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AAON RQ Series Indirect Fired Heat Pump Yearly Maintenance

The AAON RQ Series Indirect Fired Heat Pump Yearly Maintenance is a standard procedure that checks the operation quality of the machines components. Be sure to follow the safety steps provided to avoid any accidents.

MaintainX

04/26/2021

AAON RQ Series Indirect Fired Heat Pump Yearly Maintenance

At least once each year, a trained, qualified service technician should check out the unit. Fans, evaporator coils, and filters should be inspected at least monthly.

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 vent extensions are used they must meet category III requirements.

This appliance contains a wire screen at the 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 vent outlet.

A good practice is to check for debris each time the air filters are changed.

In the event the 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 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.

Gas Heat Exchanger Removal

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

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

Removal

Disconnect all wiring on the heat exchanger.

Disconnect flex gas lines and pull out of the way.

Remove screws around the perimeter of the heat exchanger face plate that connect it to the unit. Only the outermost screws should be removed.

Pull the heat exchanger straight back and out of the unit. It may be necessary to remove some of the control door jambs.

Reinstallation

Ensure that the neoprene isolator is installed around the perimeter of the heat exchanger.

Insert heat exchanger into opening so that the back of the main plate is against the unit bulkhead.

Figure 29 - Gas Heat Exchanger

Attach the heat exchanger to the bulkhead using the holes around the perimeter.

Connect flex gas lines to the piping on the heat exchanger. If flexible gas piping in the unit must be replaced connectors cannot be reused, only new connectors must be used.

Connect wiring per the wiring diagram on the controls compartment door. Purge gas lines to the gas valves at the unit

DX Cooling

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

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

Check compressor operation, rotation, amperage and voltage to the unit nameplate (check the amperage on the load side of the compressor contactor).

Condenser Fan

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

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.

Removal

Take off the fan grill by removing the screws that attach it to the top of the unit.

Disconnect the wiring from the motor and loosen the bolt that clamps the motor mount to the motor.

Remove the motor and fan through the top of the orifice.

Figure 30 - Removal of a Condenser Fan Assembly

Reinstallation

Set the motor back into the motor mount and tighten bolt. Adjust fan until the top of the blade is even with the top of the orifice.

Reconnect wires, then attach the fan grill at all the points where screws were removed.

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 service technician.

Evaporator Coil

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

Removal

Evacuate refrigerant from the systems.

Remove the TXV bulbs from the suction lines. Disconnect the suction and liquid line copper connections to the evaporator coil.

Figure 31 - Evaporator Coil Access

Remove screws attaching filter rack to the evaporation coil at the front and back of the coil. It may be necessary to remove the economizer assembly (if equipped) to access the screws at the back.

Slide the evaporator coil straight out of the unit

It may be necessary to make a vertical cut in the front flange of the drain pan on either side of the coil and bend the flange down between the cuts to remove the evaporator coil.

Reinstallation

Slide the new coil into the unit through the notch cut in the front of the drain pan.

Re-bend the cut flange back to the original position, then seal the cuts with polyurethane caulking.

Attach the filter at the front and back of the evaporation coil.

Reinstall economizer assembly if necessary.

Connect the suction and liquid copper connections to the evaporator coil.

Reinstall the TXV bulb on the suction line.

Evacuate the refrigerant system. Weigh in the nameplate refrigerant charge.

See Adjusting Refrigerant Charge section to check for proper sub-cooling and superheat of the refrigerant systems.

E-Coated Coil Cleaning

Documented routine cleaning of e-coated coils is required to maintain coating warranty coverage.

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 and dirt into the coil. This will make cleaning efforts more difficult.

Surface loaded fibers must be completely removed prior to using low velocity clean water rinse.

A monthly clean water rinse is recommended for coils that are applied in coastal or industrial environments to help to remove chlorides, dirt, and debris.

It is very important when rinsing, that water temperature is less than 130°F and pressure is less than 100 psig to avoid damaging the fin edges.

An elevated water temperature (not to exceed 130°F) will reduce surface tension, increasing the ability to remove chlorides and dirt.

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

Quarterly cleaning is essential to extend the life of an e-coated coil and is required to maintain coating warranty coverage.

Coil cleaning shall be part of the unit’s regularly scheduled maintenance procedures

Failure to clean an e-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

The following cleaning agent, 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 particulate:

Enviro-Coil Concentrate, Part Number HEC01.

Recommended Chloride Remover

CHLOR*RID DTS™ should be used to remove soluble salts from the e-coated coil, but the directions must be followed closely.

This product is not intended for use as a degreaser. Any grease or oil film should first be removed with the approved cleaning agent.

Remove Barrier

Soluble salts adhere themselves to the substrate.

For the effective use of this product, the product must be able to come in contact with the salts. These salts may be beneath any soils, grease or dirt; therefore, these barriers must be removed prior to application of this product. As in all surface pre

Apply CHLOR*RID DTS

Apply directly onto the substrate. Sufficient product must be applied uniformly across the substrate to thoroughly wet out surface, with no areas missed. This may be accomplished by use of a pump-up sprayer or conventional spray gun.

The method does not matter, as long as the entire area to be cleaned is wetted. After the substrate has been thoroughly wetted, the salts will be soluble and is now only necessary to rinse them off.

Rinse

It is highly recommended that a hose be used, but a pressure washer will damage the fins. The water to be used for the rinse is recommended to be of potable quality, though a lesser quality of water may be used if a small amount of CHLOR*RID DTS is added

Check with CHLOR*RID International, Inc. for recommendations on lesser quality rinse water.

Microchannel Coil Cleaning

Air-cooled heat exchangers may include microchannel coils.

Cleaning microchannel coils is necessary in all locations. In some locations it may be necessary to clean the coils more or less often than recommended. In general, a condenser coil should be cleaned at a minimum of once a year.

In locations where there is commonly debris or a condition that causes dirt/grease build up it may be necessary to clean the coils more often. Proper procedure should be followed at every cleaning interval.

Using improper cleaning technique or incorrect chemicals will result in coil damage, system performance fall off, and potentially leaks requiring coil replacement.

Documented routine cleaning of microchannel coils with factory provided ecoating is required to maintain coating warranty coverage.

Use the E-Coated Coil Cleaning section for details on cleaning ecoated coils.

Field applied coil coatings are not recommended with microchannel coils.

Allowed Chemical Cleaners and Procedures

AAON recommends certain chemicals that can be used to remove buildup of grime and debris on the surface of microchannel coils.

These chemicals have been tested for performance and safety and are the only chemicals that AAON will warrant as correct for cleaning microchannel coils.

There are two procedures that are outlined below that will clean the coils effectively without damage to the coils.

Use of any other procedure or chemical may void the warranty to the unit where the coil is installed. With all procedures make sure the unit is off before starting.

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

The water pressure used to clean should not exceed 140 psi, from no closer than 6 inches from the coils, and with the water aimed perpendicular to the coils

Simple Green

Simple Green is available from AAON Parts and Supply (Part# T10701) and is biodegradable with a neutral 6.5 pH. Recommendation is to use it at a 4 to 1 mix. Use the following procedure.

Rinse the coil completely with water. Use a hard spray but be careful not to bend or damage the fins. A spray that is too hard will bend the fins. Spray from the fan side of the coil.

With a pump sprayer filled with a mix of 4 parts water to one part Simple Green spray the air inlet face of the coil. Be sure to cover all areas of the face of the coil.

Allow the coil to soak for 10-15 minutes.

Rinse the coil with water as in step one.

Repeat as necessary.

Water Flush

This procedure can be used when the only material to cause the coil to need cleaning is debris from plant material that has impinged the coil face.

Rinse the coil completely with water. Use a hard spray but be careful not to bend or damage the fins. A spray that is too hard will bend the fins. Spray from the fan side of the coil.

Spray and rinse the coil from the face.

CAUTION! Use pressurized clean water, with pressure not to exceed 140 psi. Nozzle should be 6” and 80° to 90° from coil face. Failure to do so could result in coil damage.

Application Examples

The two procedures can be used to clean microchannel coils. They will fit with the application depending on the area. In some areas where the spring/summer has a large cottonwood bloom #2 might work fine if the unit is installed on an office building and

Generally the best and broadest based procedure is #1. The grease cutting effect of the Simple Green is good for restaurant applications

Other Coil Cleaners

There are many cleaners on the market for condenser coils. Before using any cleaner that is not covered in this section you must get written approval from the AAON warranty and service department. Use of unapproved chemicals will void the warranty.

AAON testing has determined that unless a chemical has a neutral pH (6-8) it should not be used

Beware of any product that claims to be a foaming cleaner. The foam that is generated is caused by a chemical reaction to the aluminum fin material on tube and fin coils and with the fin, tube, and coating material on microchannel coils.

Microchannel coils are robust in many ways, but like any component they must be treated correctly. This includes cleaning the coils correctly to give optimal performance over many years.

Roofing

The cleaning procedures outlined here use relatively benign ingredients. When working with a rooftop unit care should be taken to make sure the chemicals will not adversely affect the roof coating.

Checking with the roofing supplier/manufacturer is the best way to proceed. If the roofing supplier/manufacturer is not available testing of the chemicals on the roof coating is recommended.

Commercial roofing material manufacturers using PVC and EPDM have been contacted and indicate that there should be no problem with any of the procedures outlined above.

Supply Fan

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

CAUTION! Blower wheels and bands 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 exce

Factory Lubrication

Note: Bearing lubrication only applies to belt driven fan motors such as the energy recovery wheel power exhaust fan motor.

All original fan motors and bearings are furnished with factory lubrication. Some applications will require that bearings be relubricated periodically.

The schedule will depend on the operating duty, temperature variations or other severe atmospheric conditions.

Bearings should be re-lubricated when at normal operating temperatures, but not running.

Rotate the fan shaft by hand and add only enough grease to purge the seals. DO NOT OVERLUBRICATE.

Recommended greases are:

SHELL OIL - DOLIUM R

CHEVRON OIL - SRI No. 2

TEXACO INC. - PREMIUM RB

Removal

Remove fan access panel on the back side of the unit. Panel is attached with eight 5/16” bolts.

Figure 32 - 2-6 ton Supply Fan

Remove wire connections from motor. For EC motors unplug the wire harness at the control module that connects to the unit control panel.

Through the blower access opening, remove the two 5/16” bolts that connect the blower assembly to the inlet wall (see Figure 33).

Figure 33 - RQ Supply Fan Removal Bolts

Through the coil access door, remove the two 5/16” bolts that connect the blower assembly to the inlet wall from air entering side of the wall (see Figure 33).

Slide blower assembly

wire frame motor mount

motor

blower wheel

inlet sheet-metal slide

out of unit through blower access opening (see Figure 34).

Figure 34 - RQ Supply Fan Removal Slide

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 deenergized

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 set point 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.

Recommended 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 Procedure Hub 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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