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AAON V3 Series 450-10,000 Vertical Indoor Packaged Rooftop Yearly Maintenance

The AAON V3 Series 450-10,000 Vertical Indoor Packaged Rooftop Yearly Maintenance is a routine service check that ensures the quality of performance of your machine.

MaintainX

04/26/2021

AAON V3 Series 450-10,000 Vertical Indoor Packaged Rooftop Yearly Maintenance

The AAON V3 Series 450-10,000 Vertical Indoor Packaged Rooftop Yearly Maintenance is a routine service check that ensures the quality of performance of your machine.

At least once each year, a qualified service technician should check out the unit. Supply fans, evaporator coils and air filters should be inspected monthly.

WARNING! Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Installation and service must be performed by a qualified installer. A copy of this IOM should be kept with the unit

Periodically during operation, it is necessary to perform routine service checks on the performance of the unit. This includes checking of the air flow, the air filters, condenser water flow and refrigerant charge.

See Startup section for information on air flow adjustment and refrigerant charge adjustment

DX Cooling

Set unit controls to cooling mode of operation with supply fans on.

Check the fans for correct operating direction, amperage and voltage.

Condensate Drain Pans

Drain pans will have moisture present and require periodic cleaning to prevent microbial growth.

Cleaning of the drain pans will also prevent any possible plugging of the drain lines and overflow of the pan itself

Cleaning of the drain pans and inside of the unit should be done only by qualified personnel.

Gas Heating

WARNING! Once a year, before the unit is in operation for the heating season, a qualified service technician should inspect all flue product carrying areas of the furnace and main burners for continued safe operation

DANGER! LEAK CHECK GAS PIPE The gas pipe in the unit should be checked for leaks before startup. Leak checking is the responsibility of the installing contractor. All connections should be checked for leaks annually after installation. Failure to leak che

Make sure all gas supply lines have been purged of air before turning on the electrical power switch.

Turn the gas valve to the on position (see startup instructions). Turn the main electrical power on and set the controls to the heating mode of operation.

The combustion ventilation motor should operate. The control will automatically supply energy to the igniter and the gas valve after the heating call is made.

The flame sensing probe detects the presence of the flame. Should no flame be detected in 10 seconds, the ignition system will recycle. If no flame is detected after 3 tries, ignition system will lockout.

Remove the call for heating. The main gas valves should be extinguished.

The supply fans are controlled by the ignition system. In the fan “Auto” mode the fan comes on 45 seconds after the flame is proved and goes off 120 seconds after the heating call is removed.

Furnace combustion ventilation air and flue openings should be checked annually for debris and obstructions. If flue vent extensions are used they must meet category IV requirements.

This appliance contains a wire screen at the flue vent outlet. Each heating season, prior to placing the appliance in heat mode maintenance check that no debris or foreign matter has accumulated in the flue vent outlet. A good practice is to check for deb

In the event the flue vent outlet becomes blocked do not attempt to start the appliance in heat mode until the entire vent opening is cleared.

In the event the unit shut down because the flue vent was blocked a qualified technician or service agency should monitor the unit prior to re-starting.

The gas burner and heat exchanger should never require cleaning. If cleaning is necessary, this indicates faulty operation of the unit.

Cleaning should only be done by a qualified service agency and only after consultation with an AAON service representative.

If induced draft blower/motor assembly has to be replaced, care must be taken to provide an airtight seal between the blower housing and the burner box.

Furnace Maintenance

WARNING! Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Startup and service must be performed by a Factory Trained Service Technician. A copy of this IOM should be kept wit

WARNING! Disconnect all electrical power sources before servicing the unit. More than one power source may be provided. Failure to do so may result in injury or death from electrical shock or entanglement in moving parts.

CAUTION! If any original wiring needs to be replaced it must be replaced with wiring materials suitable for 105ºC. Label all wires prior to disconnection when servicing unit. Wiring errors can cause improper or dangerous operation. Verify proper operation

Condensate Drainage System Inspection

Inspect condensate drain lines to be sure they are free of debris and free flowing.

Inspect all condensate lines for freezing and verify operation of freeze protection (heat trace tape). The factory installed section of the condensate line includes a heat trace. All field installed condensate lines must also include heat trace.

Inspect and clean out all waterless p-traps of condensate/ mildew buildup.

Inspect and replace the condensate neutralizer cartridge if necessary.

Furnace Exhaust Vent Termination

Inspect all flue exhaust vent terminations/outlets. Remove any ice accumulation. Ice accumulation can affect performance and operation of the furnace.

Inspect the roof floor in front and/or below any flue exhaust termination and furnace access door. Remove any ice accumulation.

Furnace Inspection

Turn off all electrical power to the unit before inspection and servicing.

The furnace should be inspected annually by a qualified service agency. Check condition and determine.

burners

heat exchanger

draft inducer

vent system

operating controls

wiring should be determined

Check for obvious signs of deterioration, accumulation of dirt and debris and any heat or water related damage. Any damaged or deteriorated parts should be replaced before the unit is put back into service.

Clean draft inducer and vent ducts with a soft brush or vacuum.

Check Heat Exchanger for cracks. If any are present, replace heat exchanger before putting unit back into service.

Check the attachment point of the furnace to the cabinet or ducts to verify that they are air tight.

Check the automatic gas valve to insure that the gas valve seat is not leaking.

Inspect and clean condensate drain trap(s).

If condensate neutralizer tube is installed, recharge per instructions.

Inspect and clean secondary coil fins.

Check wiring connections to be sure they are secure and inspect wiring for any deterioration.

Label all wires prior to disconnection when servicing unit. Wiring errors can cause improper or dangerous operation. Verify proper operation after servicing

Furnace Operation Check

Turn on power to the unit and set thermostat or heat controller to call for heat, allowing furnace to operate.

Check for proper start-up and ignition as outlined in Start-Up section.

Check the appearance of the burner flame.

Check that the circulating air fan is operating and verify the proper airflow through furnace.

Verify proper flow of condensate from drain system.

Return thermostat or heat controller to normal setting

E-Coated Coil Cleaning

Documented quarterly cleaning of e-coated coils is required to maintain coating warranty coverage. E-Coated Coil Maintenance Record document is available on the AAON website.

WARNING! Electric shock hazard. Shut off all electrical power to the unit to avoid shock hazard or injury from rotating parts

Surface loaded fibers or dirt should be removed prior to water rinse to prevent restriction of airflow.

If unable to back wash the side of the coil opposite of the coils entering air side, then surface loaded fibers or dirt should be removed with a vacuum cleaner.

If a vacuum cleaner is not available, a soft non-metallic bristle brush may be used. In either case, the tool should be applied in the direction of the fins. Coil surfaces can be easily damaged (fin edges bent over) if the tool is applied across the fins

Use of a water stream, such as a garden hose, against a surface loaded coil will drive the fibers, dirt and salts into the coil. This will make cleaning efforts more difficult. Surface loaded fibers must be completely removed prior to using low velocity c

Quarterly cleaning is required to maintain warranty coverage and is essential to maintain the life of an E-coated coil. Coil cleaning shall be part of the unit's regularly scheduled maintenance procedures.

Failure to clean an E-coated coil on the prescribed quarterly cycle will void the warranty and may result in reduced efficiency and durability in the environment.

A routine two-step quarterly coil cleaning is required to maintain warranty.

Step one is to clean the coil with the below approved coil cleaner (see approved products list under the "Recommended Coil Cleaners” section.

Step two is to use the approved salt/chloride remover under the "Recommended Chloride Remover” section to dissolve soluble salts and revitalize the unit. It is very important when cleaning and/or rinsing not to exceed 130°F and potable water pressure is l

CAUTION! High velocity water from a pressure washer or compressed air should only be used at a very low pressure to prevent fin and/or coil damages. The force of the water or air jet may bend the fin edges and increase airside pressure drop. Reduced unit

Failure to clean anE-coated coil will void the warranty and may result in reduced efficiency and durability.

CAUTION! Harsh chemicals, household bleach, or acid cleaners should not be used to clean outdoor or indoor e-coated coils. These cleaners can be very difficult to rinse out of the coil and can accelerate corrosion and attack the E-coating. If there is dir

For routine quarterly cleaning, first clean the coil with the below approved coil cleaner. After cleaning the coils with the approved cleaning agent, use the approved chloride remover to remove soluble salts and revitalize the unit.

Recommended Coil Cleaner – Step 1

GulfCoatTM Coil Cleaner, assuming it is used in accordance with the manufacturer's directions on the container for proper mixing and cleaning, has been approved for use on E-coated coils to remove mold, mildew, dust, soot, greasy residue, lint and other p

Recommended Chloride Remover – Step 2

CHLOR*RID® Concentrate, assuming it is used in accordance with the manufacturer's directions on the container for proper mixing, has been approved for use on E-coated coils to remove chlorides/salts & sulfates. Never use any chloride removers that are not

Warranty Protection – Step 1

Complete the coil cleaning following these steps:

Ensure that the power to the unit is off and locked out

Clean the area around the unit if needed to ensure leaves, grass or loose debris will not be blown into the coil.

Remove panels or tops as required gaining access to the coil(s) to be cleaned.

Using a pump up sprayer, fill to the appropriate level with potable water and add the correct amount of approved cleaner as per manufacture instructions leaving room for the pump plunger to be reinserted.

NOTE: Coils should always be cleaned / back flushed, opposite of airflow to prevent impacting the dirt into the coil.

If the coils have heavy dirt, fibers, grass, leaves etc. on the interior or exterior face areas, a vacuum and brush should be used to remove those surface contaminants prior to applying cleaner. The interior floor, drain tray or pan areas should also be v

Apply the mixed cleaner to coil surfaces using a pressurized pump up sprayer maintaining a good rate of pressure and at a medium size nozzle spray, (not a solid stream and not a wide fan but somewhere in the middle). Work in sections/panels ensuring that

Apply the cleaner to unit interior air exiting side coil surfaces first. Work in sections/panels moving side to side and from top to bottom.

Using pressurized potable water, (<100 psi), rinse the coils and continue to always work in sections/panels. Start at the top of the coil and slowly move vertically downward to the bottom. Then, staying in the same vertical area, slowly move back up to th

Now move over slightly overlapping the area just completed and repeat above. Continue until all coil areas on the inside of the unit have been rinsed

Complete steps 5-9 for the exterior air entering side of the coils.

Final rinse – Now complete a quick rinse of both sides of the coil including the headers, piping, ubends and hairpins.

If the coil has a drain pan or unit floor that is holding rinse water or cleaner, extra time and attention will need to be taken in those areas to ensure a proper rinse has been completed.

Warranty Protection – Step 2

Complete the coil chloride (salt) removal following these steps:

CHLORRID® is a concentrate to be used for both normal inland applications at a 100:1 mix ratio OR for severe coastal applications 50:1 mix ratio with potable water, (2.56 ounces of Chlorrid to 1 gal of water).

Using a pump up sprayer, fill to the appropriate level with potable water and add the correct amount of CHLOR*RID® salt remover leaving room for the pump plunger to be reinserted.

Apply CHLOR*RID® to all external coil surfaces using a pressurized pump up sprayer maintaining a good rate of pressure and at a medium size nozzle spray, (not a solid stream and not a wide fan but somewhere in the middle). Work in sections/panels ensuring

Generously soak coils by spraying CHLOR*RID® directly on and into the fin pack section. Let stand for 5 to 10 minutes keeping the area wetted. Do not allow to dry before rinsing

Using pressurized potable water, (<100 psi), rinse the CHLOR*RID® and dissolved chlorides/salts off of the coils continuing to always work in sections/panels.

Starting at the top of the coil, begin rinsing the coil from side to side until you reach the bottom. Repeat as many times as is necessary to ensure all coil sections/panels have been completed and are thoroughly rinsed.

Reinstall all panels and tops that were removed.

Winterizing Coils

In some cases it may be necessary to winterize water coils to prevent them from freezing.

First completely drain the coils. There is a drain located below the ‘water in’ connection and a vent connection located above the ‘water out’ connection.

Auxiliary drain piping can also be added to exterior water piping if yearly winterizing is necessary.

After the coil is drained, fill with an antifreeze solution using a circulating pump. Then thoroughly drain.

Supply Fans

CAUTION! Blower wheels must be inspected for excessive dust build up periodically and cleaned if required. Excessive dust build up on blower wheels may cause an unbalanced state; leading to vibration and/or component failure. Damages due to excessive dust

WARNING! Electric shock hazard. Shut off all electrical power to the unit to avoid shock hazard or injury from rotating parts.

Phase and Brownout Protection Module

The DPM is a Digital Phase Monitor that monitors line voltages from 200VAC to 240VAC 1ɸ and 200VAC to 600VAC 3ɸ. The DPM is 50/60 Hz self-sensing. DPM should be wired according to unit specific wiring diagram include in the control compartment

When the DPM is connected to the line voltage, it will monitor the line and if everything is within the setup parameters, the output contacts will be activated. If the line voltages fall outside the setup parameters, the output relay will be de-energized

Once the line voltages recover, the DPM will re-energize the output relay after the restart time delay. All settings and the last 4 faults are retained, even if there is a complete loss of power.

DPM Setup Procedure

With the supply voltage active to the module, you can setup all of the DPM’s settings without the line voltage connected.

To change the setpoint parameters use the right arrow key to advance forward through the setpoint parameters and the left arrow to backup if needed. When each parameter is displayed use the up/down keys to change and set the parameter.

After adjustments are made or if no adjustments are made it will take 2 to 4 minutes before the DPM energizes the output relay unless there is an out of tolerance issue with the incoming line voltage.

Default Set-up

Line Voltage 460VAC, 3Ø

Over & Undervoltage ±10%

Trip Time Delay 5 Seconds

Re-Start Time Delay 2 Minutes

Phase Imbalance 5%

Source: Aaon

Please note that any procedure, checklist, or other document available in the MaintainX Global Procedure Library is provided for general education and information only and does not constitute legal, medical, or financial advice. MaintainX makes the materials available AS IS and AS PROVIDED, without warranties of any kind. By downloading or using any such materials, you assume the risk that they may not be appropriate for your specific situation and agree that you are solely responsible for any such use, including compliance with applicable law and with meeting any conditions of product warranties.

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