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V-Cube Installation, Operation and Maintenance

1. Table C4 Start up Readings Exhaust Fans Amp Draw Full O L Min O L Set Max O L Set Load Amp RPM Hertz at Min Hertz at Min Amps Setting Hertz Hertz Rotation Nameplate Correct Amps L1 L2 L3 Fan 1 Fan 2 Fan 3 Fan 4 Fan 5 Fan 6 Fan 7 Fan 8 Fan 9 Fan 10 Fan 11 Fan 12 VCES V CUBE IOM 1A 36 Table C5 Start up Readings Condenser Fans Serial Number Rotation Correct Amp Draw Nameplate Amps L1 L2 L3 Full Load Amps O L Amp Setting Fan 1 Fan 2 Fan 3 Fan 4 Fan 5 Fan 6 Fan 7 Fan 8 Fan 9 Fan Fan Fan Fan Fan Fan O u jUujNIIo Fan Table C6 Start up Readings Compressors Nameplate Amps Amp Draw L1 L2 L3 Full Load Amps After compressor has been running for 15 minutes check for the following Suction Pressure Discharge Pressure Super heat Hot Gas Bypass Functioning Liquid Subcooling Outdoor Ambient Temperature During AC Cooling Start up F C Compressor 1 Compressor 2 Compressor 3 Compressor 4 Compressor 5 Compressor 6 Compressor 7 Compressor 8 Compressor 9 Compressor 10 Compressor 11 Compressor 12 Compressor 13 Compressor 14 Compressor 15
2. Table 3 Bearing set screw torque in Ib in 4 Check the fan and motor sheave alignment using a Manufacturer straight edge along the outside edges of the sheaves et Screw Link for equal sized fixed sheaves as shown in Figure 13 Diameter Belt Sealmaster SKF McGill Dodge and Figure 14 at time of start up after 24 hours of operation monthly for the initial three months 10 40 35 35 then every three months thereafter When properly 1 4 90 65 50 85 um aligned the straight edge should touch the full face 5 16 185 125 165 165 160 of both sheaves With one adjustable and one fixed 3 8 325 230 290 290 275 sheave with unequal sizes use a string placed at the 7 16 460 350 350 _ center grove of both sheaves pulled tight to check U2 680 500 620 600 alignment Adjust sheaves for proper alignment and set screws to proper torque 5 8 1 350 1 100 1 325 1 200 3 4 2 350 2 000 ee poral Split pillow block bearings are fixed to the shaft with tapered sleeves and generally do not have set screws q 3 Check each V belt tension and adjust 3 the motor base for correct amount according to the deflection Straight outlined in the Measuring Belt Tension procedure edge below and in Appendix H for type of belt at time of start up daily for the first week until they should acquire their permanent set then monthly All belts should have approximately the same amount of de flection Be aware of mismatc
3. Figure D7 Tighten cap screw to Ya of the coupling VCES V CUBE IOM 1A Step 4 Once all four corner latches have been tightened within Ya of the leg extension coupling complete the installation by tightening each corner until the latch and leg extension coupling meet as illustrated in Figure D8 Tighten each corner until the latch and coupling meet Ei Figure D8 Tighten until latch and coupling meet Once all four corners have been tightened the filter should now be properly seated and sealed Figure D9 Properly installed filter Repeat the process with all remaining filters working from the bottom to the top 41 Appendix E Electric Heating Coil and Controls Information This electric heating coil module covered by this appen dix is a component of a Listed product subject to the guidelines of application as designated by the Certifying Agency and outlined in the appliance Manufacturer s In stallation and Operation Instructions The information provided in this appendix applies to the electric heating coil module installed in the appliance and to its operation maintenance and service Refer to the ap pliance manufacturer s instructions for information related to all other components 1 Mechanical Installation of Electric Coil Heaters 1 1 Handling 1 1 1 1 1 2 Inspect the heater carefully and report any dam age to the manufacturer Do not install a damaged heater 1 2 Instal
4. Appendix D HEPA Filter Installation These instructions are for installing AAF HEPA filters 1172 depth into AAF HEPA holding frames The holding frames are available in multiple sizes and materials but include the PN series of 30619XX XXX where the X s vary with frame size and material All frames latches extension legs and filters are sold separately Please read the entire installation instructions before beginning the installation process Install filters into the HEPA holding frames only after the frames have been securely installed into existing ductwork or housing Frames should be bolted or pop riveted to gether into the permanent structure through the predrilled holes around the outside perimeter of the frames Frames should be sufficiently caulked and sealed to prevent any air bypass or leakage Required tools for filter installation e T handle Hexkey size 5 32 Framing Components Required e AAF HEPA holding frames PN 30619XXXXX e Leg extensions four per frame PN 3061991 00X e Latches four per frame PN 3062007 00X Figure 01 Leg extensions and latches Step 1 At the inside corner of each frame are four tabs two per side Place a leg extension over the four tabs as shown in Figure D2 below then pull back on the leg extension lock ing it into place Pull leg extension back to lock it into place Corner tabs on frame Figure D2 Place leg extensions over the frame tabs then pull b
5. Compressor 16 VCES V CUBE IOM 37 Serial Number Table C7 Start up Readings Water Source Heat Pump WSHP Water Cooled Condenser WCC Waterside Cooling Mode Waterside Heating Mode Entering Leaving Temperature Entering Leaving Temperature Entering Leaving Temperature Temperature Difference Temperature Temperature Difference Pressure Pressure US GPM F C F C F C F C F C F C PSI PSI Condenser 1 Condenser 2 Condenser 3 Condenser 4 Condenser 5 Condenser 6 Condenser 7 Condenser 8 Condenser 9 Condenser 10 Condenser 11 Condenser 12 Condenser 13 Condenser 14 Condenser 15 Condenser 16 Table C8 Start up Readings Electric Heating Coil Stage L1 Amps L2 Amps L3 Amps Check for Hot Pots 1 2 3 4 5 6 Item Description Yes No Is the unit stored indoors in a clean dry environment 1 Is the indoor storage facility temperature regulated to within 5O F to 75 F Is the indoor storage facility humidity regulated to within 1096 to 5096 RH 2 Is the unit mounted on a level surface along the perimeter of the base with weight evenly distributed Has the plastic wrapping been removed from the unit to perform inspection and mainte nance 3 Has the plastic wrapping been saved for future use
6. IMPORTANT Complete this form for each unit and email fax or mail to Venmar CES immediately after start up to validate warranty and to provide valuable informa tion for personnel performing future maintenance or for factory assistance to address below Read the Installation Operation and Maintenance Instructions Manual and the EPICTM System Keypad Operation Guide and the Sequence of Operation before proceeding Leave a copy of this report with the owner and at the unit for future reference and permanent record To ensure proper operation of each unit qualified personnel should perform the start up complete the checklist and report All units are functionally tested except when shipped in multiple pieces Start up adjustments may be required If the unit is shipped as a single piece blowers and compressors if equipped are set up to run correctly when power is connected If any blower is running backwards or compressor is mak ing loud noises disconnect power and switch two leads on three phase power to ensure proper rota tion and avoid damage If units are equipped with compressors power must be turned on for 24 hours prior to a call for cooling for the compressor crankcase heaters to be energiz ing to prevent possible damage The Bacview keypad located at the control panel will allow for manual override for start up mode of operation selection and includes an internal time clock if remote interlocks are not provided Tab
7. Many of the following steps need to be performed with the unit powered off and locked out Disconnect the main power switch to the unit before performing service and maintenance procedures Blank off Plate if applicable 1 Optional blank off plate s are available so that main tenance staff can block the intake of a single fan to prevent back flow until service on an inoperative as sembly can be performed or it can be mounted on spare FANWALL cube s until they are required to be put into service 2 First disconnect power to the fan array control panel Follow all lockout and tag out procedures 3 The blank off plate is fitted to the inlet side of the FANWALL cube on the optional airflow straight ener panel frame if supplied or onto a matching Z frame There are 12 pre drilled holes which are Figure 32 Blank off plate Step 4 located in the corners and middle of the airflow straightener panel frame or Z frame matching predrilled holes in the blank off plate for fastening together with tek screws FANWALL cube Airflow straightener panel rame f TE if Kur Figure 31 Blank off plate Step 3 VCES V CUBE IOM 1A 25 Motors A WARNING Many of the following steps need to be performed with the unit powered off and locked out Disconnect the main power switch to the unit before performing service and maintenance procedures Motors will operate effectively for years if they are kept c
8. Has the plastic wrapping been re applied to the unit when the unit has been shipped to jobsite Recommend Has a desiccant pouch been placed in the control panel VCES V CUBE IOM 1A 38 Serial Number Item Description Inspection Date Reading Refrigerant pressure at storage Date PSIG Compressor 1 Compressor 2 Compressor 3 Compressor 4 Compressor 5 Compressor 6 Compressor 7 Compressor 8 Refrigerant pressure every 3 months Compressor 1 Compressor 2 Compressor 3 Compressor 4 Compressor 5 Compressor 6 Compressor 7 Compressor 8 Rotate blower impellers every 2 months Date PSIG Date Date Date PSIG Date Date Date Date PSIG Date Supply Exhaust Other Grease fan bearings as required Supply Exhaust Other This unit has been checked out and started according with the above procedures and completed ating satisfactorily After 24 hours of s tion shut down the unit and check all orms and is oper atisfactory opera foundation bolts shaft bearings drive set screws valve train and terminals Tighten where required Additional Comments VCES V CUBE IOM 1A Start up By Company Name Date Email Telephone Email to tech support venmarservice venmarces com or Fax to 819 399 2612 39
9. control system which determines when to divert water to the economizer coil for energy conservation in cooling mode Water Piping Components Not Included Water piping vibration eliminators manual or automatic shut off valves pressure and temperature gauges water strainer vent valves or air vents flow measuring and balancing valves pressure relief valves or other safety or VCES V CUBE IOM 1A control piping requirements are not available and must be field provided and installed outside of the unit IMPORTANT WCC external water supply and return piping shall be in accordance with National and Local Codes Line sizing pressure limiting devices backflow preventers strainers valves flow temperature and pressure measuring freeze protection all other safety or control piping requirements for system operation are the sole responsibility of the Installing Contractor and or Design Engineer The water supply must be sized for the maximum flow as indicated on the submittals Recommended Piping Components and Installation Recommended and required WCC water line piping and components with a detailed functional description are out lined below 1 All WCC should be connected to supply and return piping in a two pipe reverse return configuration A reverse return system is inherently self balancing and requires only trim balancing where multiple quanti ties of heat pumps with different flow and pressure drop characteris
10. Check for dirt in the water system water flow rates water temperatures airflow rates may be dirty filters and air temperatures If the lockout occurs in the morning following a return from the night setback enter ing air below machine limits may be the cause Water treatment is important for proper condenser opera tion More frequent cleaning will be necessary if water is not properly treated For water treatment instruction con sult your local water treatment specialist 29 Monthly Check water cooled condensers for scaling and pro ceed with brushing and cleansing if necessary Quarterly e Check oil level in compressor half site glass Semi annually e Check operation of crankcase heaters e Check for broken or loose pipe clamps e Check moisture indicator of refrigerant site glass A Caution or Wet condition requires changing fil ter drier If Wet condition does not improve it will be necessary to evacuate system Yearly e Look for any sign of oil on all refrigeration compo nents including coils compressors controls tubing etc Oil would indicate a refrigerant leak Check water lines for leaks e Check expansion valve bulb properly attached to suction line properly isolated e Check the condensate drain pan and clean and flush as required Troubleshooting Lubrication R410a should be used only with polyolester POE oil The HFC refrigerant components in R410a will not be compat ibl
11. Short circuit connect the incoming supply line to the outgoing return line prior to the factory installed piping at each connection point before flushing to prevent the introduction of dirt into the unit from the supply line completed on site This will prevent the introduction of dirt into the unit 3 Fill the system at the city water makeup connection with all air vents open After filling close all air vents 4 Start the main circulator with the pressure reducing valve open Check vents in sequence to bleed off any trapped air to provide circulation through all compo nents of the system 5 While circulating water check and repair any leaks in the piping Drains at the lowest point s in the sys tem should be opened for the initial flush and blow down making sure city water fill valves are set to VCES V CUBE IOM 1A make up water at the same rate Check the pressure gauge at the pump suction and manually adjust the makeup to hold the same positive steady pressure both before and after opening the drain valves Flush should continue for at least two hours or longer until clean drain water is visible 6 Shut off the circulator pump and open all drains and vents to completely drain down the system Short circuited supply and return lines coming to the unit should now be removed and supply and return lines connected to the unit supply and return connections Do not use sealers at the swivel flare connections of the hose s 7 i
12. a filter change C Are the filter pressure differential gauges switches or sensors free of dirt and set at a value VCES V CUBE IOM 1A 33 Serial Number Table C1 Pre Start up Checklist Checklist Item Yes N A Have coils been checked for fin damage and dirt straightened with a fin comb and cleaned a Are all pipe connections tight and have they been checked for damage that may have occurred dur 7 ing shipping or installation b Has the piping to the coils and WSHP WCC been completed and have the piping lines been flushed filled vented and tested at 1 2 times the operating pressure Scroll compressor RIS vibration isolator bolts are factory tightened to the correct torque setting for operation and do not require field adjustment a Are the refrigerant components and piping in good condition and have no damage or leaks from shipping or installation 8 b Are the refrigerant lines spaced at least 1 apart and from the compressor after shipping and installation C Are the refrigerant line clamps still secure and have their rubber lining d Is the clearance around the air cooled condenser within minimum clearance and the discharge clear from blockage 9 Are all motorized damper control arms control rods and shafts tight a Do all non motorized dampers rotate freely 10 Is the ductwork connected complete and free of obstructions 11 Have
13. all condensate drain connections been trapped installed correctly and filled 12 Are all shipped loose or field supplied components correctly installed and wired 13 Hasthe wiring diagram been marked up accordingly and left with the unit 14 Has the power supply and control wiring been inspected and approved by the Local Authorities 15 Have factory and field wiring connections been checked and tightened 16 Is voltage at the disconnect switch within 1096 of nameplate and are phase to phase readings within 296 of nameplate 17 Have field piping and venting installation connections for heating and cooling options been com pleted and tested 18 Are heating and cooling enable switches set to the Off position 19 Hasthe electric coil installation and pre start up checks been completed per Appendix E 20 Have all safety switches overloads or other devices that are manual reset been checked and reset 21 If units are equipped with compressors has power been turned on for 24 hours prior to a call for cooling VCES V CUBE IOM 1A 34 Serial Number Table C2 Start up Checklist Checklist Item Yes N A Before proceeding complete the Pre Start up Checklist Close all access panels or doors Turn the main disconnect to the On position The unit can be started by using the keypad and selecting the mode of operation from the Keypad Operation Guide and the Sequence of Operation Run through
14. an electrical fault should occur Failure to follow this warning could result in the installer being liable for personal injury of others The unit is factory wired unless otherwise specified except for power connections shipping split locations shipped loose sensors items or remote control options as indicated in the electrical schematics and sequence of control The unit may or may not have an optional factory installed door interlocking disconnect in the control panel VCES V CUBE IOM 1A If the unit control panel disconnect is not supplied the Electrical Contractor must provide and install disconnect outside of the unit as per local electrical codes and run the power supply wiring to the control panel e For multi section modular units the Electrical Con tractor must join the low voltage wiring between unit sections using quick connections supplied by Venmar CES and join the high voltage wiring between sec tions at the junction boxes or extend coiled wiring e Check nameplate for correct power supply require ments e See electrical schematics and sequence of control lo cated in the control panel pocket for field wiring of power connections shipped loose sensors items or remote control interlocks The Electrical Contractor must locate install and wire sensors items or remote control interlocks as per electrical schematics and se quence of control e Numbered terminals strips are included in the control panel for
15. coil Replace solenoid coil Too much refrigerant is being fed to the evaporator and the superheat is too low cannot be adjusted Dirt or foreign material lodged in thermostatic expansion valve Disassemble valve remove dirt and re verify superheat Defective thermostatic expansion valve Replace thermostatic expansion valve Compressors lockout on high head pressure or run at higher than design head pressure Insufficient fluid flow across condenser coil Clean dirty condenser coil Comb damaged fin surface with fin comb Tighten loose fan belt s Condenser fan failure Verify fan rotation Verify fan rpm Check fuses Verify overload Check fan controls Check for motor burnout High pressure control Check for proper setting Service valve failure Discharge valve fully back sealed Refrigerant overcharge Verify condenser subcooling 15 F 9 C If above 15 F 9 C adjust charge based on maintaining suction pressure Supply water temperature may be too high Verify water temperature rise entering and leaving unit to determine if adequate water is flowing Water control valves not operating properly Verify and repair water control valves Condenser fan s short cycling Improperly set sequencing control Set for correct pressure and differential VCES V CUBE IOM 1A 50 VCES V CUBE IOM 1A 51 sf VENMARCES A CES Grou
16. ease of connection and service e All field wiring and components must comply with NEC and local requirements In Canada electrical connections must be in accordance with CSA C22 1 Canadian Electrical Code Part One e Install copper wiring of proper size to handle current load e Mounting of field provided components in the con trol panel is allowed as long as their space was con sidered during the submittal process Non considered electrical components are not allowed in the control panel It is the responsibility of the Control Contrac tor to provide his own power source s for any field added electrical components The control panel mounted transformers are not rated for external components power supply unless otherwise listed on the electrical schematics Electrical Field Connections Shipped loose sensors items or remote control wiring can be located next to the power feed cable provided it is inserted in shielded cable that will protect it from elec tromechanical interference Ensure the power feed cable ground is securely connected to the terminals located in the control panel VCES V CUBE IOM 1A Electrical Contractor must provide wiring for controls that are supplied optionally and shipped loose or field sup plied Mark the electrical schematic with the connections completed and leave them with the unit for start up and service CAUTION High voltage power lines shipped loose sensors items or remote control op
17. hoisting cables slowly and gradually increase the cable tension until the full unit or unit section weight is suspended Avoid sud den jerking movements Do not permit the unit or unit section to be suspended by the lifting lugs for an extended period of time Once the unit or unit section leaves the trailer ensure it is level at all times Adjustable spreader bars typ yore typ Detail A Use clevis and clevis pin to attach cable to lifting lugs 12 12 Pulleys 1 dq Adjustable c spreader bars 12 Figure 1 Use adjustable spreader bars pulleys and cables attached to all lifting lugs to apply an even lifting force Assembling a Multi section Modular Unit Special attention must be taken to ensure that a multi section modular unit has an air and water tight seal at every section split Follow the next set of instructions for assembling a multi section modular unit 1 Remove the yellow lifting lugs located on the section joint if any once the first section is set in place IMPORTANT Yellow lifting lugs located on the section joint if any must be removed once the first section is set in place to allow the next section to be pulled to the first 2 Set the second section approximately 6 152 mm from the first section see Figure 2 Remove the yellow lifting lugs located on the section joints if any from th
18. holding pressure must then be reinstalled VCES V CUBE IOM 1A 6 Rotate blower impellers by hand every two months grease fan bearings as required following proper practices Do not over grease the bearings as this may rupture the seals and lead to premature bearing failure during operation 7 Ensure that all unit doors are kept closed 8 Continue above maintenance schedule until unit start up For all checks listed above please complete the Extended Dormant Unit Maintenance Checklist below and send a copy to the Venmar CES service department every six months and when unit is put into service If the unit has been dormant for an extended period after initial start up all start up checks should be repeated be fore operating the unit Refer to the V Cube Start up Report and Checklist in Appendix C and complete these checks Failure to comply with the above recommenda tions may result in component failure and surface corro sion on the interior and exterior of the unit Please note that if the unit is being stored outdoors or remains dormant for an extended period after initial startup this may result in condensation within the unit which could result in premature degradation of the unit and potential issues within the control panel In this event the installation of a desiccant pouch in the control cabinet is highly recommended all ventilation ducts should be capped covered to prevent chimney effect all liquid pipes water
19. operation Evaporator Section The direct expansion coil is constructed of seamless cop per tubing expanded into full collared aluminum fins The tubes are arranged for a counter flow circuit and stag gered to provide maximum heat transfer A pressure type distributor with hot gas inlet port and a heavy duty copper suction header are included Additional refrigerant circuit components include thermostatic expansion valves with external equalizer and hot gas bypass valves on the full face of the leaving side of the direct expansion coil HGBP option is removed when optional digital scroll compressors are utilized Components of a Direct Expansion Dx System The evaporator is that part of the low pressure side of the refrigerant system in which the liquid refrigerant boils or evaporates absorbing heat as it changes into a vapor VCES V CUBE IOM 1A Distributor Liquid line Y Hot gas bypass line Suction line Expansion valve Check valve on remote condensing application optional Figure 11 Direct expansion Dx coil Thermostatic Expansion Valve The thermostatic expansion valve TXV is a precision de vice designed to meter the flow of refrigerant into the evaporator thereby preventing the return of liquid refrig erant to the compressor By being responsive to the tem perature of the refrigerant gas leaving the evaporator and the pressure in the evaporator the thermostatic expansion valve can control the
20. or when the operation of heating equip ment is essential may require more spare parts than listed Please contact the service department at Venmar CES for recommendations VCES V CUBE IOM 1A Minimum spare parts include e One matching set of fan belts belt driven fans only e One set of filters e One set of shell and tube condenser head gaskets per condenser water cooled units only Unit Inspection on Arrival Inspect the equipment exterior and interior for any dam age that may have occurred during unit shipment and for shipped loose parts Ensure there is no damage to any protruding exterior components such as door handles disconnect switch handle etc or to internal components such as fans motors heat exchanger dampers and drains File a claim with the shipping company if the unit is dam aged Check the packing slip against all items received If any items are missing sign the carrier s bill of landing with the notation Shipment Received Less Item Con tact the factory immediately if damage is found No return shipment will be accepted without authorization Unit Application Limitations CAUTION Venmar CES equipment is not designed to be used for temporary heating cooling and or ventilation during con struction Using Venmar CES units for temporary ventilation dur ing construction is subject to the unit warranty terms and should be reviewed carefully before proceeding as this may void the standard w
21. out Disconnect the main power switch to the unit before performing service and maintenance procedures 5 After removing the motor pedestal 5 retaining bolts slide the motor fan pedestal assembly out to the point where the motor lifting ring is clear of the cube frame enough to use If a mechanical device is avail able for use attach it to the motor lifting ring Lift and remove the motor pedestal with motor and fan wheel from the cube The motor pedestal with motor and fan wheel can be turned 180 and slid back into the cube on the pedestal mounting angles or re moved from unit for further disassembly 6 Mark the location of the trans torque bushing on the shaft and the fan To remove the fan wheel from the motor shaft remove the trans torque bushing retain ing hex nut using a 1 socket with a 12 extension by turning counter clockwise Loosen progressively until the bushing is free from wheel hub and motor shaft Remove fan wheel hub assembly see Figure 19 Figure 19 Mark location and remove trans torque bushing and fan wheel from motor 7 If needed the motor may now be removed for ser vice by removing all four 3 8 motor retaining nuts and bolts Be sure to mark the motor base pattern and bolt holes used on the motor pedestal Rubber isolator pads between the motor base and the ped estal are optional and if supplied be sure not to lose them see Figure 20 If the motor is to be replaced make sure to remove
22. recom mended by local safety associations are continu ously in use If any questions arise during the installation proce dure please contact the factory The Installing Contractor is responsible for the unit being air and water tight including all section joints on the unit All holes that have been made by the Installing or Electrical Contractor after receiving and installing the unit must be well sealed to prevent air and or water infiltration All rigging equipment and labor as applicable is provided by the Installing Contractor as detailed below It is highly recommended that extra quantities of all items listed be on hand The rigging procedure and or equipment used to lift the unit may differ depending on the physical dimen sions of the unit its location the jobsite the Installing Contractor and Crane Operator preferences ifting crane of the appropriate capacity djustable spreader bars ables cables chains or straps tools required to pull the sections together hains chain blocks chain type come alongs etc construction equipment and labor required to complete the work according to local codes e Condensate and or P trap piping hardware e All tools and materials required for level unit installa tion Installation and Assembly Materials for Multisection Modular Units e Polyvinyl gasket with adhesive strip 2 x 172 13 x 38 mm x required length applied between unit sec tions for
23. refrigerant gas leaving the evapora tor at a predetermined superheat Three forces that gov ern the operation of the TXV are 1 The pressure created by the remote bulb and power assembly P1 2 The evaporator pressure P2 3 The equivalent pressure of the superheat spring P3 Bulb clamp ap e Remote clamp Diaphram External equilizer port Figure 12 Thermostatic expansion valve TXV Dampers A WARNING tion All Venmar CES dampers and linkages are assembled with non lubricating bearings Many of the following steps need to be performed with the unit powered off and locked out Disconnect the e Attachment mechanism linking motors to dampers main power switch to the unit before performing service should be checked for tightness and maintenance procedures e Damper jackshafts if provided are fitted with grease nipples and should be lubricated once a year Use a premium quality lithium based grease conforming Units from Venmar CES may or may not incorporate the to NLGI Grade 2 or 3 examples are Mobil Mobilith use of dampers If dampers are present within the unit AWO Chevron Amolith 2 Texaco Premium RB or the following maintenance should occur in order to pre Shell Alvania 2 vent the unit from working under too much pressure and to prevent any other issues e Dampers should be inspected for dirt check the shaft arms bars and controls rod every three Dampers must be kept free of foreign matter t
24. split section joints and duct opening con nections e 3 8 x 2 Grade 5 full thread zinc plated bolts with two washers and one nut each to secure sec tions together gt n gt e D VCES V CUBE IOM 1A e Adseal 1800 series from Adchem Adhesives clear silicone based sealant or equivalent for side and top joints Rigging Lifting and Assembling Instructions Depending on size the unit or unit sections of a multi sec tion modular unit will arrive at the jobsite on a standard flatbed or special low bed trailer Each unit or unit section is identified with labels as per the mechanical drawings At ground level ensure that any crating used for shipping purposes is removed if there is a possibility that it will in terfere with the placing or assembling of the unit or unit sections on the structural steel or housekeeping pad Unit or unit sections shall be lifted by cables attached to all the lifting lugs Consult the mechanical drawings located in the pocket of the control panel for the number of lift ing lugs number of sections and unit weight For multi section modular unit check for additional lugs located between split sections Lifting lugs are factory bolted to the unit or unit section base CAUTION All lifting lugs provided must be used when rigging units or unit sections Rigging and lifting unit or unit sections without using all lifting lugs provided will compromise the structural integrity of
25. the complete sequence of operation of the unit adjusting setpoints and documenting as required Once completed return the unit to the correct mode of operation and adjust the time clock if required Are dampers operating properly Are fans rotating in the correct direction Adjust the supply air fan motor VFD to the correct supply air For occupied recirculation mode adjust outside air and exhaust air damper positioner to achieve the required air volumes Check amperage draw to each motor on each phase against motor nameplate FLA If significantly different check ductwork static and or take corrective action Recheck the voltage at the disconnect switch against the nameplate and against phase to phase readings on three phase with all blowers operating If the voltage is not within 1096 of rated or 296 of phase to phase have the condition corrected before continuing start up Feel the compressor crankcases They should be warm if the disconnect has been on for at least 24 hours This will assure that no refrigerant liquid is present in the crankcase which could cause compressor damage or failure to occur on start up Before activating the compressor on WSHP units are water shut off valves open and is water circu lating through the water to refrigerant heat exchanger Check the incoming line water pressure to ensure it is within design and acceptable limits 13 14 Enable cooling and check if the sound o
26. the shaft grounding ring off the front of the motor that is being replaced Install the shaft grounding ring onto the new motor by drill ing and taping mounting holes Use a 7 64 or a 35 drill bit and 46 32 tap Clean away any chips and shavings before installing the shaft grounding ring VCES V CUBE IOM 1A Motor mounting bolts 8078 9 AHU o93 Ss 3 Motor support platform Figure 20 Remove motor retaining bolts do not lose rub ber isolator pads if provided 8 Toreinstall the motor fan wheel and fan wheel motor pedestal assembly back into the cube reverse the steps above noting the following a Insert the four 3 8 motor retaining bolts into the holes in the motor pedestal from the under side make sure to use a standard washer on the bolt side install the rubber isolator pads if sup plied between the pedestal and motor base and only a locknut is required on the motor side b Square the motor on the pedestal according to markings and tighten the bolts With rubber iso lator pads tighten the bolts to 20 ft lbs Without rubber isolator pads tighten the bolts to 40 ft lbs c Install the fan wheel on the motor shaft with the hub facing towards you Line up the markings on the hub trans torque bushing shaft Make sure that the trans torque bushing nut is flush to the hub Tighten the bushing nut progressively to 80 ft lbs turning clockwise 9 Lift the motor pedestal with motor and fan wheel turn 180 if p
27. to maintain a minimum total pressure of 0 07 of water for a constant flow 3 5 Manual Reset Thermal Cut out This protection device is standard on all heaters of less than 300 volt and 30 kW and is optional on all other heat ers Please check the auto reset thermal cut out before resetting the manual thermal cut out If any defect has been detected in the auto reset thermal cut out it will be necessary to replace it before resetting the manual reset thermal cut out 4 Maintenance All electric coil heaters have been designed to operate long term without problems Those responsible for equip ment and maintenance should be aware of the following suggestions 4 1 Visual Inspection It is strongly recommended to complete a periodic inspec tion This precautionary step will help to keep your instal lations operating well Note these eventual first signs of problems e Accumulation of dust on the heating elements e Signs of overheating on the heater frame e Traces of water or rust on the control box VCES V CUBE IOM 1A 4 2 Electrical Inspection Two weeks after start up all electric connections to con tactors should be checked and tightened up Before each heating season check the resistance between the heating elements and ground It is also recommended to check the electrical connections to heating elements magnetic contactors and main power lugs This inspection is recom mended monthly during the first four mo
28. 0 to 10 60 8 6 7 5 5 7 7 10 to 8 50 19 2 16 7 13 0 5V 9 00 to 11 80 23 3 20 3 15 6 12 50 to 16 00 27 3 23 8 18 5 12 50 to 16 00 50 9 44 3 34 4 8V 17 00 to 20 00 57 1 49 8 38 6 21 00 to 24 80 61 3 53 3 41 4 2 20 to 3 35 5 5 4 8 3 9 3VX 3 65 to 4 12 6 4 5 7 4 4 4 50 to 5 60 7 5 6 6 5 0 6 00 to 10 60 8 6 7 5 5 7 4 40 to 8 50 19 2 16 7 13 0 5VX 9 00 to 11 80 23 3 20 3 15 6 12 50 to 16 00 27 3 23 8 18 5 Plunger with Body with deflection deflection force scale Ibs distance scale inches Small O ring Large Figure H1 Belt tension adjustment VCES V CUBE IOM 1A 46 Appendix I FANWALL Inlet Cone Alignment Table 11 FANWALL Wheel Cone Alignment Dimensions Inches Wheel Size Backplate OD Blade Width Backplate Extension Wheel Cone Overlap 10 10 375 3 495 0 700 0 250 12 12 500 4 280 0 700 0 250 14 13 750 4 720 0 700 0 250 16 16 750 5 760 0 700 0 250 20 20 451 6 990 0 700 0 400 22 22 701 7 780 0 700 0 400 Blade width 100 wide Backplate lt gt extension CSS I Figure I1 FANWALL inlet cone alignment VCES V CUBE IOM 1A Wheel cone Backplate OD overlap 47 Appendix J Filter Resistance and Latches Table J1 Prefilters MERV 8 g Capacities CFM Resistance Capac
29. None C 86 19516104 4 nominal 2i Knock on A 2 500026048 4 Knock on 4 4 4 500026049 None HEPA frame 12 HEPA 2 VP 2 208290023 4 VP 4 19516310 None C 80 19516103 12 double header 2 C 80 VP 2 19516103 208290023 4 C 80 VP 4 19516103 19516310 VCES V CUBE IOM 1A Appendix K Troubleshooting Table K1 Troubleshooting V Cube Symptom Possible Cause Corrective Action General Air supply too cold Noisy unit Supply and exhaust air are unbalanced Blower wheel is rubbing on other parts Check filters and enthalpy wheel for blockage Balance flow of supply and exhaust air so that exhaust air is equal or greater than supply air Install a post heat module Adjust wheel or replace defective part Blower wheel is out of alignment Remove the motor blower assembly Adjust the blower wheel Sheaves are out of alignment Verify wheel alignment Align belt using a straight edge Excessive belt tension causes bearings to screech Adjust belt tension Low belt tension causes belts to squeal Adjust belt tension Ducts are vibrating Install flexible connections Unit is too close to occupants Install a silencer Bearings wear down Excessive vibration Replace shaft and bearings Verify wheel alignment too quickly Belt too tight Adjust belt tension ion Reverse rotation or motor so that wheel turns in
30. V Cube Floor by floor Vertical Self contained System Installation Operation and Maintenance Instructions Manual ZA Mammoth Capacities 9 150 tons 2012 Venmar CES Inc Table of Contents 3 6 Ae IEO E T E E et ce Matsa Deere EE eae tees io sata ee ee 4 56 4 63 Recommended Spare Parts tee eet rne ERU eie ERE ee EE ere RED NEC Ee Pe ri Eae Daten eR RE Se een 4 Unit Inspection on ou g17 RR 5 Unit Application Limitations RRRRRRRRRRRRREEMEMMM 5 tala tu Hesse rta 5 atl OMe s Li ete ae 518 Unit Location Reguirements u nennen en nennen 5 Rigging Lifting and Assembling 2404424044400nnnunnnannnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnennnnnnnnnnnnann 6 Suspended Unit Installation 44u04440044Hnannnnnnnannnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnennnnnnnnnnnnnnnnnn nn 11 11 Field Fabricated Electrical GOMMECtlONS fvsctes EE 11 Coil or Water Cooled Condenser WCC Piping Connections esses eene eene nennen nnn 13 Condensate Drain Trap and Lines erede e a edt ee re este 13 Starbup z ose ee LEE S LE Chie he aan RE EM iP iE ipe Eier T Ee E E 14 Pre Start Up CO CCK dec m 14 Start Up Procedure rede edu e tain Mee cule ie Dude re oe i Aeon 15 Airflow Balancing 4 ee evene Cete dade a eA a ene er e oca RR ak de eg aee abe ae ae ape a
31. Ya polyvinyl gasket me L Figure 5a Install a polyvinyl gasket strip on each vertical outside wall 14 6 4 mm from the outside side edge from top to bottom of the side joint When compressed a small gap will remain which will allow the Adseal 1800 series silicone based sealant or equivalent to seal the vertical side edges explained in Figure 8 Figure 5b Install two horizontal polyvinyl gasket strips along the base frame one at the top and one at the bottom of the base frame between the two vertical side gasket strips so there is full contact between gasket strips for air and water tightness Figure 5c Install one horizontal polyvinyl gasket strip along the top frame between the two vertical side gasket strips so there is full contact between gasket strips for air and water tightness N internal partition s divider s mie ee Ne see Figure 50 Where two or more internal air tunnels cor ridors are present install the gasket strips on the middle internal horizontal and or vertical partition s divider s between the perimeter gasket strips so there is full contact between gasket strips for air and water tightness VCES V CUBE IOM 1A 7 Use tools chains chain blocks 7 chain type come along etc connected to the side lifting lugs at tached to the base on both sid
32. ack to lock the leg extension into place Repeat Step 1 with each of the four corners The frame with leg extensions should look like Figure D3 VCES V CUBE IOM 1A Figure D3 Frame with leg extensions installed Step 2 Insert the HEPA filter into the HEPA holding frame The HEPA should be installed with the gasket side of the filter facing the frame Insert the filter as far into the frame as possible so that the gasket material is contacting the frame see Figure D4 below Insert filter until the gasket material contacts 4 the filter frame aE M Figure D4 Insert HEPA filter into frame until the gasket comes in contact with the holding frame The filter should now be resting inside of the holding frame as shown to the left When installing the filters into 40 a frame bank of multiple frames install the lower filters first so that the upper filters can rest on the lower filters Figure D5 Filter placed inside of frame Step 3 Place a latch so that it overlaps the leg extension as shown below in Figure D6 Align the latch s cap screw with the threaded coupling on the end of the leg exten sion and tighten using the hexkey Tighten the cap screw until there is an approximately 74 gap between the latch and the leg extension coupling as shown below in Figure D7 Repeat this step with all four corners Align cap screw with coupling z Tighten until there is a gap of approximately 1 4
33. ad must be used to check operation ac 15 Check the reference setpoints on the keypad opera cording to sequence and to adjust setpoints while tion guide against the sequence of operation adjust power is on for start up and while performing ser and record changes as required vice 16 When unit has achieved steady state take measure All units are factory run tested Fans compressors ments and complete the readings section of the and condenser fans if equipped and refrigerant pip start up report in Appendix C ing is not split for shipment are set up to run correct 17 Set the keypad to each mode of operation and check when power is connected If any one fan is running the operation according to sequence backwards or compressor is making loud noises dis 18 For recirculation scheduling mode the outside air and connect power and switch two leads on three phase exhaust air dampers must be adjusted during start up power to ensure proper rotation and avoid damage to achieve the required outside and exhaust air vol With multi section units with split wiring connections umes See Airflow Balancing for further information check rotation of fans compressors and condenser 19 Send copy of the completed start up reports to Ven mar CES to validate warranty Maintain a copy of the reports at the unit for future reference Airflow Balancing IMPORTANT Before measuring supply and exhaust flows the building must be in its normal state e Hermeti
34. any drug store A WARNING Acid burns to the skin can result from touching the sludge in the burned out compressor Rubber gloves should be worn when handling contaminated parts 3 Inspect all system controls such as expansion valves solenoid valves check valves reversing valves con tactors etc Clean or replace if necessary remove all installed filter driers IMPORTANT Before starting the new compressor replace any ques tionable components 30 4 Install the recommended size suction 4 line filter drier and new size liquid line filter drier Evacuate sys tem using the triple evacuation method Re charge the system with new refrigerant do not use the re covered refrigerant See unit s nameplate for proper refrigerant charge Start the compressor and put the system in opera tion As the contaminants in the system are filtered out the pressure drop across the suction line filter drier will increase Observe the differential across the filter drier for a minimum of two hours If the pres sure drop exceeds the maximum limits for a tempo rary installation replace the filter drier and restart the system see literature from filter drier s manufacturer for pressure drop maximum limits After the completion of Step 5 allow the unit to op erate for 48 hours Check the odor warning smell VCES V CUBE IOM 1A cautiously and compare the color of the oil with the sample taken in Step 2 Use of an Acid Te
35. arranty conditions Fine dust larger particulate matter solvents varnishes and other chemicals may cause filter clogging and elevated cabinet pressures higher power consumption and possible irreparable damage to a variety of other key components that may be present in the system Potential damages in clude but are not limited to these examples Installation Unit Location Requirements Consult local building codes and electrical codes for spe cial installation requirements and note additional require ments listed in this manual In choosing the installation location of the unit consider the following factors e The unit should be installed to allow easy access for maintenance and for systems operation e Clearance around the unit should be per the recom mended clearances indicated on the mechanical sub mittal drawings varies per unit frame size in order to allow easy access for maintenance and for system operation For clearances to remove specific compo nents please consult factory e Locate the unit in an area requiring the least amount of ductwork and direction changes to allow optimum performance to reduce pressure loss and to use less electricity to achieve proper ventilation Ductwork must be in accordance with ducting mechanical rules to prevent sound issues and system effects VCES V CUBE IOM 1A e The unit should be mounted on a level foundation to allow condensation to flow into internal drains The founda
36. box Before operation start the motor slowly to ensure the fan rotation is correct If the fan wheel is not rotating correctly check the motor leads for proper installation a Drive side Clockwise rotation when looking at motor end b Inlet side Counter clockwise rotation looking at 3 fan inlet IMPORTANT Before restarting re balance the fan wheel once the motor rotation and alignment have been corrected be fore placing the unit in operation Fan Wheel Cone Alignment 1 To align fan wheel cone first disconnect power to the fan array control panel Follow all lockout and tag out procedures 2 If the optional backdraft damper is furnished on the inlet side of the fan it must be removed first Remove all tek screws on all sides attaching the damper frame to the inlet side panel and remove it from the cube The purpose of the damper is so that main Figure 24 Fan wheel cone alignment Step 3 tenance staff can block the intake of a single fan to prevent back flow until service on an inoperative as VCES V CUBE IOM 1A sembly can be performed Note the directions of the damper blades are running vertical The damper is installed directly onto the FANWALL cube inlet side panel and over the optional airflow straightener if supplied Figure 23 Fan wheel cone alignment Step 2b If the optional airflow straighteners are furnished on the inlet side of the fan it must be removed next Re move a
37. cal tests This requires an ac curate VOM Meter 1 With all wires removed from the compressor termi nals measure resistance from each terminal to the compressor casing If any terminal shows a direct ground zero resistance a failure has occurred If not continue 2 With all wires removed from the compressor terminals measure resistance from each compressor terminal They should read the same If two or more terminals show zero resistance between them the compressor motor has failed for actual resistance value refer to the respective compressor manual or contact the Cus tomer service Department at Venmar CES 3 If steps 1 and 2 have not clearly identified a compres sor failure it will be necessary to meg the compres sor motor refer to the respective compressor manual or contact the Customer service Department at Ven mar CES Compressor Burnout System Cleanup Any maintenance requiring refrigerant evacuation must be performed using proper recovery procedures 1 In order to avoid losing refrigerant to the atmo sphere recover refrigerant using standard recovery procedures and equipment Remove the inoperative compressor and install the replacement 2 Since the normal color of refrigerant oil varies from oil to oil take a sample of oil from the replacement compressor and seal in a small glass bottle for com parison purposes after the cleaning operation is com plete Suitable two ounce bottles are available at
38. cally close doors and windows Shut down hot air generators and combustion water heaters Install all ventilation system components filters grilles diffusers etc For proper performance the unit must operate at the spec ified supply and exhaust flow rates as shown in the me chanical drawings Unit fan speed s and damper positions are theoretically set at the factory based on the ductwork static pressures and flow rates specified in the mechanical drawings If conditions change or verification is required airflow measurements should be taken using AMCA sug gested methods This would normally be a velocity traverse measurement or flow measuring station FMS installed in the ducts Where space is limited in the outdoor air and exhaust air pressure drop readings can be taken across the energy recovery heat exchanger with economizer heat recovery bypass dampers closed if equipped and com pared to the submittal documents Heat recovery perfor mance is tested in accordance to AHRI Standard 1060 and is accurate to within 5 if there is no dirt buildup in the heat recovery heat exchanger Should flow rates need to be reset adjust the outside air exhaust air or mixed air dampers variable speed sheaves VFD fan speed setpoint positions or change the sheaves Flow measuring stations FMS and magnahelic gauges can also be used to measure supply and exhaust flow It is im portant to locate the FMS in the warm side ductwork
39. cations the water supply line and return line should be insulated to prevent condensate and an antifreeze solution should be used to protect water to refrigerant heat exchanger from freez ing damage IMPORTANT A hydrostatic test must be performed in the field by the Installing Contractor at 1 25 times the operating pressure on all equipment involving piping connections to verify that the installed unit and its connections to the network are free of leaks prior to the unit being set in operation This test shall be performed after the unit is completely piped to the network and shall cover the connections between the unit and the network as well as all internal components of the unit Condensate Drain Trap and Lines Cooling coils humidifiers or other options that can pro duce condensation are provided with a drain pan with a 1 32 mm MPT Male Pipe Thread drain connection A drain trap and condensate line of equal size must be field provided by the Installing Contractor on the drain connections and coupled to the building drainage system to prevent air or sewer gases from being pulled into the unit caused by the negative suction pressure and forcing water out of the pan into the unit or from air escaping into the drain caused by positive pressure See Appendix B for illustrations and dimensional information on positive VCES V CUBE IOM 1A and negative pressure trapping height Slope the drain lines downward in direction of
40. d to give the needed periodic inspections of the bearings before these deflection theoretical intervals g Compare the force scale reading in Step F above with the correct value for the belt style and cross section The force scale reading should be be tween the minimum and maximum values shown in Appendix H e Place the scale end of the tension checker VCES V CUBE IOM 1A 19 A WARNING Many of the following steps need to be performed with the unit powered off and locked out Disconnect the main power switch to the unit before performing service and maintenance procedures Table 4 Recommended Grease Quantity Ru e Inches Millimeters Ounces Kilograms 0 500 0 750 13 19 0 125 0 004 0 875 1 187 25 31 0 375 0 011 1 250 1 500 32 38 0 625 0 018 1 687 1 937 43 49 0 875 0 025 2 000 2 437 51 62 1 250 0 035 2 500 2 937 63 75 2 000 0 056 3 000 3 437 76 87 3 500 0 098 3 500 4 000 89 102 6 000 0 168 4 187 4 937 106 125 10 000 0 280 Table 5 Generally Recommended Relubrication Frequency in Months Fan wheels housings and drive assemblies 6 should be checked for dirt buildup annually and cleaned if necessary to keep them from becoming unbal anced and to prevent loss of airflow Clean with compressed air to reduce any dirt dust lint or larger particulates that have bonded to the fan impeller housing or drive assembly Block dirt from entering the unit and ductwork if necessary or r
41. dings on three phase with all fans operating If the voltage is not within 10 of rated or 2 of phase to phase have the condition corrected before continuing start To ensure proper operation of each unit qualified person 7 nel should perform the start up as outlined below based on options included with unit and complete the Start up Report and Checklist in Appendix C for permanent record A completed report and checklist will provide valuable in fans for correct rotation to ensure wiring connections are correct Before proceeding complete the Pre 1 Start up Checklist Check that all access panels or doors are closed Open the access door to the main control panel to access the keypad interface device Bump start the unit to verify that the fan wheel s are rotating in the correct direction Set the keypad to occupied mode with heating and cooling disabled and fan s enabled Check that dampers are operating properly VCES V CUBE IOM 1A formation for personnel performing future maintenance up 8 Check amperage draw to each motor on each phase IMPORTANT against motor nameplate FLA If significantly differ A completed copy of the Start up Report and ent check ductwork static and or take corrective ac Checklist must be sent back to the factory for war tion ranty validation and for factory assistance 9 Feel the compressor crankcases They should be General information on the factory installed and warm if the discon
42. e con nections in the return water line to measure the required flow rate h A two way motorized on off water shut off valve to isolate water flowing through both the econo mizer coil if equipped and water to refrigerant condenser for conservation when the unit is off The motorized water valve must open 90 seconds prior to compressor start up and remain open five seconds after the compressor is shut off i A relief valve in the water supply or inlet line if the maximum pressure of components is less than the water supply pressure to prevent dam age injury or death due to instantaneous release of high pressure water A WARNING To prevent injury or death due to instantaneous release of high pressure water provide relief valves on system water piping This will also help prevent water pump damage or stoppage due to excessive system pressure 4 WCC should not be connected to the incoming sup ply and return piping until the water supply system has been cleaned and flushed completely After the cleaning and flushing has taken place the initial con nection should have all valves wide open in prepara tion for the water system flushing 5 Automatic flow controlled devices must not be in Stalled prior to system cleaning and flushing Cleaning and Flushing 1 Prior to first operation of the WCC the water circula tion system must be cleaned and flushed of all con struction dirt and debris by the Installing Contractor 2
43. e second section to allow sections to be pulled together VCES V CUBE IOM 1A Figure 2 Set the next section approximately 6 152 mm from the first section 3 Corner reinforcement brackets or angle bars may have been used to support multi section modular unit walls during transportation rigging and lifting at the split The brackets shown in Figure 3 are for larger units Simple angle bars are used for smaller units not shown The corner reinforcement brackets or angle bars are no longer required after rigging and lifting and must be removed IMPORTANT After the corner reinforcement brackets or angle bars have been removed from the split section set the screws along with the rubber washers that were holding the brackets or angle bars back in place for water tightness Figure 3 Corner reinforcement brackets or angle bars to be removed from the split section Reset the screws with rubber washer in place for water tightness 4 Verify that these two sections are aligned square at the joint in all three directions 5 For modular integrated water cooled units the compressor condenser section should first be mated to the coil section as outlined in Figure 2 prior to mounting the fan section The internal water and re frigerant piping must then be completed in the field by the Installing Contractor Once the field piping is complete a bead of Adcoustik butyl sealer should be appli
44. e with mineral oil or alkylbenzene lubricants RA10a systems will be charged with the OEM recommended lu bricant ready for use with R410a Charging Due to the zeotropic nature of R410a it should be charged as a liquid In situations where vapor is normally charged into a system a valve should be installed in the charging line to flash the liquid to vapor while charging CAUTION It is very important to make certain that the recycle or re covery equipment used is designed for RA10a The pres sure of R410a refrigerant is approximately 6096 greater than that of R22 Pressure gauges require a range up to 800 psig high side and 250 psig low side Recovery cylin ders require a 400 psig rating IMPORTANT Filter driers must be replaced each time a system is open to atmosphere ex for a defective component replace ment refrigerant leak etc Compressor Burnout When a motor burnout occurs in a compressor the result ing high temperature arc causes a portion of the refriger ant oil mixture to break down into carbonaceous sludge VCES V CUBE IOM 1A corrosive acid and water Such contamination resulting from a burnout can result in repeat failures if the contami nants are allowed to reach and remain in the crankcase of the replacement compressor This situation can be prevented by following proper cleanup procedures after a burnout To determine if a compressor burnout has actually oc curred run the proper electri
45. earance around the water cooled condenser WCC is in accordance with minimum recommended clearances Check motorized damper control arms control rods and shafts for tightness a Check that non motorized dampers rotate freely Check that ductwork is connected complete and free of obstructions Check that condensate drain connections have been trapped installed correctly and filled Check that all shipped loose or field supplied compo nents have been correctly installed and wired Check that the wiring diagram has been marked up accordingly and left with the unit Check that all power supplies and control wiring have been inspected and approved by the Local Au thorities having jurisdiction Check all factory and field wiring connections for tightness Tighten if necessary Check that all fuses are properly installed in holders Check the voltage at the disconnect switch against the nameplate and against phase to phase readings on three phase If the voltage is not within 1096 of rated or 296 of phase to phase have the condition corrected before continuing start up Check that all field piping and venting installation and connections for the heating and cooling options have been completed and tested Set the heating and cooling enable switches to the Off position Start up Procedure Recheck the voltage at the disconnect switch against the nameplate and against phase to phase rea
46. ecautions marked in literature and on labels attached to the unit Follow all safety codes A WARNING Disconnect the main power switch to the unit before per forming service or maintenance Electric shock can cause personal injury or death General Information This manual is designed to provide general information on the common operation of all standard and optional components that may have been installed in the unit Note that some sections of this manual may not apply to your unit This manual has been designed for a general purpose and describes all options offered by Venmar CES Inc that could be included in the unit Consult the manual from the component manufacturer if more detailed technical information about a specific component is required All documentation that was specifically designed for your unit has been included in the pocket of the control panel including and if applicable e Warranties e Mechanical drawings e Unit nomenclature e Electrical schematics e Sequence of control e DDC controller documentation when supplied Controller user s manual Communication protocol documentation Hardware documentation Keypad documentation Recommended Spare Parts Spare parts should be ordered at the time the installa tion is accepted by the owner Spare parts will reduce the down time in the event of a failure The list of spare parts outlined below is considered minimal Installation in remote locations
47. ed to the top of the condenser compressor section as illustrated in Figure 4a The fan blower as sembly should then be gently lowered on top of the compressor condenser section as shown in Figure 4b Finally the top and bottom sections should be joined together with bolts nuts and washers as per Figure Ac After reassembly the unit will require pump down evacuation and refrigerant charging Factory shall provide dry nitrogen holding charge only Re frigerant additional copper piping and insulation for field connections shall be supplied by others Filter drier shall be shipped loose for field installation V2 13 mm bead of ADBOND 1465 acoustical butyl sealant Detail at A Figure 4a Apply a 12 bead of Adcoustik butyl sealer atop of the condenser compressor section prior to placing the fan blower section above it Figure 4b Gently lower the fan blower section atop of the compressor condenser section VCES V CUBE IOM 1A with bolts nuts and washers Do not over tighten 6 Install the 2 x 172 13 x 38 mm 6 polyvinyl gasket with adhesive strip directly on one side of the split section perimeter frames and middle interior parti tions as shown in Figure 5a through Figure 5d Figure 5 General gasket layout IMPORTANT Make sure to have full contact between strips wherever a discontinuity is present for air and water tightness
48. emove fan assembly from unit Alternatively use low pressure steam a degreaser and rag If a sheave requires cleaning detergent and water can also be used En sure the belt is dry before starting up the unit IMPORTANT Be careful not to remove or dislodge balancing clips on the fan blades while cleaning Operating 0 500 1 000 1 125 1 500 1 625 1 937 2 000 2 500 2 687 3 187 3 437 3 937 Speed RPM 13 35 mm 28 38 mm 41 49 mm 50 63 mm 68 81 mm 87 100 mm up to 500 6 6 6 6 5 4 500 1 000 6 6 6 5 4 3 1 000 1 500 5 5 5 4 3 3 1 500 2 000 5 4 4 3 2 1 2 000 2 500 4 4 3 2 1 2 500 3 000 4 3 2 1 2 3 000 3 500 3 2 2 2 3 500 4 000 3 2 1 4 000 4 500 2 1 1 4 500 5 000 2 1 VCES V CUBE IOM 1A 20 FANWALL Array A WARNING Many of the following steps need to be performed with the unit powered off and locked out Disconnect the main power switch to the unit before performing service and maintenance procedures Maintenance Schedule FANWALL array of multiple direct driven plenum fan and motor cubes are equipped with permanently sealed bearings and do not require lubrication The following maintenance schedule is recommended 1 Monthly a Check the fan wheel to inlet cone alignment for possible noise from the wheel rubbing against the inlet cone See Fan Wheel Cone Alignment below for instructions 2 Eve
49. enance Procedure ssssssssssseseeeeeen nennen nnne nnn nnn enn 44 Appendix G V Cube Maintenance Summary Chart uursnsessssesnsnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnennnnnnnnnnn nn 45 Appendix H Measuring and Adjusting V belt Tension uusrs440usnnnnonnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnannnnnnennnnnnnnnnn nn 46 Appendix I FANWALL Inlet Cone Alignment us004420s4nnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 47 Appendix J Filter Resistance and Latches eseese einean a aaa aaan e aaa nennen nenne nen ae aaraa editae ebah henas eu ELSE nennt 48 Appendix K Troubleshooting saiaga eet eee e De e etate eed OY ERK 49 Manufacturer reserves the right to discontinue or change specifications or designs without notice or obligation VCES V CUBE IOM 1A Nomenclature Model Indicator V V Cube Volume Control V Variable air volume C Constant air volume Condenser N No cooling X Dx without WiSE coil W Dx with WISE coil Y Chilled water cooling Z Remote condenser A Airside economizer Nominal Tonnage Number of Compressors 0 Air handler T Tandem compressors H Heat pump Voltage F 208 230 3 60 L 220 240 3 60 G 460 480 3 60 K 575 3 60 J 380 415 3 50 Heating Type E Electric H Hot water S Steam X No heat Frame Size S Small M Medium L Large T Tall Control Panel Location L Left handed
50. eration components including coils compressors etc to indicate a refrigerant leak gt oO Verify or proper superheat Verify each circuit refrigerant site glass when the circuit is operat ing under steady state full load conditions It should be full and clear If not look for refrigerant leaks VCES V CUBE IOM 1A 45 Appendix H Measuring and Adjusting V belt Tension Table H1 Measuring V belt Tension Recommended Deflection Force Ibs V belt Cross Section small Sheave Diameter m Retensioned Range Inches Initial Installation Maximum Minimum 3 00 to 3 40 3 3 2 9 2 2 A 3 60 to 4 20 3 5 3 1 2 4 4 60 to 6 00 3 7 3 3 2 5 4 60 to 5 40 6 0 5 1 4 0 B 5 60 to 7 40 6 3 5 5 4 2 8 60 to 9 40 6 6 5 7 4 4 7 00 to 8 50 13 2 11 5 8 8 C 9 00 to 12 00 13 9 12 1 9 3 13 00 to 16 00 14 6 12 6 9 7 12 00 to 15 50 26 5 22 9 17 6 D 16 00 to 18 00 27 8 24 3 18 7 22 00 to 27 00 29 1 25 6 19 6 17 70 to 23 60 39 7 34 4 26 5 E 23 70 to 31 50 41 7 36 2 27 8 31 60 to 39 60 43 7 37 9 29 1 2 10 to 3 40 4 4 3 7 2 9 AX 3 60 to 4 20 4 6 4 0 3 1 4 60 to 6 00 4 9 4 2 3 3 3 70 to 5 40 7 7 6 6 5 1 BX 5 60 to 7 40 8 2 7 1 5 5 8 60 to 9 40 8 6 7 5 5 7 5 80 to 8 50 17 2 15 0 11 5 CX 9 00 to 12 00 18 1 15 7 12 1 13 00 to 16 00 19 0 16 5 12 8 2 65 to 3 35 5 5 4 8 3 9 3V 3 65 to 4 12 6 4 5 7 4 4 4 50 to 5 60 7 5 6 6 5 1 6 0
51. es of the unit to pull the second or next section to the first end section evenly until both sections are Ya 6 4 mm apart on the full joint perimeter as in Figure 6 Remove any yellow side lifting lugs that interfere with the chains for pulling sections together When joining sections together always apply the pulling force to the lifting lugs attached to the unit structural base never to the corner posts and pull uniformly from both sides of the unit section IMPORTANT Unit sections must be drawn together using the lifting lugs attached to the unit structural base only CAUTION Do not use the vertical side casing framing or bolt holes to pull sections together as this may cause the corner posts to warp and break their air and water tight seal Tools supplied by others Figure 6 Use tools chains chain blocks chain type come along etc hooked to the unit lifting lugs attached to the structural base on both sides of the unit to pull the second or next section to the first section evenly 8 With the sections pulled together use the 3 8 x 212 bolts nuts and washers to secure the sections together along the sides as in Figure 7 Start at the bottom and gradually tighten all bolts to apply an even load along both sides and along the top not at one place until sections or gasket is compressed within Ya 6 4 mm Figure 7 Secure the sections pulled together with bolts n
52. f the compressor is normal or if there is excessive vibration Check all field and factory refrigerant and water piping connections for leaks and correct On units with WSHP after a few minutes of operation a Check the supply discharge temperature status on the keypad for cooling air delivery Mea sure the temperature difference between entering and leaving water In cooling mode the temperature difference should be approximately 1 5 times greater than the heating mode temperature difference For example if the cooling temperature difference is 15 F 8 3 C the heating temperature difference should be approximately 7 F to 10 F 3 9 C to 5 6 C Adjust the combination shut off balancing valve in the return line to a water flow rate which will result in the 7 F to 10 F 3 9 C to 5 6 C difference Alternatively if a flow measuring valve or pressure gauge connections are included take the flow reading or pressure drop compared to the submittal information and adjust the shut off balancing valve in the return line to the cor rect flow pressure drop reading b Measure the temperature difference between entering and leaving air and entering and leav ing water With entering water of 60 F to 80 F 15 6 C to 26 7 C leaving temperature should rise through the unit should not exceed 35 F 19 4 C If the air temperature exceeds 35 F 19 4 C then the water flow rate is inadequate or the airflow rate may be low and a sec
53. f the following steps need to be performed with the unit powered off and locked out Disconnect the main power switch to the unit before performing service and maintenance procedures Compressors Scroll type compressors are the most common type of compressor used by Venmar CES Other types of compres sors are available upon request if required Maintenance and service on compressors must be completed by a li censed service mechanic Provincial or state regulations frequently require such qualifications for compressor main tenance If a compressor cycles leaks or has any defects contact Venmar CES as soon as possible Water Cooled Condensers Shell and Tube Condensers Most integrated water cooled units contain shell and tube condensers Periodically water tubes should be mechanically cleaned to ensure optimum condenser ef ficiency Frequency of cleaning will depend on individual water conditions so a suitable cleaning schedule should be arranged based on experience and knowledge of the building or local water supply loop Cleaning brushes are available from most refrigeration supply outlets For better results always remove both heads before cleaning water tubes Note that head gaskets do not require renewing at every maintenance operation However if the head gasket is physically disfigured or deteriorated in any way the system will require new gaskets in order to retain the water tight seal required for correct system
54. flow not less than 1 8 per foot toward the building drainage system otherwise use a condensate pump Refer to local codes for proper drain age requirements Installing a plug for cleaning of the trap is recommended Fill the P traps with water before starting the unit Check and clear drains annually at start of cool ing season Drainage problems can occur should drains be inactive and dry out or due to reduced water flow caused by buildup of algae Regular maintenance will prevent these from occurring Start up Pre Start up Check Before requesting start up check that the installation is complete and unit is ready Complete the pre start up below if items are applicable and the checklist in Appen dix C for each unit For torque values on set screws belt tension etc check under Operation and Maintenance 1 Check the electrical disconnect is in 1 the Off posi tion 2 Check the split section joints are properly installed on multi section units 3 Check that all holes that have been made by the Installing Contractor after receiving the unit in the casing partitions or floor have been well sealed to prevent air and or water infiltration 4 Check the unit for obstructive packaging objects near or in fans dampers etc 5 Remove all retaining bolts on fan bases a Check that the fan impellers are rotating freely b Check fan impeller and drive set screws Tighten if required c Check the fan bearing set scre
55. fting lugs from the unit base may be removed if desired or left in place When removing lifting lugs on the exterior of the base set the bolts back in place and seal with clear silicone based sealant for water tightness 1 8 x 1 neoprene Bead of Adseal 1800 SOFT SEAL gasket clear silicone based bs sealant Figure 9 a Install the gasket strips on the inside edges of the inside caps b Install caps in place with self drilling screws C Apply a continuous bead of Adseal 1800 clear silicone based sealant or equivalent to the inside cap seams and partition s divider s Suspended Unit Installation To install units that will be permanently suspended the units must be set on structural steel beams that are sup ported by vertical rods Venmar CES recommends beams under the full perimeter and all cross members requiring support In addition to these recommendations a Struc tural Engineer must be involved to properly size the sup porting structural elements Note that the locations of the beams shall be coordinated with the location of access doors to prevent any interference see Figure 10 Single section unit shown for multi sectional unit suspension consult factory Figure 10 Indoor suspended installation Field Fabricated Ductwork On indoor or indoor vertical duct connections make con nections to the casing by applying Adseal 1800 silicone based sealant or equivalent around the connection and screwing f
56. hat might months impede normal free movement Bearings between blades e Inspect the seals to ensure none have pulled loose or and frames are made of polymer and require no mainte deteriorated If a seal has been damaged repair or nance Note that the damper shafts do not need lubrica replace it with the same seal or same seal material Contact Venmar CES for replacement parts Belt Driven Fans Belt driven fan motor and drive assemblies should be checked and inspected at regular intervals per the inspec tion list and procedures below Listen for vibrations or unusual sounds Severe damage premature failure and loss of airflow can be avoided by regular inspection and maintenance Check the fan wheel hub bearings and drive sheave set screws for tightness according to the set screw torque chart in Table 2 below at time of start up after 24 hours of operation monthly for the initial three months then every three months thereafter If wheel or bearing set screws have worked loose check the wheel for any signs of movement inlet space clearance between the fan wheel and housing or loose blades If Loctite was used on any set screws that have come loose the set screws must be re moved and cleaned before re tightening and Loctite must be re applied 1 Check the fan motor and bearing mounting bolts for tightness according to the bolt torque chart in Table 1 below at time of start up after 24 hours then every three mont
57. hed or worn belt sets If a belt must be changed ensure to change all belts ua on the same drive at the same time Never replace sheave just one belt within a set Figure 13 Equal sheave Figure 14 Unequal sheave Measuring Belt Tension size alignment size alignment a Measure the belt span with a span scale b Divide the belt span by 64 to determine the belt 5 Belt driven fan bearings are fitted with grease nipples deflection needed to check tension for lubrication The grease quantity and lubrication c Set the O ring on the span scale to the required interval depends on bearing fan size and rpm and deflection value are indicated in Tables 4 and 5 Use a premium qual d Set the small O ring at zero on the force scale ity lithium based grease conforming to NLGI Grade 2 or 3 examples are Mobil Mobilith AW2 Chevron squarely on one belt at the center of the belt Amolith 2 Texaco Premium RB Shell Alvania 2 span Apply force on the plunger until the bot or Esso Beacon 325 Clean the grease nipple first tom of the large O ring is even with the top of then rotate the fan shaft slowly by hand while add the next belt or until it is even with a straight ing grease The lubrication intervals are theoretical edge laid across the sheaves and will depend on site conditions hours of opera f Read the force scale under the small O ring to tion and temperature It is recommended to make determine the force require
58. hs Table 1 Minimum head bolt torque in Ib ft Grade 5 bolts Size Inches Thread Designation Minimum Torque 17420 UNC 6 Table 2 Wheel set screw torque in Ib ft 1 4 28 UNF 7 Set Screw Size Carbon Steel Set Screw Torque 8 UNC 14 Diameter Inches Ib in Ib ft 5 16 24 UNF 16 3 8 16 UNC 24 1 4 75 6 2 3 8 24 UNF 28 5 16 144 12 0 7 6 14 UNC 42 3 8 252 210 7 16 20 UNF 45 1 2213 UNC 69 7 16 396 33 0 1 2 20 UNF 83 1 2 600 50 0 9 16 12 UNC 99 5 8 1 164 97 0 9 16 18 UNF 118 5 8 11 UNC 150 3 4 2 016 168 0 5 8 18 UNF 176 718 3 204 267 0 3 4 10 UNC 254 1 4 800 400 0 3 4 16 UNF 301 Stainless steel set screws are not hardened and should not be 718 9 UNC 358 tightened to more than half the values shown 7 8 14 UNF 422 1 8 UNC 500 1 14 UNF 602 Soft metric conversions are not acceptable for screw and hex sizes VCES V CUBE IOM 1A 18 A WARNING h If the deflection value is below the minimum tighten the belts If the deflection value is above the maximum loosen the belts The tension on new belts should be checked during the first day of operation at the end of the first week and monthly thereafter Many of the following steps need to be performed with the unit powered off and locked out Disconnect the main power switch to the unit before performing service and maintenance procedures
59. ity in w g Depth Nominal Size i g Medium High Medium High Final 2 51 mm 12 24 2 305 x 610 51 mm 600 1 000 0 12 0 23 1 00 24 x 24 x 2 610 610 51 mm 1 250 2 000 0 12 0 23 1 00 4 102 mm 12 x 24 x 4 305 x 610 x 102 mm 600 1 200 0 12 0 27 1 00 24 x 24 x 4 610 x 610 x 102 mm 1 200 2 400 0 12 0 27 1 00 Table J2 4 102 mm Final Filters A E Resistance in w g Filter Efficiency MERV Rating Nominal Size Capacities CFM T Initial Final 12 x 24 x 4 305 x 610 x 102 mm 1 000 pen 0 ER MERE 24 x 24 x 4 610 x 610 x 102 mm 2 000 did tap 12 x 24 x 4 305 x 610 x 102 mm 1 000 oa 0 en ME 24 x 24 x 4 610 610 x 102 mm 2 000 ui ae 12 x 24 x 4 305 x 610 x 102 mm 1 000 ES 0 PER MERY IS 24 x 24 x 4 610 610 x 102 mm 2 000 Qu kag Table J3 12 305 mm Final Filters gt 3 Resistance in w g Filter Efficiency MERV Rating Nominal Size Capacities CFM Initial Final 12 x 24 x 12 305 x 610 x 305 mm 1 000 l 0 00565 MERV M 24 x 24 x 12 610 x 610 x 305 mm 2 000 nd 1 30 12 x24 x 12 305 x 610 x 305 mm 1 000 ae 0 80705 MER 24 x 24 x 12 610 x 610 x 305 mm 2 000 0 33 tg 12 x24 x 12 305 x 610 x 305 mm 1 000 0 er ME 24 x 24 x 12 610 x 610 x 305 mm 2 000 0 39 ung Table J4 Filter Latches for Front Loading Access Final Filter Prefilter Latch Venmar PN None 2 C 70 207312240 4 C 86 19516104
60. kin 16 c P araaelastiiedns 16 unnn nenna nenn nan nna 16 16 Maintenance Refrigerant Systems eec ed eret e p ono gae egest t e oit Du eg sure ee Dee o 17 18 18 5 Belt FANWADLDLEC Araya ir cae eA As a attra ER T ATE 21 cduevavesnesusbunstdrstesereeeseeiys 26 dcl cec 9 ets 26 nein 26 27 Controls ced rtaor e TroubleshOOtilg ooi eter ette ener detis une teta uit cosmic err ie ETE 27 Appendix A Water Cooled Condenser WCC Piping Installation Maintenance and Troubleshooting 28 Appendix B Positive and Negative Pressure Trapping sessssesesssesses eterne nennen nns nnne nnns 32 Appendix C V Cube Start up Report and Checklist uuurs40r4nnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn enn 33 Appendix D HEPA Filter Installation ssssessesessseseseseeeeeen nennen nnne nnnm ennnenn entre eae aeee inns enn trnr inns snnt en nnns nennen 40 Appendix E Electric Heating Coil and Controls 7 42 Appendix F Extended Dormant Unit Maint
61. laced on the pedestal mounting angles for disassembly with the fan wheel inlet toward the inlet cone Place motor pedestal into the cube on the pedestal mounting angles and slide the pedestal forward to the line that you previously marked Line the four pedestal bolt holes up with the bolt holes on the mounting angles Insert four V bolts into the holes make sure to use a standard washer on the bolt side and a standard washer and lock washer on the nut side Hand tighten the bolts for now 10 Check the inlet cone alignment to the fan wheel Fan wheel should not be rubbing against the fan inlet cone when rotated by hand The fan wheel to inlet cone clearance should be approximately 1 16 gap and the overlap should be as indicated in Appendix for the fan wheel size Adjust the overlap of the wheel and cone by moving the motor pedestal for 22 A WARNING Many of the following steps need to be performed with the unit powered off and locked out Disconnect the main power switch to the unit before performing service and maintenance procedures ward or backward Fan wheel should not be rubbing on the inlet cone If cone alignment is required see instructions for Fan Wheel Cone Alignment below Once alignment and overlap are correct tighten the four Ya pedestal mounting bolts to 90 ft lbs x imd Figure 21 Check fan wheel cone alignment and overlap 11 Reconnect the four wire electrical 11 cable from the motor junction
62. langed ducts directly to the casing and or flange with self drilling sheet metal screws It is important to seal all duct connections to prevent air leakage and system performance problems Ductwork must be supported by the building structure For duct connection sizes see the mechanical drawings Insulate and weatherproof all external ductwork joints and roof openings with counter flashing and mastic in accordance with applicable codes Ductwork running through roof decks must comply with local fire codes Ducts passing through unconditioned spaces must be in sulated and covered with a vapor barrier The ventilation system should be designed according to maximum airflow needs To minimize noise level and loss of pressure ducts should be designed for a maximum air velocity of 1 200 feet per minute keeping the direction and transition changes to a minimum To further reduce noise transmission line the first 15 feet 4 572 mm of duct with acoustic insulation Elbows with a turning radius equal to or greater than 1 or 90 elbows with turning vanes should also be used Electrical Connections A WARNING When installed the unit must be electrically grounded in accordance with local codes or in the absence of local codes with the National Electrical Code ANSI NFPA70 and or the Canadian Electrical Code CSA C22 1 Unit cabinet must have an uninterrupted unbroken electrical ground to minimize the possibility of personal injury if
63. lation Heater Position 1 2 1 The axis of the duct must always be perpendicular to the face of the heater 1 2 2 The heating elements must always be installed horizontally Model SC or ST Slip in Type 1 2 3 Cut an opening in the side of the duct 1 2 4 Slip the heater into the duct until the hole is com pletely covered by flanges around the heater 1 2 5 Fasten the heater to the duct with sheet metal Screws and seal openings with a suitable sealing compound 1 2 6 If the heater is heavy use additional hangers to support the heater Model FC or FT Flanged Type 1 2 7 Flange both ends of the duct outwards on three sides to match the heater s flanges 1 2 8 Fasten the heater to the duct with sheet metal screws for heavy heaters use nuts and bolts and additional hangers to support the heater 1 2 9 Seal openings with a suitable sealing compound IMPORTANT Do not install spray humidifiers upstream of duct Install it downstream instead Do not cover the control box with thermal insulat ing materials Use special air intake louvers of weatherproof con struction for preheat duct heaters to avoid intake of water or snow particles Make sure that motorized damper blades are not blocked with snow or dirt Inspect the dampers regularly to ensure a suitable airflow VCES V CUBE IOM 1A Remove the shipping covers just before installation 2 Electrical Installation of Electric Coil Heaters 2 1 Disconnect all powe
64. le C1 Pre Start up Checklist Venmar CES Inc 200 Rue Carter St L onard d Aston QC Canada JOC 1MO Email to tech support venmarservice venmarces com Fax 899 319 2612 Phone 1 866 4 VENMAR Unit Identification Information Project Job Name Job Address Model Number Serial Number Tag Jobsite Contact Email Telephone Checklist Item Yes N A Is the electrical disconnect set to the Off position Have the split section joints been properly installed on multi sectional units to prevent air and or water infiltration Have all holes made by the Installing Contractor in the casing partitions or floor been well sealed Have obstructive packaging objects near or in fans dampers etc been removed a Has the inside of the unit been cleaned of all debris Have all retaining bolts on fan bases been removed Do all the fan impellers rotate freely Are all fan impellers and drive set screws tight Are all the fan bearing set screws or locking collars tight Are all fan belts aligned and have proper tension v o lnlo o Are the fan flexible joint connections well attached Are all air filters installed and clean a Are all face mounted filters attached with four clips each b Do all sliding filters have a retainer at the end track and well attached blank offs satisfactory to the end user to trigger
65. lean dry and properly lubricated An excessive running current is a good indication of the overall condition of the motor Check the following items every six months unless otherwise indicated for proper performance e Motors must be cleaned with moderate air pressure around 25 to 30 psi Dirt must be blown away from vent fins and all other accessible areas All areas sur rounding the motor must be kept clear so air can circulate freely to cool the motor e Ensure all connections are secure Look for loose wires and loose contacts Repair and tighten any de fective connection e Ensure the motor is operating at the current indi cated on the nameplate If not a physical or electrical restriction is working against the motor and it must be repaired e Ensure the motor is not vibrating too much A signifi cant vibration can come from a loose mounting bolt or an unbalanced impeller If significant vibration has occurred be sure to repair it and inspect the mount ing base and the flexible duct connection for any damage Motor lubrication must occur once a year when grease nipples are provided with a premium quality lithium based grease conforming to NLGI Grade 2 or 3 examples are Mobil Mobilith AW2 Chevron Amo lith 2 Texaco Premium RB Shell Alvania 2 or Esso Beacon 325 Clean the grease nipple first then rotate the motor shaft slowly by hand while adding grease with a low pressure grease gun Do not over lubricate Fil
66. ll tek screws on the airflow straightener panel frame and remove it from the cube 23 A Many of the following steps need to be performed with the unit powered off and locked out Disconnect the main power switch to the unit before performing service and maintenance procedures 4 Gently rotate the fan wheel to verify location of ad justment required fan wheel Figure 25 Fan wheel cone alignment Step 4 5 To make adjustment loosen do not remove all the cone retaining fasteners Figure 26 Fan wheel cone alignment Step 5 6 Using a rubber mallet gently tap around the cone until desired clearance is acquired between fan wheel and inlet cone rw Figure 27 Fan wheel cone alignment Step 6 Gently tap cone VCES V CUBE IOM 1A 7 Gently rotate the fan wheel to verify cone adjust ment for proper clearance from wheel m Gently rotate fan wheel Figure 29 Fan wheel cone alignment Step 7b and Step 9b 8 Tighten all the cone retaining fasteners Figure 30 Fan wheel cone alignment Step 8 9 Once again gently rotate the fan wheel to verify cone alignment 10 To install the optional airflow straightener or back draft damper reverse the steps above 24 A WARNING 4 Place the blank off plate over the optional airflow straightener panel frame if supplied or onto the matching Z frame and pre drilled holes and fasten together with or remove tek screws
67. n the cooling mode A re frigerant pressure transducer is also included and fac tory installed in the compressor compartment on the compressor discharge which will modulate the water flow to the condenser using a 2 to 10 VDC signal to prevent the compressor discharge pressure from fall ing below the compressor operating limit The regu lating valve may be factory installed or shipped loose for field installation depending on the unit configura tion and or options selected 2 A flow switch on the water return or leaving side of the condenser is factory provided and installed in the compressor or coil compartment to monitor the pres ence or absence of flow which will shut down the compressor operation if no flow is detected 3 A water temperature sensor on the water supply or entering side of the condenser is factory provided and installed in the compressor or coil compartment to monitor the water temperature which will shut down disable the compressors if the entering water temperature drops below 70 F For units with wa terside economizer coils WISE the entering water temperature sensor shall be utilized to compare the unit entering water temperature to the unit entering air temperature and enable WISE operation when ap plicable 4 A waterside economizer coil WiSE along with dual two way modulating water economizer valves and a temperature sensor shall be supplied with the unit The water temperature sensor is input to the DDC
68. nect has been on for at least 24 programmed DDC control system regarding the hours This will assure that no refrigerant liquid is navigation and monitoring of the unit with the present in the crankcase which could cause compres standard keypad are provided in separate docu sor damage or failure to occur on start up ments For more specific information regarding the 10 Before activating the compressor s ensure that any sequence of control the different options of control water shut off valves are open and that water is or network communications see these documents circulating through the water to refrigerant heat ex included with the unit in the control panel pocket changer Check the incoming line water pressure to If units are equipped with compressors power must ensure it is within design and acceptable limits be turned on for 24 hours prior to a call for cooling 11 Enable cooling and check that compressors and con for the compressor crankcase heaters to be energiz denser fans are rotating in the correct direction ing to prevent possible damage 12 Check if the sound of the compressor is normal or if there is excessive vibration A WARNING 13 Check all field and factory refrigerant and water pip Electric shock can cause personal injury or death ing connections for leaks and correct Only qualified service personnel should install and 14 Check the operation of the control options provided service this equipment on the unit The keyp
69. nit the coil section 3 Remove soft debris from both sides of the coil with a soft brush Controls General controls information regarding the navigation and documentation that is contained in the control panel of monitoring of your unit with the standard keypad DDC your unit Please contact the factory if this information is points list ladder diagram and specific sequence of opera missing or has been lost tion or required network communication is included in the Troubleshooting See Appendix K for trouble shooting information VCES V CUBE IOM 1A 27 Appendix A Water Cooled Condenser WCC Piping Installation Maintenance and Troubleshooting Units have the WCC supply and return line internally coupled manifold and piped to the unit exterior The WCC connections shall have copper IPS connections See the submittal drawings for size location flow rate type of fluid pressure drop information and components included and factory installed for the supply and return connections Optional Water Piping Components The following components may or may not be included and factory installed depending on the water conditions and or options selected 1 A two way or three way modulating 1 head pressure control valve may be included in the compressor or coil compartment to maintain stable operation of the refrigeration systems when operated on ground loop or cooler water systems when the design inlet water temperature is below 70 F i
70. nstall any automatic flow controlled devices that were removed for flushing 8 Refill the system with clean water Test the water using litmus paper for acidity and treat as required to leave the water slightly alkaline pH 7 5 to 8 5 The specified percentage of antifreeze may also be added at this time Use commercial grade antifreeze designed for HVAC systems only Do not use auto motive grade antifreeze 9 Once the system has been filled with clean water and antifreeze if used precaution should be taken to protect the system for dirty water conditions Dirty water will result in system wide degradation of per formance and solids may clog valves strainers flow regulators etc Additionally the heat exchangers may become clogged which reduces compressor ser vice life or causes premature failure 10 Start the circulation pumps After full flow has been established through all components air vented lines checked for leaks and loop temperatures stabilized the WCC will be ready for check start up and water a balancing General Maintenance Recording of performance measurements of volts amps and water temperature difference both heating and cool ing is recommended A comparison of logged data with start up and other annual data is useful as an indicator of general equipment condition Periodic lockouts almost always are caused by air or water problems The lockout shut down of the unit is a normal protective result
71. nths of opera tion After that two inspections per heating season are sufficient 4 3 Checkpoints e Check all fuses e Check the resistance to ground for each circuit e Check the resistance phase to phase for each circuit e Check the tightening of connections at all contactors and heating elements e Check all contactors 4 4 Off season Maintenance Where tubular heating elements are used it is strongly recommended that you start the heating system from time to time This precaution will prevent moisture from perco lating through the terminal gaskets into the heating ele ment and accumulating in the insulating powder Should a heater be shut off for a long period we recommend that you check carefully the resistance to ground for each circuit It is important not to power a heater when too low a resistance to ground has been measured It is also rec ommended to pay attention to any other heater operating in normal conditions Control components such as step controllers or modulating valves SCR should be main tained and checked according to respective manufacturers instructions Any defective components should be replaced only with identical original parts 43 Appendix F Extended Dormant Unit Maintenance Procedure The following procedures must be applied to any unit which is stored for a period exceeding one month which are required in order to maintain our warranty Failure to comply with the procedures outlined bel
72. ond check may be required after airflow balancing 16 On units with integrated air cooled condensers check condenser fans are rotating in the correct direction Measure the temperature difference between entering and leaving air 17 18 19 On units with electric heating coils check supply air proving interlock switch setting to ensure mini mum supply airflow prior to operation Enable heating options see Start up and check instructions in Appendix E for electric coil and complete For electric heating coil option check the amp draw on each stage the operation of the sequence or SCR controller and the coil for any hot spots 20 Check the operation of the control options provided on the unit 21 Check the setpoints on the DDC Points Reference adjust and record changes as required 22 Has air balancing been completed for both occupied and unoccupied operation 23 When unit has achieved steady state take measurements and complete readings section of start up report VCES V CUBE IOM 1A 35 Serial Number Nameplate voltage Input voltage L1 L2 L2 L3 L1 L3 Table C3 Start up Readings Supply Fans O L O L Set Max O L Set Amp at Min Hertz at Min Setting Hertz Hertz Rotation Nameplate Correct Fan 1 Fan 2 Fan 3 Fan 4 Fan 5 Fan 6 Fan 7 Fan 8 Fan 9 Fan 10 Fan 11 Fan 12
73. or glycol mixture should be drained or capped off if necessary and all peripheral electrical penetrations should be properly sealed 44 Appendix G V Cube Maintenance Summary Chart Table G1 Maintenance Summary Chart V Cube Item No Description Monthly Quarterly Semi annually Annually General Fans Inspect the general condition of the unit Remov e any dirt or debris Check for unusual noise or vibration Lubricate the door latch mechanisms Clean fans with stream of water Align or replace belts and drives Adjust belt tension Check motor voltage and current Lubricate the motor and shaft bearings Lubricate motor base adjusting screws x X x x x x Dampers Visual inspection for dirt or leakage Lubricate damper linkage Air filters Coils Clean and replace prefilters Clean and replace final filters Inspect holding frames sliding rack Clean the coils x ilo Rum a3lo eo uoju 5 w w Winterize the water coil Electric UJ gt Verify all electrical connections tighten if necessary UJ vI Verify all fuse holders UJ Verify all motor overload settings Condenser fans UJ N Inspec fan blades for cracks UJ oco Inspec for wear and tension x lt x lt x Cooling section UJ Mo Look for oil on all refrig
74. ow may result in damage and will void unit warranty 1 Unit must be stored indoors in a clean dry and tem pered environment heated in the winter and air cooled in the summer Ambient air conditions should be from 50 F to 75 F with percentage RH from 10 to 50 The unit needs to be stored in a warehouse or some type of enclosure Note that storing units outdoors is contraindicated and will void our war ranty 2 Unit must be stored on a level surface with the weight of the equipment evenly distributed through its base The unit location must be free from exces sive vibration and accidental impacts 3 Once the unit has been unloaded in its resting loca tion the plastic wrapping must be removed from the unit by cutting along the corner edges in order to perform proper inspections and maintenance on the equipment The plastic wrapping should be kept and re applied to the unit when the unit will finally be shipped to the jobsite 4 If applicable a certified qualified refrigeration techni cian should record refrigerant pressures on all com pressors at time of storage Each compressor must maintain refrigerant pressure in the system 5 If applicable a certified qualified refrigeration tech nician should check refrigerant pressure in each compressor every three months Refrigerant pressure must be maintained in the system If zero pressure is found this indicates a leak in the system Leak s must be identified and repaired A
75. p Company info venmarces com www venmarces com Venmar CES Inc has a policy of continuous improvement and reserves the right to change design and specifications without notice FANWALL TECHNOLOGY and FANWALL are trademarks of Huntair Inc Products in this literature are covered by one or more of the patents listed on www ces group com patents 2014 Venmar CES Inc VCES V CUBE IOM 1A February 2014
76. r sources before opening the control box and working within 2 2 Read the nameplate carefully and consult wiring diagram before starting to wire 2 3 Supply Wires Use only wires suitable for 167 F 75 C Wires shall be sized according to the Canadian Electrical Code require ments All wires must be brought in through knock outs 2 4 Disconnecting Means Install a disconnect switch close to the heater according to the code unless a disconnect switch is already built into the heater 2 5 Control Circuit Wiring Use Class Il wiring for control circuit connections to the duct heater 2 6 Magnetic Contactors If magnetic contactors are mounted outside of the duct heater use only contactors approved for e 250 000 operations when controlled by auto reset thermal cut out A and by other switching devices in series with this cut out thermostat step controller airflow switch etc e 100 000 operations when controlled by auto reset thermal cut out A alone e 100 000 operations when controlled by auto reset thermal cut out A plus manual reset cut out in se ries A and M e 6 000 operations when controlled by manual reset cutout M alone 2 7 External Controls Ratings Rating of external control devices shall be suitable for han dling the VA ratings as marked on the nameplate other wise a backup relay must be used 2 8 Airflow Interlock Heaters are generally supplied with one extra terminal ma
77. re the sole responsibility of the Installing Contractor and or Design Engineer Refer to ASHRAE handbooks and local building codes for correct piping and electrical control for proper installations Refer to the mechanical drawings for coil performance design information Connections to the unit coil water steam or non inte grated direct expansion WCC or humidifier are by others Refer to the mechanical drawings and the instructions on the casing for correct orientation of external piping External supply and return piping connection provision design and all other safety freeze protection or electrical control requirements for system operation are the sole responsibility of the Installing Contractor and or Design Engineer Refer to ASHRAE handbooks and local building codes for correct piping and electrical control for proper installations Refer to the mechanical drawings for coil per formance design information For WCC units see Appendix A See the piping schematics for optional piping components and sequence of opera tion for electrical control options or interlocks supplied with the unit CAUTION A water and glycol mixture is used for factory tests and to prevent any possibility of freezing during transit and or storage In units that include factory installed water piping some glycol may remain in the system Flush the system in the field prior to installation if no glycol traces are desired In low temperature appli
78. rked for fan interlock or air sensing device connection Remove jumper between terminals and C before con necting the fan interlock Select a suitable airflow sensing device of the differential pressure sensing type with snap acting contacts A slow make slow brake device may cause undue cycling and in some instances chattering of the contactors When fresh air dampers are used make sure the heater is properly interlocked to prevent it from being energized before the damper is fully open 42 3 Operating Electric Coil Heaters 3 1 Minimum Airflow Ensure that sufficient airflow as marked on the nameplate is passing through the heater Airflow should be evenly distributed across the entire face of the heater Use air turning vane at duct elbows and splitter damper at duct branchoffs to streamline the airflow in the heater Use suitable airflow sensing device or interlock the heater with fan An insufficient airflow will lead to the opening of the autoreset thermal cut out or damage to the heating ele ments 3 2 Warning The air flowing through the duct where the heater is in stalled shall not contain any combustible particles nor any flammable vapor or gas 3 3 Air Temperature The air temperature should not exceed 120 F 49 C at the heater outlet 3 4 Minimum Static Pressure and Air Direction The heater is protected by a differential pressure switch To keep the contact of this switch closed it is necessary
79. ry six months a Check motor bearings for possible binding noise or overheating b Check fan wheels for dirt and grease accumula tion Clean as necessary Do not use any caustic Cleaning solutions 3 Annually a Lightly lubricate damper and linkage bushings on backdraft dampers if equipped 4 Every two years a Examine fan housings and motor pedestal for corrosion Clean and touch up with paint as nec essary 2 Figure 15 FANWALL array Fan Wheel and Motor Removal 1 Disconnect power to the fan array control panel before maintenance Follow all lockout and tag out procedures 2 Remove the optional safety screen if provided on the motor end only of the cube in question by re moving all four hex screws from the holding flange that retains the safety screen see Figure 16 VCES V CUBE IOM 1A MI ABIT aii Figure 16 Remove safety screen on motor end 3 Disconnect the four wire electrical cable from the motor junction box Make note of wire locations for reinstallation later see Figure 17 Figure 17 Remove electrical cable 4 Mark motor pedestal location on the motor pedestal mounting angles both sides then loosen and re move four bolts that retain the motor pedestal to the mounting angles see Figure 18 Figure 18 Remove motor pedestal retaining bolts 21 A WARNING Many of the following steps need to be performed with the unit powered off and locked
80. s and final filters it is recommended that prefilters be changed twice as often as final filters Running a unit with dirty and inef ficient filters will lower the airflow and thus lower the air quality of the area CAUTION Do not use acidic chemical coil cleaners Do not use alka line chemical coil cleaners with a PH value greater than 8 5 or lower than 6 after mixing without using an alu minum corrosion inhibitor in the cleaning solution Using these types of cleaners may result in unit damage Coil fins can be cleaned by using steam with detergent hot water spray or a commercial chemical coil cleaner After cleaning the coil be sure to rinse thoroughly 26 A WARNING 4 Using a steam cleaning machine clean the leaving air side of the coil first going downward then clean the entering air side Use a block off to prevent the steam from penetrating a dry section of the unit 5 Allow the unit to dry thoroughly before restoring Many of the following steps need to be performed with the unit powered off and locked out Disconnect the main power switch to the unit before performing service and maintenance procedures power Cleaning Procedure 6 Damaged coil fins should be straightened by using a 1 Shut down the unit by closing the main disconnect at fin comb 0 the power inlet 7 Close all panels and doors once the coil is dry 2 Open panels or doors to gain access to both sides of 8 Restore electrical power to the u
81. st Kit is recommended to test for acid content If the oil is discolored has an acid odor is acidic or if the mois ture indicator indicates a high moisture content in the system change the filter driers The compressor oil can be changed if considered desirable Allow the system to operate for an additional four hours and recheck as before Repeat until the oil remains clean odor and acid free and the color approaches that of the original sample Replace the liquid line filter drier with one of the normally recommended size Remove the suction line filter drier After the cleaning procedure is completed recheck in approximately two weeks to ensure that the system condition and operation is completely satisfactory 31 Appendix B Positive and Negative Pressure Trapping Positive Pressure Trapping Removable plug Cleanout Minimum 0 5 13 mm 0 5 13 mm maximum total static pressure 3 9375 100 mm if unit has a 6 152 mm tubular steel base gt pipe diameter insulation X TXIK Negative Pressure Trapping Removable plug 1 Cleanout 1 36 mm for each 1 25 mm of maximum negative static pressure 1 25 mm Half of H 3 9375 100 mm if unit has a 6 152 mm tubular steel base J pipe diameter insulation X lt gt VCES V CUBE IOM 1A 32 Appendix C V Cube Start up Report and Checklist
82. ters Standard 2 51 mm and 4 102 mm prefilters are dis posable and should be replaced every three months or sooner if the pressure drop across the filters is too great High efficiency filters optional should be replaced when dirty Venmar CES recommends that they be used only in combination with 2 51 mm or 4 102 mm prefilters in order to protect them from premature clogging and to increase their effective lifespan The tables in Appendix J provide data relative to the pressure drop across clean fil Dirt on the surface of the coil reduces its ability to transfer heat which lowers the efficiency of the unit resulting in poor air quality and expensive operating costs Because of the condensate on the coil the dirt often becomes wet and contributes to the growth of microbial organisms Negligence in maintenance may result in serious health related indoor air quality problems The coil should be kept clean for maximum performance To achieve maxi mum efficiency clean the coil often during periods of high demand or when dirty conditions prevail Venmar CES recommends cleaning the coil a minimum of once per year to prevent dirt buildup in the coil fins where it may not be visible VCES V CUBE IOM 1A ters and indicate the type of reading that should be given on the magnahelic gauge The data relative to accurate pressure drop across the filters is available in the submit tal If the system is equipped with both prefilter
83. the Fan wheel is turning the wrong direction pup direction of the arrows shown on the fan Increase speed by increasing the diameter of motor sheave Rotation speed is too low or installing a smaller fan sheave Poor airflow Filters are blocked Air leakage Replace filters Seal all leaks in ducts and unit walls Fan belt is slipping Adjust belt tension Fan motor overload Low static pressure Verify presence of filters and other duct components Set balancing damper so that it reduces the passage of air Electric tension of motor is too low high Adjust tension Excessive fan speed Reduce blower speed Low motor power Install more powerful motors Exhaust fan not working Unit equipped with recirculation defrost system is in defrost mode Wait until the defrost cycle is over A wire is disconnected Connect the wire Filters are out of filter rack Filters are too dirty and have been sucked into the unit Clean or change the filters and consider revising maintenance schedule Filters are wet Water infiltration or condensation See Water Issues section below Filter rack is damaged Repair filter racks and reinstall filters Some filter clips are missing Order new clips from Venmar CES Water Issues Water carryover from wet cooling coil onto the floor motor or fan housing Airflow is too high Lower airflow b
84. the unit or unit section Never lift rig or ceiling suspend from the top of the unit or unit sections Using a forklift or similar device for moving lifting or rigging unit or unit sections is prohibited The use of a forklift or other similar device is only allowed for modular unit sections that are mounted on wooden skids within the factory prior to shipment The sections must be forklifted individually along its longest side only When lifting the unit or unit sections use adjustable spreader bars pulleys cables straps or chains in order to properly distribute the load applying an even vertical lifting force only at all the lifting lugs to prevent structural damage to the unit or unit section or prevent cables from rubbing against the cabinet see Figure 1 Provide ad ditional blocking and coverings as required to prevent damage to the unit finish and or components The adjust able spreader bars are required to maintain a clearance between the cables and the unit or unit section of at least 12 305 mm beyond the sides Venmar CES will not be responsible for any damage caused to the unit casing dur ing the lifting process Main areas where damage may occur are electrical panels filter gauges roofing corners door handles and paint finish The lifting point must be at the center of gravity to ensure that the unit or unit section is level during hoisting and prior to setting When com mencing to hoist take up the slack in the
85. tics exist in the same loop 2 The water line piping may be steel copper or PVC Avoid dissimilar metal fittings as they may corrode The piping should be installed with a minimum number of bends and elevation changes for best per formances Size piping to minimize system pressure drop 3 Water line piping should contain a Short sections of high pressure flexible hose or vi bration eliminators to reduce vibration and noise transmission One end of the hose should have a Swivel fitting to facilitate removal for service Hard piping connections are not recommended due to the possibility of vibration that could dam age piping connections joints or transmit noise Where hard piping is used unions should be provided in the supply and return lines for service and removal b Manual shut off valves in supply and return water lines for isolation and service C Pressure and temperature gauge connections in the supply and return water lines to aid in start up and service d A water strainer 16 20 mesh minimum or some means of removing foreign matter from the water e Manual vent valves and or automatic air vents at the high points of the system in the supply and return water lines to discharge non condensable 28 air in order to avoid unexpected high head pres sure and poor cooling heating performance f A flow balancing valve in the return water line to set the required flow rate g A flow measuring valve or pressure gaug
86. tion field wiring entry points may only be field extended through the cabinet within des ignated areas The unit cabinet and or floor must be wisely penetrated in order to keep their integrity Access openings in the floor can only be cut or drilled for piping and wiring high and low voltage in the designated rect angular areas within an upturned 1 25 4 mm flange as provided during the submittal process and located on the mechanical drawings Access openings must be sized field cut or drilled by the Installing Contractor within the rectangular flanged area then sealed air and water tight If insulation was removed to create floor access openings insulation must be put back in place to avoid condensa tion Do not cut or drill holes through floor of unit in non designated areas without consulting the factory first The structural integrity of the floor may be compromised and possible leaks develop Coil or Water Cooled Condenser WCC Piping Connections CAUTION Internal coil water steam or non integrated direct ex pansion WCC piping connections within the unit may only be field extended through the cabinet within desig nated areas Connections to the unit coil water steam or nonintegrated direct expansion WCC are by others External supply and return piping connection provision design and all other safety such as dielectric couplings or other freeze protection or electrical control require ments for system operation a
87. tion must provide adequate continuous support to the full perimeter of the base and all cross members requiring support to minimize deflection of the unit base frame to not more than 1 16 1 6 mm over the entire length and width In addition to these recommendations a Structural Engineer must be involved to properly size supporting structural ele ments e Once the unit is in place within the mechanical equipment room mount the unit on a housekeeping pad of sufficient height in order to allow for drain trap height and condensate lines to slope toward the building drain install condensate pumps to reduce height of the housekeeping pads or drill holes in the concrete pad or mechanical room floor for sufficient trap height Rigging Lifting and Assembling IMPORTANT Carefully read all the instructions contained herein Before proceeding with any work correlate these instructions with the information provided on the curb and equipment shop drawing for the specific project These instructions outline the suggested method of rigging lifting and installing a Venmar CES unit All local codes and fire regulations must be verified and adhered to by the Installing Contractor Before assembling hoisting or setting any pieces of the supporting curbs or units verify that the proper unit is being directed to the correct location as des ignated by the architectural and engineering design drawings Safety first Ensure that all safety practices
88. to minimize the effect of differences in air density especially when balancing during extremely cold outside conditions or to take temperature readings and make the necessary corrections if installed in the cold side ductwork Air density variations can affect the FMS by more than 1596 The FMS should be located downstream in straight sec tions of duct and not immediately after fans or obstruc tions that will cause turbulent flow If the unit has been in operation before the air balancing ensure the unit filters are clean or include pressure drop readings across the filter banks with the report Maintenance Long term Storage Maintenance Procedures A WARNING Many of the following steps need to be performed with the unit powered off and locked out Disconnect the main power switch to the unit before performing service and maintenance procedures Please refer to Appendix F Extended Dormant Unit Main tenance Procedure and Checklist for maintenance instruc tions to follow if the unit is to be stored for a period of time exceeding one month Following the instructions in this appendix will assist in preventing potential unit dam age that may result from an extended storage period Maintenance Summary Chart Please refer to Appendix G for a recommended list of routine maintenance items and time intervals A more de tailed description of maintenance items follows VCES V CUBE IOM 1A Refrigerant Systems A WARNING Many o
89. unit R Right handed unit V V Y 000 o G S M IL cm 6 US Listed Intertek CES Group LLC d b a Venmar CES furnishes equipment pursuant to its then current Terms and Conditions of Sale and Lim ited Warranty copies of which can be found under the Terms amp Conditions of Sale and Warranty link at www ces group com Extended warranties if any shall be as offered and acknowledged in writing by Venmar CES VCES V CUBE IOM 1A Safety Considerations Warning Caution and Important notes appear through out this manual in specific and appropriate locations to alert Installing Contractors and maintenance or service personnel of potential safety hazards possible equipment damage or to alert personnel of special procedures or in structions that must be followed as outlined below A WARNING Identifies an instruction which if not followed might cause serious personal injuries including possibility of death CAUTION Identifies an instruction which if not followed might se verely damage the unit its components the assembly or final installation IMPORTANT Indicates supplementary information needed to fully complete an instruction or installation Hazards may exist within this equipment because it con tains electrical and powerful moving components Only qualified service personnel should install or service this equipment Untrained personnel can perform basic main tenance such as maintaining filters Observe pr
90. uts and washers Do not over tighten CAUTION Do not over tighten the side bolts as this may cause the corner posts to warp and break their air and water tight seal 9 After two sections are assembled verify that the assembly is level and square If an adjustment is re quired make certain to address it immediately not at the end of the final assembly 10 If multi section unit has more than two sections fol low Steps 1 through 9 for each additional section always pulling the next section from the first end sec tion 11 Apply a generous bead of Adseal 1800 series clear silicone based sealant or equivalent to the exterior side frame joint seams to completely cover the sec tion split gasket and in such a way that the silicone bead meets with both frames as in Figure 8 The bead of clear silicone based sealant should fill the 1 4 gap as shown in Figure 8 up Ya bead Adseal 1800 clear silicone based sealant N L Figure 8 Apply a continuous bead of Adseal 1800 clear silicone based sealant or equivalent to the exterior side frame joints and for indoor units along the top frame joints VCES V CUBE IOM 1A 12 All lifting lugs removed on the exterior of the base for pulling sections together must be returned or if not desired the bolts must be set back in place Once removed the bolts must be returned and sealed with clear silicone based sealant for water tightness All other li
91. ws or locking col lars Tighten if required d Check fan belt alignment and tension 6 Check that the air filters are installed and clean Replace if necessary See Appendix D for optional downstream high efficiency HEPA filter installation if supplied a Check all face mounted filters are attached with four clips each b Check each sliding filter has a retainer at the end track and well attached blank offs c Check that the filter pressure differential gauges switches or sensors are free of dirt and set at a value satisfactory to the end user to trigger a fil ter change 7 Check coils if fins have been damaged in shipping installation or building construction and are clean Straighten fins with fin comb and clean coil if re quired a Check all pipe connections are tight and that no damage has occurred during shipping or instal lation b Check that the piping to the coils and WCC have been completed piping lines have been flushed filled vented and tested at 1 25 times the oper ating pressure c Refer to Appendix A for WCC piping installation and check that it is complete VCES V CUBE IOM 1A 8 16 17 Scroll compressor RIS vibration isolator bolts are fac tory tightened to the correct torque setting for op eration and do not require field adjustment a Check that refrigerant components and piping are in good condition and have no damage or leaks from shipping or installation b Check that the cl
92. y adjusting the drive Drain pan not properly draining Clean drain pan and ensure suction into the unit is not too high Coil bulkhead penetration Be sure any field penetrations are sealed Missing or improper intermediate drain pan Install or clean the intermediate drain pan Water inside the unit Unit was not properly sealed when installed Seal all section joints Sections under negative pressure require special attention to sealing Electrical or piping conduits not properly sealed Inspect and seal any holes made for electrical wires or piping conduits Drain pan not properly draining Trap is not properly installed Revise trap installation and dimensions Unit is not installed on level Revise the level of curbs Pressure exceeds the design Verify design pressure versus unit pressure and check the segment which houses the drain pan VCES V CUBE IOM 1A 49 Table K1 Troubleshooting V Cube Symptom Possible Cause Corrective Action Prefilter is wet Outside air hood is shipped loose and was not well sealed when installed Reinstall hood ensuring the flange is properly sealed Airflow exceeds design conditions and sucks water into the unit Redesign the hood or lower the cfm of the unit Refrigerant Issues Solenoid valve does not open No power to coil Check circuit connections Defective solenoid

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