

32

33

34

35

13

B1: Type

0 = No Boilers

B2: Boiler Quantity

0 = No Boilers

B3: Type and Pipe Size

0 = No Boilers

B4: Boiler Capacity

0 = No Boilers

UNIT FEATURE OPTIONS 1: Unit Orientation

E = Walk-in Vestibule Left Access Left Water

Connections

F = Walk-in Vestibule Left Access Right Water

Connections

G = Walk-in Vestibule Left Access Bottom Water

Connections

J = Walk-in Vestibule Right Access Left Water

Connections

K = Walk-in Vestibule Right Access Right Water

Connections

L = Walk-in Vestibule Right Access Bottom Water

Connections

2: Pumping Style

0 = No Pumps

A = Const. Primary Pumping System Small Pipe Size

B = Const. Primary Pumping System Large Pipe Size

C = Var. Primary Pumping System Small Pipe Size

D = Var. Primary Pumping System Large Pipe Size

E = Primary/Secondary Pumping System Small Pipe

Size

F = Primary/Secondary Pumping System Large Pipe

Size

3A: Building Pump Configuration

0 = No Building Pumps

A = 1 Pump + High Eff Motor

B = 1 Dual Pump + High Eff Motors

C = 2 Single Pumps + High Eff Motors

D = 1 Pump + VFD + High Eff Motor

E = 1 Dual Pump + 2 VFD's + High Eff Motors

F = 2 Single Pumps + 2 VFD’s + High Eff Motors

K = 1 Pump + Field Installed VFD + High Eff Motor

L = 1 Dual Pump + 2 Field Installed VFD's + High

Eff Motors

M = 2 Single Pumps + 2 Field Installed VFD’s +

High Eff Motors

3B: Building Pump Series and RPM


A = 4360 (1,170 nominal rpm)

B = 4360 (1,760 nominal rpm)

C = 4360 (3,520 nominal rpm)

D = 4380 (1,170 nominal rpm)

E = 4380 (1,760 nominal rpm)

F = 4380 (3,520 nominal rpm)

G = 4300 (1,170 nominal rpm)

H = 4300 (1,760 nominal rpm)

J = 4300 (3,520 nominal rpm)

K = 4382 (1,170 nominal rpm)

L = 4382 (1,760 nominal rpm)

M = 4382 (3,520 nominal rpm)

N = 4302 (1,170 nominal rpm)

P = 4302 (1,760 nominal rpm)

Q = 4302 (3,520 nominal rpm)



GE

N

MJR

EV

SIZ

E

SE

RIE

S

MN

RE

V

VL

T

A1

A2

A3

A4

A5

B1

B2

B3

B4

1

2

3A

3B

3C

3D

4A

4B

4C

4D

5A

5B

5C

5D

6

7

8A

8B

8C


9

10

A

10B

10C

10

D

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

A

26B

26C

26

D

26E

26

F

27

28

29

30

31

32

33

34

35

14

3C: Pump Size


A = 1.5B

B = 2B

C = 2D

D = 3D

E = 1.5x1.5x6

F = 2x2x6

G = 3x3x6

H = 4x4x6

J = 6x6x6

K = 1.5x1.5x8

L = 2x2x8

M = 3x3x8

N = 4x4x8

P = 5x5x8

Q = 6x6x8

R = 8x8x8

S = 2x2x10

T = 3x3x10

U = 4x4x10

V = 6x6x10

W = 8x8x10

Y = 4x4x11.5

Z = 5x5x11.5

1 = 6x6x11.5

2 = 8x8x11.5

3 = 4x4x13

4 = 6x6x13

5 = 8x8x13

3D: Building Pump Motor Size


A = 0.5 hp

B = 0.75 hp

C = 1 hp

D = 1.5 hp

E = 2 hp

F = 3 hp

G = 5 hp

H = 7.5 hp

J = 10 hp

K = 15 hp

L = 20 hp

M = 25 hp

3D: Building Pump Motor Size Continued

N = 30 hp

P = 40 hp

Q = 50 hp

R = 60 hp

S = 75 hp

4A: Recirculating Pump Configuration

0 = No Recirculating Pumps

A = 1 Pump + High Eff Motor

B = 1 Dual Pump + High Eff Motors

C = 2 Single Pumps + High Eff Motors

4B: Recirculation Pump Series & RPM


A = 4360 (1,170 nominal rpm)

B = 4360 (1,760 nominal rpm)

C = 4360 (3,520 nominal rpm)

D = 4380 (1,170 nominal rpm)

E = 4380 (1,760 nominal rpm)

F = 4380 (3,520 nominal rpm)

G = 4300 (1,170 nominal rpm)

H = 4300 (1,760 nominal rpm)

J = 4300 (3,520 nominal rpm)

K = 4382 (1,170 nominal rpm)

L = 4382 (1,760 nominal rpm)

M = 4382 (3,520 nominal rpm)

N = 4302 (1,170 nominal rpm)

P = 4302 (1,760 nominal rpm)

Q = 4302 (3,520 nominal rpm)



GE

N

MJR

EV

SIZ

E

SE

RIE

S

MN

RE

V

VL

T

A1

A2

A3

A4

A5

B1

B2

B3

B4

1

2

3A

3B

3C

3D

4A

4B

4C

4D

5A

5B

5C

5D

6

7

8A

8B

8C


9

10

A

10B

10C

10

D

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

A

26B

26C

26

D

26E

26

F

27

28

29

30

31

32

33

34

35

15

4C: Recirculating Pump Size


A = 1.5B

B = 2B

C = 2D

D = 3D

E = 1.5x1.5x6

F = 2x2x6

G = 3x3x6

H = 4x4x6

J = 6x6x6

K = 1.5x1.5x8

L = 2x2x8

M = 3x3x8

N = 4x4x8

P = 5x5x8

Q = 6x6x8

R = 8x8x8

S = 2x2x10

T = 3x3x10

U = 4x4x10

V = 6x6x10

W = 8x8x10

Y = 4x4x11.5

Z = 5x5x11.5

1 = 6x6x11.5

2 = 8x8x11.5

3 = 4x4x13

4 = 6x6x13

5 = 8x8x13

4D: Recirculating Pump Motor Size


A = 0.5 hp

B = 0.75 hp

C = 1 hp

D = 1.5 hp

E = 2 hp

F = 3 hp

G = 5 hp

H = 7.5 hp

J = 10 hp

K = 15 hp

L = 20 hp

M = 25 hp

4D: Recirculating Pump Motor Size Continued

N = 30 hp

P = 40 hp

Q = 50 hp

R = 60 hp

S = 75 hp

5A: Boiler Building Pump Configuration

0 = No Boiler Pumps

5B: Boiler Building Pump Series & RPM

0 = No Boiler Pumps

5C: Boiler Building Pump Size

0 = No Boiler Pumps

5D: Boiler Building Pump Motor Size

0 = No Boiler Pumps

6: Refrigeration Options

0 = None

A = Hot gas bypass on non-variable capacity

compressor circuits

B = Hot gas bypass on all circuits

7: Refrigeration Accessories

0 = Standard

A = Sight Glass

B = Compressor Isolation Valves

C = Option A + B

8A: Unit Disconnect Type

0 = Standard Single Point Power Block

A = Single Point Power Non-fused Disconnect

8B: Disconnect 1 Size

0 = Power Block

N = 100 amps

R = 150 amps

U = 225 amps

V = 250 amps

Z = 400 amps

3 = 600 amps

5 = 800 amps

7 = 1200 amps



GE

N

MJR

EV

SIZ

E

SE

RIE

S

MN

RE

V

VL

T

A1

A2

A3

A4

A5

B1

B2

B3

B4

1

2

3A

3B

3C

3D

4A

4B

4C

4D

5A

5B

5C

5D

6

7

8A

8B

8C


9

10

A

10B

10

C

10

D

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

A

26B

26C

26

D

26E

26

F

27

28

29

30

31

32

33

34

35

16

8C: Blank

0 = Standard

9: Accessories

0 = None

B = Phase & Brown Out Protection

10A: Unit Control Sequence

0 = Standard AAON Controls

10B: Unit Control Supplier

E = MCS Controls

10C: Control Supplier Options

0 = None

A = Touchscreen Computer Interface

C = Modem

G = Option A + C

10D: BMS Connection & Diagnostics

0 = None

A = BACnet IP

B = BACnet MSTP

C = Modbus IP

D = Modbus RTU

E = LonTalk

H = No BMS Connection with Diagnostics

J = BACnet IP with Diagnostics

K = BACnet MSTP with Diagnostics

L = Modbus IP with Diagnostics

M = Modbus RTU with Diagnostics

N = LonTalk with Diagnostics

11: Cabinet Options

0 = None

B = Access Door Windows

12: Vestibule Accessories

0 = None

A = Refrigerant Leak Detector

B = Motorized Service Vestibule Fresh Air

C = Vestibule Heating (Electric)

D = Vestibule Cooling (Fan/Coil)

F = Option A + B

G = Option A + C

12: Vestibule Accessories Continued

H = Option A + D

K = Option B + C

L = Option B + D

N = Option C + D

R = Option A + B + C

S = Option A + B + D

U = Option A + C + D

Y = Option B + C + D

3 = Option A + B + C + D

13: Maintenance Accessories

0 = None

A = 115VAC Convenience Outlet Factory Wired

B = 115VAC Convenience Outlet Field Wired

C = Service Lights

F = Option A + C

J = Option B + C

14: Option Boxes

0 = None

A = 2 ft Option Box

B = 4 ft Option Box

C = 6 ft Option Box

D = 8 ft Option Box

F = 10 ft Option Box

G = 12 ft Option Box

15: Code Options

0 = Standard ETL U.S.A. Listing

A = Chicago Code

B = ETL U.S.A. + Canada Listing

16: Shipping Splits

0 = One Piece Unit

A = Two Piece Unit

17: Air-Cooled Condenser Accessories

0 = None (No Air-Cooled Condenser)

H = Cond Coil Guards + 3Φ Condenser Fan Motor +

Fan Cycling (35°F) J = Cond Coil Guards + 3Φ Condenser Fan Motor +

VFD Condenser Fan Head Pressure Control (0°F) S = Cond. Coil Guards + Low Sound ECM Cond.

Fans – Head Pressure Control (0°F)



GE

N

MJR

EV

SIZ

E

SE

RIE

S

MN

RE

V

VL

T

A1

A2

A3

A4

A5

B1

B2

B3

B4

1

2

3A

3B

3C

3D

4A

4B

4C

4D

5A

5B

5C

5D

6

7

8A

8B

8C


9

10

A

10B

10C

10

D

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

A

26B

26

C

26

D

26E

26F

27

28

29

30

31

32

33

34

35

17

18: Evaporative-Condensed Chiller Accessories

0 = None (No Evaporative-Condenser)

A = No Sump Heat

B = Sump Heaters

19: Blank

0 = None

20: Blank

0 = None

21: Chiller Compression Tank

0 = None

A = AX-15V

B = AX-20V

C = AX-40V

D = AX-60V

E = AX-80V

F = AX-100V

G = AX-120V

H = AX-180V

J = AX-200V

K = AX-240V

L = AX-260V

M = AX-280V

22: Boiler Compression Tank

0 = None

23: Blank

0 = Standard

24: Chiller Accessories

0 = None

A = Glycol chiller

B = Air Separator

C = Thermometers & Pressure Gauges

D = Chemical Pot Feeder

E = Auto Glycol Feeder

F = Option A + B

G = Option A + C

H = Option A + D

J = Option A + E

K = Option B + C

L = Option B + D

24: Chiller Accessories Continued

M = Option B + E

N = Option C + D

P = Option C + E

Q = Option D + E

R = Option A + B + C

S = Option A + B + D

T = Option A + B + E

U = Option A + C + D

V = Option A + C + E

W = Option A + D + E

Y = Option B + C + D

Z = Option B + C + E

1 = Option B + D + E

2 = Option C + D + E

3 = Option A + B + C + D

4 = Option A + B + C + E

5 = Option A + B + D + E

6 = Option A + C + D + E

7 = Option B + C + D + E

8 = Option A + B + C + D + E

25: Blank

0 = Standard

26A: Blank

0 = Standard

26B: Blank

0 = Standard

26C: Blank

0 = Standard

26D: Blank

0 = Standard

26E: Blank

0 = Standard

26F: Blank

0 = Standard



GE

N

MJR

EV

SIZ

E

SE

RIE

S

MN

RE

V

VL

T

A1

A2

A3

A4

A5

B1

B2

B3

B4

1

2

3A

3B

3C

3D

4A

4B

4C

4D

5A

5B

5C

5D

6

7

8A

8B

8C


9

10

A

10B

10C

10

D

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

A

26B

26C

26

D

26E

26

F

27

28

29

30

31

32

33

34

35

18

27: Blank

0 = Standard

28: Blank

0 = Standard

29: Blank

0 = Standard

30: Blank

0 = Standard

31: Blank

0 = Standard

32: Blank

0 = Standard

33: Warranty

0 = Standard Warranty

D = Compressor Warranty Years 2-5

34: Cabinet Material

D = Galvanized Cabinet 6” Base Rail + Double Slope

Roof

H = Galvanized Cabinet 8” Base Rail + Double Slope

Roof

35: Paint & Special Pricing Authorizations

B = Premium AAON Gray Paint Exterior

E = Premium AAON Gray Paint Exterior + Shrink

Wrap

X = Special Pricing Authorization + Premium AAON

Gray Paint Exterior

1 = Option X + Shrink Wrap

4 = Special Pricing Authorization + Special Exterior

Paint Color

7 = Option 4 + Shrink Wrap

19

General Information

AAON LZ Series chiller outdoor mechanical

rooms are complete self-contained liquid

chilling units. They are assembled, wired,

charged, and run-tested. Models are available

for air-cooled and evaporative-condensed

applications. Chiller primary pumping

packages, primary/secondary pumping

packages, and boilers with pumping package

are available as optional features.

Codes and Ordinances

LZ Series units have been tested and

certified, by TL, in accordance with UL

Safety Standard 1995/CSA C22.2 No. 236.

System should be sized in accordance with

the American Society of Heating,

Refrigeration and Air Conditioning

Engineers Handbook.

Installation of LZ Series units must conform

to the ICC standards of the International

Mechanical Code, the International Building

Code, and local building, plumbing and

waste water codes. All appliances must be

electrically grounded in accordance with

local codes, or in the absence of local codes,

the current National Electric Code,

ANSI/NFPA 70 or the current Canadian

Electrical Code CSA C22.1.

Receiving Unit

When received, the unit should be checked

for damage that might have occurred in

transit. If damage is found it should be noted

on the carrier’s Freight Bill. A request for

inspection by carrier’s agent should be made

in writing at once. Nameplate should be

checked to ensure the correct model sizes and

voltages have been received to match the job

requirements.

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

RISK OF ELECTRICAL SHOCK

Electrical raceways are located in the upper wall sections of the unit. DO NOT CUT OR DRILL into the wall sections of the unit that are within 12 inches of the roofline.

WARNING

The Clean Air Act of 1990 bans the intentional venting of refrigerant as of July 1, 1992. Approved methods of recovery, recycling, or reclaiming must be followed.

CAUTION

Coils and sheet metal surfaces present sharp edges and care must be taken when working with equipment.

WARNING

Failure to observe the following instructions will result in premature failure of your system and possible voiding of the warranty.

WARNING

20

If repairs must be made to damaged goods,

then the factory should be notified before any

repair action is taken in order to protect the

warranty. Certain equipment alteration,

repair, and manipulation of equipment

without the manufacturer’s consent may void

the product warranty. Contact AAON

Technical Support for assistance with

handling damaged goods, repairs, and freight

claims: (918) 382-6450.

Storage

If installation will not occur immediately

following delivery, store equipment in a dry

protected area away from construction traffic

and in the proper orientation as marked on the

packaging with all internal packaging in

place. Leave all internal packaging in place

and secure all loose-shipped items.

Outdoor Mechanical Room

Failure to observe the following instructions

will result in premature failure of your

system, and possible voiding of the warranty.

Never turn off the main power supply to the

unit, except for complete shutdown. When

power is cut off from the unit, any

compressors equipped with crankcase heaters

cannot prevent refrigerant migration. This

means the compressor will cool down, and

liquid refrigerant may accumulate in the

compressor. The compressor is designed to

pump refrigerant gas and damage may occur

when power is restored if liquid enters the

compressor.

COMPRESSOR CYCLING

3 MINUTE MINIMUM OFF TIME To prevent motor overheating compressors must cycle off for a minimum of 3 minutes.

3 MINUTE MINIMUM ON TIME To maintain the proper oil level compressors must cycle on for a minimum of 3 minutes. The cycle rate must not exceed 6 starts per hour.

WARNING

Before unit operation, the main power switch must be turned on for at least 24 hours for units equipped with crankcase heaters.

CAUTION

Rotation must be checked on all MOTORS AND COMPRESSORS of three phase units. All motors, to include and not be limited to pump motors and condenser fan motors, should all be checked by a qualified service technician at startup and any wiring alteration should only be made at the unit power connection.

CAUTION

21

Always control the system from the building

management system, or control panel, never

at the main power supply (except for

emergency or for complete shutdown of the

system).

Scroll compressors must be on a minimum of

3 minutes and off for a minimum of 3

minutes. The cycle rate must be no more than

6 starts per hour.

The chiller is furnished with a flow switch

installed on the outlet of each heat exchanger.

This sensor must not be bypassed since it

provides a signal to the unit controller that

water flow is present in the heat exchanger

and the unit can operate without the danger of

freezing the liquid.

Compressor life will be seriously shortened

by reduced lubrication, and the pumping of

excessive amounts of liquid oil and

refrigerant.

Wiring Diagrams

A complete set of unit specific wiring

diagrams in both ladder and point-to-point

form are laminated in plastic and located

inside the control vestibule.

General Maintenance

When the initial startup is made and on a

periodic schedule during operation, it is

necessary to perform routine service checks

on the performance of the chiller and boiler.

This includes reading and recording suction

pressures and checking for normal sub-

cooling and superheat. See the evaporative-

condensed chiller and air-cooled chiller

sections in this manual for specific details.

Chiller Primary Pumping

Primary pumping uses a single pump to move

water (or glycol) through the chiller

evaporator and back to the building. This

pumping package provides a constant or

variable flow of water to the building. The

pump is activated whenever the chiller is

given a run signal.

Water enters the unit through the return water

piping, and then travels through an air

separator to remove any air that is entrapped

in the water. Following this, the water flows

through a suction guide with an integral

strainer. The end of the suction guide is

removable for strainer access. The strainer

assembly is composed of two parts, the

operational strainer and the startup strainer,

(located inside the operational strainer)

which is to be removed 24 hours after startup.

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 be made at the unit power connection.

CAUTION

FIELD WIRED CONNECTIONS

Some units may require field wired connections. Refer to the wiring diagrams contained within the unit to identify any components or controls requiring additional wiring in the field before placing the unit into service. All additional field wiring should be performed by a Factory Trained Service Technician.

CAUTION

22

The pump is installed after the suction guide,

and before a combination valve (Flo-Trex).

This combination valve acts as an isolation

valve, check valve, and flow balancing valve.

The evaporator is placed after the

combination valve in the water circuit, with a

flow switch installed at its inlet and outlet.

This flow switch closes when the velocity is

above 0.7 feet per second. The closing flow

switch signals the control system to indicate

flow through the heat exchanger and allow

cooling to activate as required to maintain the

setpoint. The water exiting the chiller

evaporator leaves the unit through the water

out connection.

Chiller Primary/Secondary Pumping

Primary/secondary pumping option provides

variable flow to the system. It consists of a

constant flow pump for the chiller heat

exchanger and a variable flow pump for the

building. The controls package senses

differential pressure across the pump with

pressure transducers installed at the suction

and discharge, and varies the speed of the

pump using a VFD in order to maintain a

given differential pressure across the pump.

The primary/secondary pumping package is

essentially composed of two piping loops

coupled together. The primary loop has a

constant flow rate in order to keep the chiller

heat exchanger from freezing, and the

secondary, variable flow loop, provides water

to the building. The two loops are coupled via

a water line that compensates for excess flow

in either loop. As the flow in the secondary

loop decreases below the flow in the primary

loop, excess flow bypasses the building loop

and circulates through the bypass water line.

On the other hand, as the flow in the

secondary loop increases above the flow in

the primary loop, excess flow bypasses the

chiller and circulates through the bypass

water line.

The secondary pump has its own suction

guide, combination valve, and isolation

valve, similar to the primary pump, with the

addition of an air separator to remove any air

that is entrapped in the water.

Condensing Boilers

AAON LZ chillers are available with factory

installed condensing boilers. All boiler

systems will include either fixed or variable

speed building pumps. All boiler building

pumps will be supplied with a suction guide

with a strainer and triple duty valve. The

suction guide contains both an operational

strainer and a startup strainer. The startup

strainer should be removed 24 hours after

startup. The triple duty valve functions as an

isolation valve, check valve, and flow

balancing valve.

The condensing boilers will be a water tube

design or a fire tube design. In a water-tube

boiler, the water flows through tubes with the

combustion products heating from the

outside. These boilers require a constant

water flow and will be provided with a

primary pump for each heat exchanger.

Some boilers have two heat exchangers and

will have two primary pumps. The primary

pump is controlled by the boiler and will only

come on when it has a call for heat. Water-

tube boilers are provided with flow switches,

which must make before the boiler can

operate.

In fire-tube boilers water flows through a

tank, with the combustion products inside

tubes. These boilers are capable of

significant water flow turn-down and do not

require individual primary pumps. A control

valve, operate by the boiler controls, is

provided with each boiler. A water flow

switch is not required with fire-tube boilers.

A low-level cutoff switch is used which will

prevent the boiler from operating when there

is not a sufficient water level present. Upon

23

initial startup, the boiler may have to be

cycled several times to generate an adequate

water level.

Makeup Water

A 3/4” FPT city make up water connection is

provided to replace water that is lost from the

system.

Glycol units require a glycol feeder (optional

factory installed or field installed) to replace

fluid that is lost in the system. Water should

not be directly added to glycol applications as

this would dilute the glycol concentration and

thereby increase the freezing temperature of

the fluid.

The makeup water connection is provided

with a backflow preventer that has isolation

valves on the inlet and outlet for service.

Figure 1 shows the pressure drop versus flow

rate for the backflow preventer.

Figure 1 - Backflow Preventer

There is a pressure-reducing valve after the

backflow preventer. This valve reduces the

city water pressure to maintain the operating

pressure of the system. This valve is

adjustable from 10-35 psig with a factory

setting of 30 psig. The system pressure varies

with the height of the system. The pressure-

reducing valve setting should be set so that

the pressure at the high point in the system is

high enough to vent air from the system

(usually 4 psig). There should be air vents at

all parts in the system where air could be

trapped. If the pressure is not high enough

throughout the system, flashing could occur

in the piping or the pump could cavitate.

There is an isolation valve on the inlet and

outlet of the pressure-reducing valve for

service.

The pressure reducing valve fills the system

at a reduced rate. There is a bypass around the

pressure reducing valve for the initial fill of

the system to increase the initial fill speed.

After the initial system fill, this valve should

be closed.

Compression Tank

As the water temperature in the system

increases, the volume that water displaces

increases. In order to compensate for these

expansion forces, a compression or

expansion tank must be used. The factory

installed tank option includes a pre-

pressurized diaphragm compression tank that

is preset for 12 psig.

The factory pre-charge pressure may need to

be field adjusted. The tank must be pre-

charged to system design fill pressure before

placing into operation. Remove the pipe plug

covering the valve enclosure. Check and

adjust the charge pressure by adding or

releasing air.

If the system has been filled, the tank must be

isolated from the system and the tank emptied

before charging. This ensures that all fluid

has exited the diaphragm area and proper

charging will occur.

If the pre-charge adjustment is necessary, oil

and water free compressed air or nitrogen gas

may be used. Check the pre-charge using an

accurate pressure gauge at the charging valve

and adjust as required. Check air valve for

leakage. If evident, replace the Schrader

valve core. Do not depend on the valve cap to

seal the leak. After making sure the air charge

24

is correct, replace the pipe plug over the

charging valve for protection.

Purge air from system before placing tank

into operation. All models have system water

contained behind the diaphragm.

It is recommended that the pre-charge be

checked annually to ensure proper system

protection and long life for the vessel.

Pressure Relief Valve

Required pressure relief valve is installed in

the unit. This valve is set at 125 psig. Figure

2 shows inlet pressure versus capacity for this

pressure relief valve. See appendix for

additional information.

Figure 2 - Pressure Relief Valve

Automatic Air Vent

There is an automatic air vent installed at the

high point of the system inside the pumping

package compartment. The air vent valve

must be in the proper position for operation.

Ensure that the small vent cap is loosened two

turns from the closed position, allowing air to

be vented from the system. It is advisable to

leave the cap on to prevent impurities from

entering the valve. See appendix for

additional information.

Dual Pumps

When redundant pumping is required, factory

installed dual pumps or two single pumps can

be ordered. A dual pump is a pump with two

independent motors and impellors in a single

casing. This dual pump has a swing split-

flapper valve in the discharge port to prevent

liquid recirculation when only one pump is

operating. Isolation valves in the casing allow

one pump to be isolated and removed for

service while the other pump is still

operating.

When redundant pumping is required with

high flow rates, two independent pumps may

be installed in parallel. Each pump will have

its own suction guide/strainer, combination

valve, and isolation valves.

The controls package will activate the pump

when the unit is given a run command. If the

controls do not recognize flow in 60 seconds

(factory default), the second pump will be

activated and an alarm signal will be

generated. If the second pump does not

activate, the cooling will be locked out. See

Appendix - Water Piping Component

Information for additional information.

Pressure Gauges and Thermometers

Pressure gauges and thermometers are

available as a factory installed option.

Thermometers are installed on the inlet and

outlet of the unit. One pressure gauge is

installed at each pump. This pressure gauge

is connected in three places to the water

piping before the suction guide/strainer, after

the suction guide and before the pump, and

after the pump. There is also a valve at each

of these points to isolate the pressure. To

measure the pressure at any given point, open

the valve at that point and close the other two

valves. One gauge is used so that the

calibration of the pressure gauge is irrelevant

in the calculation of the differential pressure.

25

Pipe Insulation

The water piping and components on units

with pumping packages are not insulated at

the factory. Insulation should be installed on

the water piping after the system has been

checked for leaks.

Installation

Outdoor Mechanical Room Placement

The AAON LZ Series is designed for outdoor

applications and can be mounted at ground

level or on a rooftop. It must be placed on a

level and solid foundation that has been

prepared to support its weight.

The placement relative to the building air

intakes and other structures must be carefully

selected. Be sure to observe the dimensions

that are on the rating plate of the chiller for

operational and service clearances.

Table 1 - Service Clearances

Location Unit Size

45-540 tons

Left 96”

Right

Compressor End 72”

Chiller HXC End

Top Unobstructed

Condenser coils and fans must be free of any

obstructions in order to start and operate

properly with a correct amount of airflow.

For proper unit operation, the immediate area

around condenser(s) must remain free of

debris that may be drawn in and obstruct

airflow in the condensing section.

Consideration must be given to obstruction

caused by snow accumulation when placing

the unit.

Curb and Steel Mount Installation

Make openings in the roof decking large

enough to allow for water piping, electrical,

and gas penetrations and workspace only. Do

not make openings larger than necessary. Set

the curb to coincide with the openings. Make

sure curb is level.

If an LZ with air-cooled condenser is

installed on a curb, use a curb cap for the

open area under the condenser section.

Unit specific curb drawing is included with

job submittal. See SMACNA Architectural

Sheet Metal Manual for curb installation

details.

When installed at ground level, a one-piece

concrete slab should be used with footings

that extend below the frost line. Care must

also be taken to protect the coil and fins from

damage due to vandalism or other causes.

If unit is elevated a field supplied catwalk is

recommended to allow access to unit service

doors.

This unit ships with a curb gasket that is 1¼”

wide and 1½” tall. It is recommended that this

or another similar gasket be used between the

curb and the unit to reduce vibration

transmission from the unit to the building.

All roofing work should be performed by competent roofing contractors to avoid any possible leakage.

CAUTION

26

Figure 3 - Curb Mounting with Dimensions

Figure 4 - Curb End Detail

Figure 5 - Steel Mounting Rail with Dimensions

27

Figure 6 - Concrete Pad Mounting with Dimensions

Figure 7 - LZ Base

28

Lifting and Handling

If cables or chains are used to hoist the unit

they must be the same length and care should

be taken to prevent damage to the cabinet.

See Figure 9 for additional information.

Before lifting unit, be sure that all shipping

material has been removed from unit. If the

unit is an evaporative-condensed chiller,

make sure the tank is empty before lifting.

Secure hooks and cables at all lifting points/

lugs provided on the unit.

Hoist unit to a point directly above the curb

or mounting rail. Be sure that the gasket

material has been applied to the curb or

mounting rail.

Carefully lower and align unit with utility

openings. Lower the unit until the unit skirt

fits around the curb. Make sure the unit is

properly seated on the curb and is level.

Do not push, pull or lift the unit from

anything other than its base.

Figure 8 - Lifting Points

29

Figure 9 - LZ Series Example Lifting Detail

Lifting slot locations are unit specific.

Unit must be rigged at all marked lifting points.

Vestibule Exhaust Fan

Prior to unit operation of units with service

vestibules the exhaust fan shipping support

must be removed from the exterior of the unit

The exhaust fan also includes a factory

provide exterior rain hood which must be

installed.

Figure 10 - Vestibule Exhaust Fan

30

Water Connection

Remove the shipping cover from the water

connection cutout in the post. Connect the

supply and return water lines. The standard

water connection is grooved end pipe. The

connection size is listed on the unit rating

sheet along with the designed volumetric

flow rate. The maximum operating pressure

for AAON LZ Series unit is 125 psi. Install

the flashing provided by AAON according to

the steps in Figure 11. Finished water

connection will be water tight.

Figure 11 - Water Pipe Flashing Installation

The chiller must be operated only with liquid flowing through the evaporators.

WARNING

Boilers must be operated only with liquid flowing through the boiler.

WARNING

PVC (Polyvinyl Chloride) and CPVC (Chlorinated Polyvinyl Chloride) are vulnerable to attack by certain chemicals. Polyolester (POE) oils used with R-410A and other refrigerants, even in trace amounts, in a PVC or CPVC piping system will result in stress cracking of the piping and fittings. This will result in complete piping system failure.

CAUTION

Installing Contractor is responsible for proper sealing of the water piping and electrical entries into the unit Failure to seal the entries may result in damage to the unit and property.

CAUTION

31

Temporary Drain – Evaporative

Condenser

The evaporative condenser design allows

rainwater to enter the sump tank during

transportation. AAON provides a temporary

drain system while the unit is in transit. The

temporary drain consist of an adapter that

will connect a hose from the sump drain to

the base drain. This temporary drain must be

replaced by permanent draining piping once

on site.

Figure 12 – Temporary Drain Components

Once the unit is ready for the permanent

draining, close the valve and remove the

temporary draining system. The components

that must be removed are those with number

callouts in Figure 12. The drain connection

for the permanent draining is 2” FPT.

Access Doors

Lockable access doors are provided to the

compressor and control compartment. A

light switch is provided on the wall of the

compressor and control compartment.

A separate access door is also provided to the

evaporator and pumping package

compartment. See Figure 36 for information

on leak checking these doors.

End Flashing Installation

On all LZ Series units the cabinet width will

overhang the shipping trailer on each side.

In order to secure and protect the unit during

transit the sheet metal end flashings have

been removed from the unit. The slot created

at the base of each end of the unit allows the

unit to set firmly on the trailer deck.

Sheet metal flashings are shipped loose with

the unit and once the unit is set into place the

flashings must be installed on each end of the

unit to complete the finished seal at the base.

The flashings are unit specific and designed

to cover the slot at each end of the unit to

prevent water run-off into the curb.

Failure to attach and seal the end of unit with

the flashings may result in water leakage into

the curb.

Figure 13 - Factory Supplied End Flashings

In order to prevent water leakage into the roof curb, the factory provided sheet metal flashings MUST BE attached to the unit base to cover the shipping slots at both ends of the unit.

CAUTION

32

Boiler Gas Connection Before making gas connection, make sure the

boiler is being supplied with the type of fuel

shown on the boiler nameplate.

Table 2 and Table 3 show the gas connection

size and type (NPT or flanged) provided

along with the required inlet gas pressure for

the unit. Refer to feature B on the LZ Series

unit feature string to determine which line of

the table to use. For example, a unit with

feature B = A3CC will have a 2” NPT gas

connection and require an inlet gas pressure

in the range of 6-14” W.C.

Use only pipe sealing compound that is

compatible with propane gases on all

threaded connections. Apply sparingly only

to the male threads of the pipe joints so that

the pipe sealing compound does not block

any gas flow.

Before being placed in operation, the boiler

and all gas piping connections must be

checked for leaks. The boiler must be

disconnected from the gas supply piping

system during any pressure testing of the

system at pressures in excess of .5 psig (14”

W.C.). The boiler must be isolated from the

gas supply piping system by closing the

manual shutoff valve during any pressure

testing of the system at pressures equal to or

less than .5 psig (14” W.C.).

Some leak test solutions, including soap and

water, may cause corrosion. These solutions

should be rinsed off with water after testing.

Boiler Air Intake / Vent Piping Each boiler requires the installation of air

intake and vent piping. This piping has been

removed for shipping purposes. All piping

must be reinstalled according to the

instructions provided in this section prior to

boiler operation.

All boilers must be vented and supplied with

combustion and ventilation air as described

in this section and in the Lochinvar

Installation & Operation Manual included

with the boiler. Ensure the vent and air

piping and combustion air supply comply

with instructions regarding vent system, air

system, and combustion air quality.

Inspect finished vent and air intake piping

thoroughly to ensure all are airtight and

comply with the instructions provided and

with all requirements of applicable codes.

Failure to apply sealing compound as detailed can result in property damage, personal injury, or death.

WARNING

DO NOT use matches, candles, open flames, or other ignition sources to check for gas leaks. Use only approved leak detection methods. Failure to comply with this warning can result in property damage, personal injury, or death.

WARNING

Failure to provide a properly installed vent and air system can result in property damage, personal injury, or death.

WARNING

33

Table 2 - Unit Gas Pipe Information, Feature B4 = A-J

Heating Feature Boiler

Inlet Gas

Pressure

Gas Header

B1 B2 B3 B4 Size Qty

Input

Capacity

(CFH)

Pipe

Size

Conn.

Type

A 1 C or D A

KBN400

1 400 6-14” W.C. 1 NPT

A 2 C or D A 2 800 6-14” W.C. 1 1/2 NPT

A 3 C or D A 3 1,200 6-14” W.C. 2 NPT

A 4 C or D A 4 1,600 6-14” W.C. 2 NPT

A 1 C or D B

KBN501

1 500 6-14” W.C. 1 1/2 NPT

A 2 C or D B 2 1,000 6-14” W.C. 1 1/2 NPT

A 3 C or D B 3 1,500 6-14” W.C. 2 NPT

A 4 C or D B 4 2,000 6-14” W.C. 2 NPT

A 1 C or D C

KBN601

1 600 6-14” W.C. 1 1/2 NPT

A 2 C or D C 2 1,200 6-14” W.C. 2 NPT

A 3 C or D C 3 1,800 6-14” W.C. 2 NPT

A 4 C or D C 4 2,400 2-5 psi 2 NPT

A 1 C or D D

KBN701

1 700 6-14” W.C. 1 1/2 NPT

A 2 C or D D 2 1,400 6-14” W.C. 2 NPT

A 3 C or D D 3 2,100 2-5 psi 2 NPT

A 4 C or D D 4 2,800 2-5 psi 2 NPT

A 1 C or D F

KBN801

1 800 6-14” W.C. 1 1/2 NPT

A 2 C or D F 2 1,600 6-14” W.C. 2 NPT

A 3 C or D F 3 2,400 2-5 psi 2 NPT

A 4 C or D F 4 3,200 2-5 psi 2 NPT

A 1 C or D G

SBN1000

1 1,000 6-14” W.C. 1 1/2 NPT

A 2 C or D G 2 2,000 2-5 psi 2 NPT

A 3 C or D G 3 3,000 2-5 psi 2 NPT

A 4 C or D G 4 4,000 2-5 psi 2 NPT

A 1 C or D H

SBN1300

1 1,300 6-14” W.C. 2 NPT

A 2 C or D H 2 2,600 2-5 psi 2 NPT

A 3 C or D H 3 3,900 2-5 psi 2 NPT

A 4 C or D H 4 5,400 2-5 psi 2 NPT

A 1 C or D J

SBN1500

1 1,500 6-14” W.C. 2 NPT

A 2 C or D J 2 3,000 2-5 psi 2 NPT

A 3 C or D J 3 4,500 2-5 psi 2 NPT

A 4 C or D J 4 6,000 2-5 psi 2 NPT

34

Table 3 - Unit Gas Pipe Information, Feature B4 = K-N

Heating Feature Boiler

Inlet Gas

Pressure

Gas Header

B1 B2 B3 B4 Size Qty

Input

Capacity

(CFH)

Pipe

Size

Conn.

Type

A 1 C or

D K

FBN2000

1 2,000 2-5 psi 1 1/2 NPT

A 2 C or

D K 2 4,000 2-5 psi 2 NPT

A 3 C or

D K 3 6,000 2-5 psi 2 NPT

A 4 C or

D K 4 8,000 2-5 psi 3 Flange

A 1 C or

D L

FBN2500

1 2,500 2-5 psi 1 1/2 NPT

A 2 C or

D L 2 5,000 2-5 psi 2 NPT

A 3 C or

D L 3 7,500 2-5 psi 3 Flange

A 4 C or

D L 4 10,000 2-5 psi 3 Flange

A 1 C or

D M

FBN3000

1 3,000 2-5 psi 1 1/2 NPT

A 2 C or

D M 2 6,000 2-5 psi 2 NPT

A 3 C or

D M 3 9,000 2-5 psi 3 Flange

A 4 C or

D M 4 12,000 2-5 psi 3 Flange

A 1 C or

D N

FBN3500

1 3,500 2-5 psi 2 NPT

A 2 C or

D N 2 7,000 2-5 psi 3 Flange

A 3 C or

D N 3 10,500 2-5 psi 3 Flange

A 4 C or

D N 4 14,000 2-5 psi 3 Flange

35

Sidewall Direct Boiler Venting

For units with Lochinvar Knight XL and

SYNC boilers (feature B4 = A, B, C, D, E, F,

G, H, or K), the air intake and vent piping

runs from each boiler through the sidewall of

the unit into the supplied sidewall vent

termination.

1. On the sidewall above the boiler access

door, remove the shipping cover and attach

the sidewall vent plate shipped with the unit.

Figure 14 - Sidewall Vent Shipping Cover

Removal

Figure 15 - Sidewall Vent Plate Installation

2. Attach air intake piping to the air inlet

connector on the boiler at one end and run

through the sidewall of the unit at the other

end. All air intake pipes and fittings are

PVC.

Figure 16 - Typical Air Intake Piping

Use only primer and cement approved for use with PVC (ANSI/ASTM D2564).

WARNING

36

Figure 17 - Typical Flue Vent Piping

37

3. Attach vent piping to the flue pipe adapter

on the boiler at one end and run through the

sidewall of the unit at the other end. All Vent

pipes and fittings are CPVC. Vent piping

must be pitched at a minimum of 1/4 inch per

foot back to the boiler.

4. Install the vent and air intake piping

through the wall into the sidewall vent base.

Use RTV silicone sealant to seal the air

intake pipe. Mount and secure the sidewall

vent base using stainless steel screws. Seal

all gaps between the pipes and the sidewall.

Seal around the sidewall vent base to the wall

ensuring no air gaps.

5. Assemble vent cap to vent base and

securely attach using stainless steel screws.

Figure 18 - Sidewall Vent Base

Figure 19 - Sidewall Vent Cap

Vertical Direct Boiler Venting

For units with Lochinvar Crest boilers

(feature B4 = K, L, M, or N), the air intake

and vent piping is installed to run vertically

through the roof of the unit.

1. Remove shipping covers from openings in

the roof.

Figure 20 - Roof Air Intake and Vent Piping

Shipping Covers

Use only primer and cement approved for use with CPVC (ANSI/ASTM F493).

WARNING

38

2. Attach air intake piping to the air inlet

connector on the boiler and run vertically

through the roof of the unit. The air intake

pipes and fittings will either be all PVC or all

stainless steel components.

Figure 21 - Typical Vertical Air Intake Piping

For units with PVC piping, use only primer and cement approved for use with PVC (ANSI/ASTM D2564).

WARNING

JOINT CONNECTIONS The female end of each component incorporates a sealing gasket and a mechanical locking bond. Examine all components prior to installation. Gaskets must be in proper position to prevent leakage.

CAUTION

For units with stainless steel piping, all components must be installed in accordance with the manufacturer’s instructions to ensure all joints are secure and sealed correctly.

WARNING

39

3. Insert the male end into the female section.

Push the units together and turn them until

half of the bead on the male end is c

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