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V-Cube Installation, Operation and Maintenance

1. Capacities CFM Resistance Capacity in w g Depth Nominal Size i z Medium High Medium High Final mm 12 x 24 x 2 305 x 610 x 51 mm 600 1 000 0 12 0 23 1 00 51 2 x 24 x 2 610 x 610 x 51 mm 1 250 2 000 0 12 0 23 1 00 24 mm 600 1 200 0 12 0 27 1 00 102 610 305 4 x 24 12 mm 102 4 x 24 x 4 610 x 610 x 102 mm 1 200 2 400 0 12 0 27 1 00 24 Table J2 4 102 mm Final Filters ce Resistance in w g Filter Efficiency MERV Rating Nominal Size Capacities CFM Initial Final 12 x 24 x 4 805 x 610 x 102 mm 1 000 60 65 MER 24 x 24 x 4 610 x 610 x 102 mm 2 000 0 43 os 12 24 x 4 805 610 102 mm 1 000 80789 MER a 24 x 24 x 4 610 x 610 x 102 mm 2 000 0 69 mm 1 000 102 610 305 4 24 12 O a MERVAS 24 x 24 x 4 610 x 610 x 102 mm 2 000 cee Table J3 12 305 mm Final Filters RF 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 y O 60 65 MENA 24 x 24 x 12 610 610 305 mm 2 000 Oe t9 12 x 24 x 12 305 x 610 x 305 mm 1 000 case MENA 24 24 x 12 610 x 610 x 305 mm 2 000 ee 130 12 x 24 x 12 305 x 610 x 305
2. Refrigerant Issues Solenoid valve does not open No power to coil Check circuit connections Defective solenoid 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 Condenser fan s short cycling 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 Water control valves not operating properly Improperly set sequencing control Verify water temperature rise entering and leaving unit to determine if adequate water is flowing Verify and repair water control valves Set fo
3. ioe al Electric Verify all fuse holders w O Verify all motor overload settings Look for oil on all refrigeration components including coils compressors etc to indicate a refrigerant leak S Oo Cooling Verify for proper superheat section S aire Verify each circuit refrigerant site glass when the circuit is operating under steady state full load conditions It should be full and clear If not look for refrigerant leaks VCES V CUBE IOM 1C 57 Appendix H Measuring and Adjusting V belt Tension Table H1 Measuring V belt Tension Recommended Deflection Force Ibs V belt Cross Section Smal Sneave Diameter ad Retensioned Range Inches Initial Installation Maximum Minimum 3 00 to 3 40 3 3 2 9 22 A 3 60 to 4 20 3 5 3 1 2 4 4 60 to 6 00 3 7 3 3 25 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 DL 4 4 7 00 to 8 50 13 2 115 8 8 0 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 Tf 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 7 5 80 to 8 50 17 2 15 0 11 5 CX 9 00 to 12 00 18
4. VCES V CUBE IOM 1C 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 rec ommended monthly during the first four months 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 cir cuit It is important not to power a heater when too low a resistance to ground has been measured It is also recom mended to pay attention to any other heater operating in normal conditions Control components such as step con trollers or modulating valves SCR shou
5. 13 Remove the six self drilling 5 16 hex head 12 14 1 screws with rubber washer and the junc tion plate already installed on one of the sections walls and use those to fix the two sections together ps as in Figure 8a At this moment the tools chain chain blocks chain type come along etc can be removed e No VCES V CUBE IOM 1C 14 Apply a generous bead of Adseal 1800 series clear silicone based sealant or equivalent around the junction plate previously installed on the exterior frames and the junction plate previously installed on the structural base as in Figure 8b Figure 8b Apply a generous bead of Adseal 1800 series clear silicone based sealant or equivalent around the junction plate previously installed on the exterior frames and the junction plate previously installed on the structural base See Note 1 6 0 9 69 9 C See Note 1 See Note 1 m 89 a 6 N N See Note 1 See Note 1 O 6 O O gt oO Note 1 Continuous 1 4 bead Adseal 1800 clear silicone based sealant See Note 1 15 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 Cle
6. 604 4 42 122 7 69 197 1 96 298 7 123 433 9 150 611 9 43 125 0 70 200 4 97 303 0 124 439 6 44 127 4 71 203 6 98 307 5 125 445 4 45 129 8 72 207 0 99 311 9 126 451 3 46 132 2 73 210 3 100 316 4 127 457 3 VCES V CUBE IOM 1C 64 BDF NORTEK AIR SOLUTIONS info venmarces com www venmarces com Venmar CES has a policy of continuous improvement and reserves the right to change design and specifications without notice FANWALL TECHNOLOGY and FANWALL are trademarks of Nortek Air Solutions LLC Products in this literature are covered by one or more of the patents listed on www nortekair com patents 2015 Nortek Air Solutions Canada Inc VCES V CUBE IOM 1C June 2015
7. Wheel Cone Alignment below Once alignment and overlap are correct tighten the four Y2 pedestal mounting bolts to 90 ft lbs VCES V CUBE IOM 1C Figure 20 Check fan wheel cone alignment and overlap 11 Reconnect the four wire electrical cable from the motor junction 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 fan inlet IMPORTANT Before re starting re balance the fan wheel once the motor rotation and alignment have been corrected before placing the unit in operation 29 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 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 tenance staff can block the intake of a single fan to prevent back flow until service on an in
8. already installed on one of the sections structural base to fix the two sections together 10 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 11 If multi section unit has more than two sections fol low Steps 1 through 10 for each additional section always pulling the next section from the first end section 12 Apply a generous bead of Adseal 1800 series clear silicone based sealant or equivalent to the exterior side frame joint seams from the roof to the junc tion plate fixed on the structural base sufficiently to completely cover the section split gasket and in such a way that the silicone bead meets with both frames as in Figure 7c The bead of clear silicone based sealant should fill the 1 4 gap as shown in Figure 70 Figure 7c Apply a continuous bead of Adseal 1800 Figure 8a Use the junction plates already installed clear silicone based sealant or equivalent to the on one of the sections walls to fix the two sections exterior side frame joints and for indoor units along together the top frame joints from the roof to the junction pr CCT TT 27 plate fixed on the structural base a 1 GA uF fe i e o i NEE i e i o Ya bead Adseal 1800 clear i i silicone based sealant le
9. 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 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 in the cooling mode A refrigerant pressure transducer is also included and factory 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 pres sure from falling below the compressor operating limit The regulating valve may be factory installed or shipped loose for field installation depending on the unit configuration 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 presence or absence of flow which will shut down the compressor operation if no flow is detected 3 A wa
10. and prior to setting When com mencing to hoist take up the slack in the 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 ex tended period of time Once the unit or unit section leaves the trailer ensure it is level at all times VCES V CUBE IOM 1C Figure 1 Use adjustable spreader bars pulleys and cables attached to all lifting lugs to apply an even lifting force Adjustable spreader bars typ Pulleys typ Detail A Use clevis and clevis pin to attach cable to lifting lugs Adjustable spreader bars 12 min 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 The complete fan section non compressorized unit or the bottom half compressor condenser section should be set in place first 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 fir
11. from both sides of the unit section The butyl sealer previously applied on the top surface will allow the unit section to slide into position IMPORTANT Unit sections must be drawn together using the lifting lugs attached to the unit structural base only CAUTION Do not use the roof frame iron angle to pull sections to gether as this may cause the corner posts to warp and break their air and water tight seal 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 Tools supplied by others 8 With the sections pulled together use the 3 8 x 7 bolts nuts and washers to secure the top of the sec tions together as in Figure 7a Gradually tighten the bolt until gasket is compressed within Y 6 4 mm CAUTION Do not over tighten the side bolts as this may cause the angle iron to bend and squeeze the 3 8 x 7 bolts inside the angle iron Figure 7a Use the 3 8 x 7 bolts nuts and washers to secure the top of the sections together VCES V CUBE IOM 1C 9 Remove the six self drilling 5 16 hex head 12 14 x 1 screws with rubber washer and the junction plate already installed on one of the sections structural base and use those to fix the two sections together as in Figure 7b Figure 7b Use the junction plates
12. fuses are properly installed in holders O 5 4 N Is voltage at the disconnect switch within 10 of nameplate and are phase to phase readings within 2 of nameplate 20 Have field piping and venting installation connections for heating and cooling options been completed and tested 21 Are heating and cooling enable switches set to the Off position 22 If unit is equipped with an electric coil check that the installation and pre start up checks have been completed per Appendix E 23 Have all safety switches overloads or other devices that are manual reset been checked and reset 24 If unit is are equipped with compressors has power been turned on for 24 hours prior to a call for cooling VCES V CUBE IOM 1C 44 Serial Number Table C2 Start up Checklist Checklist Item Yes N A Before proceeding complete the Pre Start up Checklist Check that all access panels or doors are closed If units are equipped with compressors feel the compressor crank cases 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 crank case which could cause compressor damage or failure to occur on start up Otherwise 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 G
13. its then current Terms and Conditions of Sale and Limited Warranty copies of which can be found under the Terms amp Conditions of Sale and Warranty link at www nortekair com Extended warranties if any shall be as offered and acknowledged in writing by Venmar CES VCES V CUBE IOM 1C 3 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 precautions marked in literature and on labels attached to the unit Fol low all safety codes A WARNING Disconnect the main power switch to
14. mm 1 000 O PRA MER IS 24 x 24 x 12 610 x 610 x 305 mm 2 000 ORF 19 Table J4 Filter Latches for Front of Upstream Loading Access Final Filter Prefilter Latch Venmar CES PN None 2 C 70 207312240 4 C 86 19516104 None C 86 19516104 4 nominal 2 Knock on 4 2 500026048 4 Knock on 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 1C 60 Appendix K Troubleshooting Table K1 Troubleshooting V Cube Symptom Possible Cause Corrective Action General Air supply too cold Supply air is unbalanced Check filters for blockage Balance flow of supply air Check operation of heating option Adjust heating setpoint Install a post heat module Noisy unit Blower wheel is rubbing on other parts 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 fl
15. necessary remove all installed filter driers IMPORTANT Before starting the new compressor replace any ques tionable components 4 Install the recommended size suction line filter drier and new size liquid line filter drier Evacuate system using the triple evacuation method Re charge the system with new refrigerant do not use the recov ered refrigerant See unit s nameplate for proper refrigerant charge VCES V CUBE IOM 1C 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 pressure drop exceeds the maximum limits for a temporary installation replace the filter drier and re start 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 cautiously and compare the color of the oil with the sample taken in Step 2 Use of an Acid Test 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 R
16. 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 con nected If any blower is running backwards or compressor is making loud noises disconnect power and switch two leads on three phase power to ensure proper rotation 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 com pressor crank case heaters to be energizing 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 Nortek Air Solutions Canada Inc Unit Identification Information 200 Carter re St Leonard d Aston QC fice 5 Canada JOC 1MO Job Address Email to Tech Support venmarservice venmarces com Fax 899 319 2612 Phone 1 866 483 6627 Model Number Serial Number Tag Jobsite Contact Email Telephone Table C1 Pre Start up Checklist Checklist Item Yes N A 1 Is the electrical disconnect set to the Off position 2 Have the split section joints been properly installed on multi sectional units 3 Have all h
17. progressively until the bushing is free from wheel hub and motor shaft Remove fan wheel hub assembly see Figure 18 VCES V CUBE IOM 1C Figure 18 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 19 Figure 19 Remove motor retaining bolts do not lose rubber isolator pads if provided EAR pa Motor mounting bolts 9078 01 Al HU 003 S 3 otor support platform 28 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 8 To re install 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 underside make sure to use a standard washer on the bolt side install the rubber isolator pads if supplied 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
18. superheat and raise heat results in increased sub cooling sub cooling 5 If the sub cooling is correct and the superheat is too CAUTION high the TXV may need adjustment to correct the superheat Do not overcharge Refrigerant overcharging leads to excess refrigerant in the condenser coils resulting in elevated compressor dis charge pressure Table L2 R410a Refrigerant Temperature vs Pressure F PSIG F PSIG F PSIG F PSIG F PSIG 20 78 3 47 134 7 74 213 7 101 321 0 128 463 2 21 80 0 48 137 2 75 217 1 102 325 6 129 469 3 22 81 8 49 139 7 76 220 6 103 330 2 130 475 4 23 86 6 50 142 2 77 224 1 104 334 9 131 481 6 24 85 4 51 144 8 78 227 7 105 339 6 132 487 8 25 87 2 52 147 4 79 231 3 106 344 4 133 494 1 26 89 1 53 150 1 80 234 9 107 349 3 134 500 5 27 91 0 54 152 8 81 238 6 108 354 2 135 506 9 28 92 9 55 155 5 82 242 3 109 359 1 136 513 4 29 94 9 56 158 2 83 246 0 110 364 1 137 520 0 30 96 8 57 161 0 84 249 8 111 369 1 138 526 6 31 98 8 58 163 8 85 253 7 112 374 2 139 533 3 32 100 9 59 166 7 86 257 5 113 379 4 140 540 1 33 102 9 60 169 6 87 261 4 114 384 6 141 547 0 34 105 0 61 172 5 88 265 4 115 389 9 142 553 9 35 107 1 62 175 4 89 269 4 116 395 2 143 560 9 36 109 2 63 178 4 90 273 5 117 400 5 144 567 9 37 111 4 64 181 5 91 277 6 118 405 9 145 575 1 38 113 6 65 184 5 92 281 7 119 411 4 146 582 3 39 115 8 66 187 6 93 285 9 120 416 9 147 589 6 40 118 1 67 190 7 94 280 1 121 422 5 148 596 9 41 120 3 68 193 9 95 294 4 122 428 2 149
19. the unit before per forming service or maintenance Electric shock can cause personal injury or death A WARNING Equipment roof external components assemblies hoods louvers dampers pipe chase etc and internal components assemblies filter racks fans supports etc are unsafe surfaces to walk and work on Proper person nel supports and ladders must be used If not followed serious injuries may occur including possibility of death General Information This manual is designed to provide general information on the common operation of all standard and optional com ponents 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 Mammoth that could be included in the unit Consult the manual from the Compo nent 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 Mechanical drawings Unit nomenclature Electrical schematics Sequence of control Variable Frequency Drive VFD manual and CD when supplied e DDC controller documentation when supplied Controller user s manual Communication protocol documentation Hardware documentation Keypad documentation Recommended Spare Parts Sp
20. the unit before performing service and maintenance procedures tom of the large O ring is even with the top of the next belt or until is even with a straight edge laid across the sheaves f Read the force scale under the small O ring to determine the force required to give the needed deflection 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 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 4 Check the fan and motor sheave alignment using a straight edge along the outside edges of the sheaves for equal sized fixed sheaves as shown in Figure 12 and Figure 13 at time of start up after 24 hours of operation monthly for the initial three months then every three months thereafter When properly aligned the straight edge should touch the full face of both sheaves With one adjustable and one fixed sheave with unequal sizes use a string placed at the center grove of both sheaves pulled tight to check alignment Adjust sheaves for proper alignment and set screws to proper torque VCES V CUBE IOM 1C Figure 12 Equal sheave Figure 13 Unequal sheave size ali
21. these two sections are aligned square at the joint in all three directions 6 Install the Y 13 1 38 mm polyvinyl gasket with adhesive strip directly on one side of the split section perimeter frames and middle interior parti tions as shown in Figure 58 through Figure 5d Figure 5 General gasket layout VCES V CUBE IOM 1C IMPORTANT Make sure to have full contact between strips wherever a discontinuity is present for air and water tightness Figure 5a Install a polyvinyl gasket strip on each vertical outside wall 1 4 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 7c a 222 6 A Polyvinyl 30100 FLD 900 V 16 25 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 Top of frame Bottom of frame PP 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 wat
22. 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 designated by the architectural and engineering de sign drawings Safety first ensure that all safety practices 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 Rigging Lifting and Assembling Equipment 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 Lifting crane of the appropriate capacity Adjustable spreader bars Cables cables chains or straps All tools required to pull the sections together chains chain blocks chain type come alongs etc e All construction equipme
23. which reduces compressor service 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 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 36 Periodic lockouts almost always are caused by air or water problems The lockout shut down of the unit is a normal protective result Check for dirt in the water sys tem 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 entering air below machine limits may be the cause Water treatment is important for proper condenser op eration Proper water treatment is essential to prevent galvanic corrosion from occurring in the condenser water system The proper use of corrosion inhibitors and main taining proper pH levels are critical elements The use of sacrificial anodes can also be beneficial in certain water applications Improper water treatment will lead to equip ment performance corrosion problems and will require frequent equipment cleaning s
24. 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 3y 3 65 to 4 12 6 4 5 7 4 4 4 50 to 5 60 7 5 6 6 5 1 6 00 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 15 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 Figure H1 Belt tension adjustment Plunger with deflection VCES V CUBE IOM 1C force scale lbs Small O ring Body with deflection distance scale inches Large O ring 58 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 Figure 11 FANWALL inlet cone alignment Blade width 100 wide Backplate extension VCES V CUBE IOM 1C L A Wheel cone Backplate OD overlap 59 Table J1 Prefilters MERV 8 Appendix J Filter Resistance and Latches
25. 1 4 75 6 2 5 16 144 12 0 3 8 252 21 0 7 16 396 33 0 1 2 600 50 0 5 8 1 164 97 0 3 4 2 016 168 0 7 8 3 204 267 0 1 4 800 400 0 Stainless steel set screws are not hardened and should not be tightened to more than half the values shown Table 3 Bearing Set Screw Torque in Ib in Set Screw Manufacturer Diameter Link Belt Sealmaster SKF McGill Dodge 10 40 35 35 1 4 90 65 50 85 5 16 185 125 165 165 160 3 8 325 230 290 290 275 7 16 460 350 350 1 2 680 500 620 600 5 8 1 350 1100 1 325 1 200 3 4 2 350 0 Size Inches Thread Designation Minimum Torque 1 4 20 UNC 6 1 4 28 UNF 7 5 16 18 UNC 14 5 16 24 UNF 16 3 8 16 UNC 24 3 8 24 UNF 28 7 16 14 UNG 42 7 16 20 UNF 45 1 2 13 UNC 69 1 2 20 UNF 83 9 16 12 UNC 99 9 16 18 UNF 118 5 8 11 UNC 150 5 8 18 UNF 176 3 4 10 UNC 254 6 UNF 301 7 8 9 UNG 358 7 8 14 UNF 422 1 8 UNG 500 1 14 UNF 602 Soft metric conversions are not acceptable for screw and hex sizes 2 Check the fan wheel hub bearings and drive sheave set screws for tightness according to the set screw torque chart in Table 2 and Table 3 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
26. 75 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 7 106 125 10 000 0 280 6 Fan wheels housings and drive assemblies 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 remove 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 Table 5 Generally Recommended Relubrication Frequency in Months Operating Speed 000 1 125 1 500 1 625 1 937 2 000 2 500 2 687 3 187 3 437 3 937 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 1C 26 FAN
27. ES V CUBE IOM 1C 61 Table K1 Troubleshooting V Cube Symptom Possible Cause Corrective Action Water Issues Water carryover from wet cooling coil onto the floor motor or fan housing Airflow is too high Lower airflow by 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 Prefilter is wet Outside air hood is shipped loose and was not well sealed when installed Re install hood ensuring the flange is properly sealed Airflow exceeds design conditions and sucks water into the unit Re design the hood or lower the CFM of the unit
28. V Cube Floor by floor Vertical Self contained System Installation Operation and Maintenance Instructions Manual M a m mo th Capacities 9 150 tons a Nortek Air Solutions Brand Table of Contents Nomenclature 3 Safety Considerations iii ria dr aio aia 4 General 4 Recommended Spare Parts micas d 4 Unit Inspection on Arrival ocio dd lidia de ai 5 Unit Application imitationS 5 Installation ca A ii ia Rec ibi 5 Unit Location 06 2222 5 Rigging Lifting and 295500 0 6 Installation andadas 15 Field Fabricated DUGKWOMK coi te 15 Electrical Connections a aa e ai r e a a aa ed o aaee 16 Coil or Water Cooled Condenser WCC Piping Connections cccccccesseneeeeeeseneeeeeesecaneeeeseseaeeeeesssnneeeeesseaeeeeessaes 17 Condensate Drain Trap and ENESi ineine daaa a ida 18 Refrigerant SyStems ean nroa a 0 0 viet ae ie eal 18 E 19 Pre StartSup Check aa Aa Aea E aeaa eee ecg ie ito pe 19 Start Up 00 20 21 Maintenance stas o relata hatte tete 22 Long term Storage Maintenance Procedures oooooccccnnnoocccnononnonnnnnnnnnnccnnnnnnnnnnnn nan nn rr nn n rra rra rre 22 Maintenance Summary illes 22 Refrigerant Systems ci Steeda apts ates icles ead pois lag eee ead ade hal een ede el ce eee 22 Dampers 505000 shes 05 23 Belt Driven Fast a o a 24 FANWALLS Arra
29. WALL Array 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 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 Every 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 necessary Figure 14 FANWALL array VCES V CUBE IOM 1C 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 15 Figu
30. age 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 Condensate piping can be steel copper or PVC See Appendix B for illustra tions and dimensional information on positive and negative pressure trapping height Slope the drain lines downward in direction of flow not less than 1 8 per foot toward the building drainage system otherwise use a condensate pump Refer to local codes for proper drainage require ments Insta
31. anged 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 33 Coils A WARNING 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 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 Cleaning Procedure and maintenance procedures 1 Shut down the unit by closing the main disconnect at the power inlet Dirt on the surface of the coil reduces its ability to transfer 2 Open panels or doors to gain access to both sides heat which lowers the efficiency of the unit resulting in of the coil section poor air quality and expensive operating costs Because 3 Remove soft debris from both sides of the coil with a of the condensate on the coil the dirt often becomes wet soft brush and contributes to the growth of microbial organisms 4 Using a steam cleaning machine clean the leaving Negligence in maintenance may result in serious health air side of the coil first going downward then clean related indoor air quality problems The coil should be the entering air side Use a block off to prevent the kept clean for maximum performance To achieve maxi steam from penetrating a dry section of the unit mum efficiency clean th
32. ar full load conditions in both heating and cooling modes and check sub cooling and superheat against values in Appendix L Table L1 If readings do not match adjust the refrigerant charge Refer to Appendix L for information on adjusting the refrigerant charge 15 On units with WCC after a few minutes of operation a Check the supply discharge temperature status on the keypad for cooling air delivery Measure 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 8 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 8 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 correct flow pressure drop reading b Measure the temperature difference between entering and leaving air and entering and leaving 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 e
33. ar silicone based sealant for water tightness All other lifting 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 VCES V CUBE IOM 1C 16 Touch up paint for scratches or marks to the exter nal finish incurred during shipment or installation can be obtained in the fastest amount of time in bulk or spray cans from a local paint supplier by providing the universally recognized RAL code To match the Venmar CES standard grey specify color RAL K7 Classic RAL7001 two component polyurethane paint with a gloss of 30 4 Paint cans 11 ounces matching the Venmar CES grey can also be obtained in a slower amount of time by contacting the following paint suppliers listed below and providing the item number item name and Vendor number below or through Venmar CES After Sales Service by email to Tech Support at venmarservice venmarces com fax 899 319 2612 or phone 1 866 483 6627 In Canada Sunamco 360 Gleme Rue C P 280 Daveluyville Quebec GOZ 0 Phone 1 866 815 4080 Contact Audrey Mallhot Item number 500049624 Item name Canette peinture grise RAL7001 Vendor number VENO0002429 In USA Using the universally recognized RAL code RAL7001 Venmar CES grey paint can be obtained from your local supplier Suspended Unit Installation To install units that will be
34. are by others Refer to the mechanical drawings and the instructions on the casing for correct orientation of external piping Exter nal supply and return piping connection provision design and all other safety such as dielectric couplings or other freeze protection or electrical control requirements for system operation are the sole responsibility of the Install ing 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 me chanical drawings for coil performance design information Refer to Victaulic installation instruction manual for proper water valve and coupling installation and assembly VCES V CUBE IOM 1C For WCC units see Appendix A See the piping schemat ics for optional piping components and sequence of op eration 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 applications 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 freezing dam
35. are 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 or when the operation of heating equip ment is essential may require more spare parts than listed Please contact the Service Department at Nortek Air Solu tions Canada for recommendations VCES V CUBE IOM 1C 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 Remove plastic wrapping protective coverings and pan els securing latches etc to inspect the equipment exte rior and interior for any damage 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 damp ers and drains File a claim with the shipping company if the unit is damaged 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 Contact the factory immediately if damage is found No return shipment will be accepted without authorization Unit Application Limit
36. ated in order to keep their integrity Access open ings in the floor can only be cut or drilled for piping and wiring high and low voltage in the designated rectangu lar areas within an upturned 1 25 4 mm flange as pro vided 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 open ings insulation must be put back in place to avoid con densation 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 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 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 non inte grated direct expansion WCC or humidifier
37. ations CAUTION Mammoth equipment is not designed to be used for temporary heating cooling and or ventilation during construction Using Mammoth units for temporary ventilation during construction is subject to the unit warranty terms and should be reviewed carefully before proceeding as this may void the standard warranty conditions Fine dust larger particulate matter solvents varnishes and other chemicals may cause filter clogging and el evated 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 include 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 submittal drawings varies per unit frame size in order to allow easy access for maintenance and for system operation For clearances to remove specific components please consult factory e Locate the unit in an area requiring the least amount of ductwork and direction changes to allow optimum performance
38. between the fan wheel and hous ing or loose blades If Loctite was used on any set screws that have come loose the set screws must be removed and cleaned before re tightening and Loctite must be re applied VCES V CUBE IOM 1C Split pillow block bearings are fixed to the shaft with tapered sleeves and generally do not have set screws 3 Check each V belt tension and adjust the motor base for correct amount according to the deflection outlined in the Measuring Belt Tension procedure 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 mismatched or worn belt sets If a belt must be changed ensure to change all belts on the same drive at the same time Never replace just one belt within a set Measuring Belt Tension a Measure the belt span with a span scale b Divide the belt span by 64 to determine the belt deflection needed to check tension c Set the O ring on the span scale to the required deflection value d Set the small O ring at zero on the force scale e Place the scale end of the tension checker squarely on one belt at the center of the belt span Apply force on the plunger until the bot 24 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
39. crank cases 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 crank case which could cause compressor damage or failure to occur on start up Otherwise turn the main disconnect to the On position The unit can be started by using the keypad and se lecting the mode of operation from the Keypad Oper ation Guide and the Sequence of Operation Disable the heating and cooling functions and set the unit to the occupied mode to bump start the fan wheel s to check their operation If units are equipped with dampers check that dampers are operating properly Check that the fan wheel s are rotating in the correct direction Adjust the fan motor VFD s to the correct air volume Hertz For occupied mode adjust outside and mixed or recirculation air damper positioners to achieve the required air volumes Re check the voltage at the disconnect switch against the nameplate and against phase to phase readings on three phase with all blower s operat ing If the voltage is not within 10 of rated or 2 of phase to phase have the condition corrected before continuing start up Check amperage draw to each motor on each phase against motor nameplate FLA If significantly differ ent check ductwork static and or take corrective action Before activating the compressor s ensure that any water shut off valves are open and that water is circulating
40. d should be lubricated once a year Use a premium quality lithium based grease conforming to NLGI Grade 2 or 3 examples are Mobil Mobilith VCES V CUBE IOM 1C AW2 Chevron Amolith 2 Texaco Premium RB or Shell Alvania 2 e Dampers should be inspected for dirt check the shaft arms bars and controls rod every three months e Inspect the seals to ensure none have pulled loose or deteriorated If a seal has been damaged repair or replace it with the same seal or same seal mate rial Contact the factory for replacement parts Belt Driven Fans 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 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 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 months Table 1 Minimum Head Bolt Torque in Ib ft Grade 5 Bolts Table 2 Wheel Set Screw Torque in Ib ft Set Screw Size Carbon Steel Set Screw Torque Diameter Inches Ib in lb ft
41. ding or pressure drop compared to the submittal information and adjust the shut off balancing valve in the return line to the correct 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 second check may be required after airflow balancing 16 On units with electric heating coils check supply air proving interlock switch setting to ensure minimum supply airflow prior to operation 17 Enable heating options and check the operation ac cording to sequence for electric coils see electric heating coil and controls information in Appendix E 18 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 19 Check the operation of the control options provided on the unit 20 Check the setpoints on the DDC Points Reference adjust and record changes as required 21 Check that air balance has been completed for both occupied and unoccupied operation 22 When unit has achieved steady state take measure ments and complete the readings section of the Start up Form and Checklist in Appendix C Send copy of
42. e coil often during periods of high 5 Allow the unit to dry thoroughly before restoring demand or when dirty conditions prevail Mammoth rec power ommends cleaning the coil a minimum of once per year 6 Damaged coil fins should be straightened by using a to prevent dirt buildup in the coil fins where it may not be fin comb visible 7 Close all panels and doors once the coil is dry 8 Restore electrical power to the unit CAUTION Do not use acidic chemical coil cleaners Do not use al kaline 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 Controls General controls information regarding the navigation and the documentation that is contained in the control panel monitoring of your unit with the standard keypad DDC of your unit Please contact the factory if this information is points list ladder diagram and specific sequence of op missing or has been lost eration or required network communication is included in Troubleshooting See Appendix K for troubleshooting information For troubleshooting information on WCC compressors and refrigeration circuits see Appendix A VCES V CUBE IOM 1C 34 Appendix A Water Cooled Condenser WCC Piping Installation Maintenance and Troubleshooting Units have the WCC supply and return line internally coupled manifold
43. e direct expansion DX coil is constructed of seam less copper tubing expanded into full collared aluminum fins The tubes are arranged for a counter flow circuit and staggered 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 TXV 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 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 Figure 10 Direct expansion coil Distributor Liquid line Hot gas bypass line Suction line zo Expansion valve Evaporator coil Check valve on remote condensing application optional 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 Thermostatic Expansion Valve The thermostatic expansion valve is a precision device designed to meter the flow of refrigerant into the evapora tor thereby preventing the return of liquid refrigerant to the compressor By b
44. e opened for the initial flush and blow down making sure city water fill valves are set to makeup 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 be fore 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 Install 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
45. eating 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 Remove the shipping covers just before installation 1 1 2 Inspect the heater carefully and report any dam age to the Manufacturer Do not install a damaged heater 1 2 Installation Heater Position 1 2 1 The axis of the duct must always be perpendicu lar 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 in
46. eeze 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 quantities of heat pumps with different flow and pressure drop characteristics 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 num ber of bends and elevation changes for best perfor mances Size piping to minimize system pressure drop 3 Water line piping should contain a Short sections of high pressure flexible hose or vibration 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 rec ommended due to the possibility of vibration that could damage piping connections joints or transmit noise Where hard piping is used unions should be provided in the supply and re
47. eing responsive to the temperature of the refrigerant gas leaving the evaporator and the pres sure in the evaporator the thermostatic expansion valve can control the refrigerant gas leaving the evaporator at a predetermined superheat Three forces that govern 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 Figure 11 Thermostatic expansion valve Bulb clamp 0 Remote clamp 3 O Diaphram External TG a equilizer port Dampers Units from Mammoth may or may not incorporate the use of dampers If dampers are present within the unit the fol lowing maintenance should occur in order to prevent the unit from working under too much pressure and to pre vent any other issues Dampers must be kept free of foreign matter that might impede normal free movement Bearings between blades and frames are made of polymer and require no mainte nance Note that the damper shafts do not need lubrica tion All Mammoth dampers and linkages are assembled with non lubricating bearings e Attachment mechanism linking motors to dampers should be checked for tightness e Damper jackshafts if provided are fitted with grease nipples an
48. epeat 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 nor mally recommended size Remove the suction line filter drier After the cleaning procedure is completed re check in approximately two weeks to ensure that the system condition and operation is completely satisfactory 38 Table A1 Troubleshooting Refrigeration Circuit VCES V CUBE IOM 1C Air Water Head Suction Compressor J J Loops Safety Symptom Pressure Pressure Amp Draw Superheat Sub cooling Temperature Temperature Lockout Differential Differential Undercharged system possible Low Low Low High Low Low Low Low pressure leak Overcharged Normal system High High High Normal High ere Normal High pressure Low airflow heating High High High High Normal Low High Low High pressure Low Low Low airflow cooling Low Low Low Low Low Low temperature Low water flow Low Low ow Lo High er High Low heating ormal ormal temperature POOE NO High High High High Low Low High High pressure cooling High airflow heating Low Low Low Low High Low Low eta temperature High airflow cooling Low High Normal High Low Low Normal High pressure High water Tow Normal Low Low Low Normal Normal Low High pressure heating High water flow l Low cooling Low Low Low Low High Normal Low temp
49. er charging unit must be operated in cooling mode to check for correct charge Charge may need to be adjusted for cooling mode If adjustments are made in the cooling mode heating mode must be re run to verify proper operation 4 After adding or removing charge the system must be allowed to stabilize typically 10 15 minutes before making any other adjustments 5 The type of unit and options determine the ranges for liquid sub cooling and evaporator superheat Refer to Table L1 when determining the proper sub cooling and superheat VCES V CUBE IOM 1C Checking Liquid Sub cooling 1 Measure the temperature of the liquid line as it leaves the condenser coil 2 Read the gauge pressure at the liquid line close to the point where the temperature was taken One must use liquid line pressure as it will vary from discharge pressure due to condenser coil pressure drop 3 Convert the pressure obtained to a saturated tem perature using the R410a refrigerant temperature verses pressure Table L2 Subtract the measured liq uid line temperature from the saturated temperature to determine the liquid sub cooling 4 Compare calculated sub cooling to Table L1 for the appropriate unit type and options Checking Evaporator Superheat 1 Measure the temperature of the suction line close to the compressor 2 Read gauge pressure at the suction line close to the compressor 3 Convert the pressure obtained to a saturated tem perature using t
50. er tightness Figure 5d Where two or more internal air tunnels corridors 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 Middle internal partition s divider s bce eee A A ee ee Se ee ee ee VCES V CUBE IOM 1C Figure 5e Where a multi sectional indoor unit with vertical and additional horizontal splits join the middle internal horizontal partition will require three gaskets one at the top of the bottom section and two at the bottom frame of the top section eee ae ee A a ss yk Be She So ee Se Se ea a ee Pulling Multi section Units Together 7 Use tools chains chain blocks chain type come along etc connected to the side lifting lugs at tached to the base on both sides of the unit to pull the second or next section to the first end section evenly until both sections are Y 6 4 mm apart on the full joint perimeter as in Figure 6 Keep the tools chains chain blocks chain type come along etc in place until further notification Remove any exterior lifting lugs that interfere with the chains for pulling sections together When joining sections together always apply the pulling force to the lifting lugs at tached to the unit structural base never to the iron angle fixed near the corner posts and pull uniformly
51. erature TXV restricted High Low Normal Low High High Low Low 39 Table A2 Performance Troubleshooting Performance Troubleshooting Heating Cooling Possible Cause Solution Insufficient capacity x x Dirty filter Replace or clean Check for dirty air filter and clean or replace Check fan motor operation and airflow restriction Too high of x Reduced or no airflow i external static Check static vs blower performance curve l Check for dirty air filter and clean or replace Check Not cooling or heating ee q roperly 0 O fan motor operation and airflow restriction Too high of 4 i external static Check static vs blower performance curve Check supply and return air temperature at the unit and xX x Leaky ductwork at the distant duct registers If significantly different duct leaks are present x Low refrigerant charge Check superheat and sub cooling adjust charge x x Restricted metering device Check superheat and sub cooling replace TXV x Defective reversing valve Perform reversing valve touch test Unit does not operate in cooling Unit undersized Re check loads and sizing x x Perform scaling check and clean if necessary exchanger x x nlet water too hot or too cold Check load loop sizing loop backfill ground moisture Check for dirty air filter and clean or replace Check fan motor opera
52. ervicing For project site specific water treatment instruction consult your local water treatment specialist Monthly e 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 crank case heaters e Check for broken or loose pipe clamps e Check moisture indicator of refrigerant site glass A Caution or Wet condition requires changing filter 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 e 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 com patible with mineral oil or alkylbenzene lubricants R410a systems will be charged with the OEM recommended lu bricant ready for use with R410a VCES V CUBE IOM 1C 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 l
53. exible 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 f Reverse rotation or motor so that wheel turns in the Fan wheel is turning the wrong direction EA direction of the arrows shown on the fan Increase speed by increasing the diameter of motor sheave Rotation Spo pao eee or installing a smaller fan sheave Poor airflow 9 Filters are blocked Replace filters Air leakage 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 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 re install filters Some filter clips are missing Order new clips from Nortek Air Solutions Canada VC
54. g stored outdoors or re mains dormant for an extended period after initial start up 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 installa tion 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 or glycol mixture should be drained or capped off if nec essary and all peripheral electrical penetrations should be properly sealed IMPORTANT Complete the Extended Dormant Unit Maintenance Checklist below send a copy to Nortek Air Solu tions Canada Service Department at the below email address or fax every six months and when unit is put into service to validate warranty and to provide valuable information to personnel perform ing future maintenance or for factory assistance Leave a copy of this report with the Owner and at the unit for future reference and permanent record Additional Comments Email to Tech Support venmarservice venmarces com Fax 899 319 2612 Unit Identification Information Project Job Name Job Address Model Number Serial Number Tag Jobsite Contact Email Telephone Maintenance By Company Name Date Email Telephone 54 Table F1 Extended Dormant Unit Maintenance Checklist Item Descript
55. gnifi 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 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 Mammoth 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 VCES V CUBE IOM 1C filters and indicate the type of reading that should be given on the magnehelic gauge The data relative to accurate pressure drop across the filters is available in the submit tal If the system is equipped with both prefilters and final filters it is recommended that prefilters be ch
56. gnment Step 78 and Step 9a Gently rotate fan wheel 31 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 Figure 28 Fan wheel cone alignment Step 7b and Step 9b 8 Tighten all the cone retaining fasteners Figure 29 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 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 VCES V CUBE IOM 1C 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 located in the corners and middle of the airflow straightener panel frame or Z frame matching pre drilled holes in the blank off plate for fastening to gether with tek screws Figure 30 Bla
57. gnment size alignment Les lignes centrales Les lignes doivent doivent tre align es tre parallales R a fixe R gle droite R a ajustable 5 Belt driven fan bearings are fitted with grease nipples for lubrication The grease quantity and lubrication interval depends on bearing fan size and rom and are indicated in Table 4 and Table 5 Use a premium quality lithium based grease conforming to NLGI Grade 2 or 3 examples are Mobil Mobilith AW2 Chevron Amolith 2 Texaco Premium RB Shell Alvania 2 or Esso Beacon 825 Clean the grease nipple first then rotate the fan shaft slowly by hand while adding grease The lubrication intervals are theoretical and will depend on site conditions hours of operation and temperature It is recommended to make periodic inspections of the bearings before these theoretical intervals 25 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 Inches Millimeters Ounces Kilograms 0 500 0 750 13 19 0 125 0 004 0 8 5 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 8
58. h steady state before taking readings e Complete based on options included with unit Nameplate voltage Input voltage 1 2 2 3 3 Table C3 Start up Readings Supply Fans Rotation Full Load Amps Amp Draw O L Amp Correct Nameplate Amps L1 L2 L3 Setting Hertz RPM Fan Fan Fan Fan Fan Fan Fan 5 lt 4 Fan o Fan o Fan a a Fan N Fan Table C4 Start up Readings Condenser Fans Rotation Full Load Amps Amp Draw O L Amp Correct Nameplate Amps L1 L2 L3 Setting Hertz RPM Fan Fan Fan Fan Fan Fan Fan oINI QJAJ AJOJN Fan oO Fan ar o Fan a a Fan a N Fan VCES V CUBE IOM 1C 46 Table C5 Start up Readings Compressors Serial Number Full Load Amps Nameplate Amps Amp Draw After compressor has been running for 15 minutes check for the following L1 L2 L3 Suction Pressure Discharge Pressure Superheat Liquid Sub cooling Hot Gas Bypass Functioning 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 Com
59. he R410a refrigerant temperature verses pressure in Table L2 4 Subtract the saturated temperature from the mea sured suction line temperature to determine the evaporator superheat 5 Compare calculated superheat to Table L1 for the appropriate unit type and options Table L1 Acceptable Refrigeration Circuit Values Air Cooled Condenser or Air Source Heat Pump Sub cooling 12 18 F Sub cooling with hot gas re heat 15 22 F Superheat 8 15 F Water Cooled Condenser or Water Source Heat Pump Sub cooling 4 8 F Superheat 8 15 F CAUTION Thermal expansion valve must be adjusted to approxi mately 8 F to 15 F of suction superheat Failure to have sufficient superheat will damage the compressor and void the warranty 63 Adjusting Sub cooling and Superheat 2 Correct an overcharged system by reducing the Temperatures amount of refrigerant in the system to lower the 1 The system is overcharged if the sub cooling tem sub cooling perature is too high and the evaporator is fully loaded 3 The system is undercharged if the superheat is too low loads on the evaporator result in increased sub high and the sub cooling is too low cooling and the evaporator superheat is within the 4 Correct an undercharged system by adding refrig temperature range as shown in Table L1 high super erant to the system to reduce
60. he cap screw until there is an approximately 14 gap between the latch and the leg extension coupling as shown below in Figure D7 Repeat this step with all four corners Figure D6 Latch overlapping leg extension v Align cap screw with coupling Place the latch so that it overlaps the leg extension 50 Figure D7 Tighten cap screw to 1 4 of the coupling Tighten until there is a gap of approximately 1 4 MSAD 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 Figure D8 Tighten until latch and coupling meet TY Tighten each corner until the latch and coupling meet VCES V CUBE IOM 1C Once all four corners have been tightened the filter should now be properly seated and sealed Repeat the process with all remaining filters working from the bottom to the top Figure D9 Properly installed filter 51 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 h
61. he unit in Off mode for 24 hours before start up This will energize crank case heat ers and assure no liquid refrigerant is present which could cause compressor damage or failure Check that this has been completed Start up Procedure To ensure proper operation of each unit qualified person nel should perform the start up as outlined below based on options included with unit and complete the Start up Form and Checklist in Appendix C for permanent record A completed report and checklist will provide valuable in formation for personnel performing future maintenance IMPORTANT A completed copy of the Start up Form and Check list must be sent back to the factory for warranty validation and for factory assistance General information on the factory installed and pro grammed DDC control system regarding the navi gation and monitoring of the unit with the standard keypad are provided in separate documents For more specific information regarding the sequence of control the different options of control or network communications see these documents included with the unit in the control panel pocket If units are equipped with compressors power must be turned on for 24 hours prior to a call for cooling for the compressor crank case heaters to be energizing to prevent possible damage Assembled units with integrated refrigerant sys tems WCC AC or WSHP are factory leak tested charged with refrigerant based on volumetric ca paci
62. her e Adseal 1800 series from Adchem Adhesives clear silicone based sealant or equivalent for side joint and top joint e Self drilling 5 16 hex head 12 14 x 1 zinc plated screws with rubber washer e Junction plates already installed on the unit 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 ship ping purposes is removed if there is a possibility that it will interfere with the placing or assembling of the unit or unit sections on the structural steel or housekeeping pad IMPORTANT For multi section modular units make certain to always rig lift and install an end section with bottom duct con nection first Unit or unit sections shall be lifted by cables attached to all the lifting lugs Consult the mechanical drawings lo cated in the pocket of the control panel for the number of lifting 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 u
63. in and terminals Tighten where required Additional Comments Telephone Start up By Company Name Date Email Email to Tech Support venmarservice venmarces com or Fax to 819 399 2612 VCES V CUBE IOM 1C 48 Appendix D HEPA Filter Installation These instructions are for installing AAF HEPA filters 11 depth into AAF HEPA holding frames The holding frames are available in multiple sizes and materials but include the PN series of 3061 9XX 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 3061 9XXXXX e Leg extensions four per frame PN 3061991 00X e Latches four per frame PN 3062007 00X Figure D1 Leg extensions and latches VCES V CUBE IOM 1C Step 1 At the inside corner of each frame are fo
64. ints if any from section lining up all the bolt holes in the junction the second section to allow sections to be pulled plates together Figure 3 Set the next section approximately 6 152 mm from the first section 4 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 4 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 c Remove the six self drilling 5 16 hex head 12 14 x 1 screws with rubber washer and the junc IMPORTANT tion plates and use those to secure the upper or top section to the lower or bottom section as shown in Figure 2c 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 Figure 2c Remove the six self drilling 5 16 hex head brackets or angle bars back in place for water tightness 12 14 x 1 and the junction plates and use those to secure sections VCES V CUBE IOM 1C 9 Figure 4 Corner reinforcement brackets or angle bars to be removed from the split section Reset the screws with rubber washer in place for water tightness 5 Verify that
65. ion Yes No s the unit stored indoors in a clean dry environment s the indoor storage facility temperature regulated to within 50 F to 75 F s the indoor storage facility humidity regulated to within 10 to 50 RH s 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 maintenance Has the plastic wrapping been saved for future use 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 Item Description Inspection Date Reading Refrigerant pressure at Date PSIG storage 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 Compressor 16 VCES V CUBE IOM 1C 55 Table F1 Extended Dormant Unit Maintenance Checklist Refrigerant pressure every three months Date PSIG Date PSIG Date PSIG Compressor 1 Compressor 2 Compressor 3 Compressor 4 Compressor 5 Compressor 6 Compressor 7 Compressor 8 Compressor 9 4 Comp
66. iquid to vapor while charging CAUTION It is very important to make certain that the recycle or re covery equipment used is designed for R410a The pres sure of R410a refrigerant is approximately 60 greater than that of R22 Pressure gauges require a range up to 800 psig high side and 250 psig low side Recovery cyl inders 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 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 crank case 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 electrical 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 ter minals measure resistance from each compre
67. ist in Appen dix C for each unit For torque values on set screws belt tension etc check under Maintenance and or Appendix sections 1 2 Check the electrical disconnect is in the Off position Check the split section joints are properly installed on multi section units 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 Check the unit for obstructive packaging objects near or in fans dampers etc a Check that the inside of the unit has been cleaned of all debris Remove all retaining bolts on fan isolation 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 screws or locking col lars Tighten if required d Check fan belt alignment and tension e Check that fan flexible joint connections are well attached 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
68. ld be maintained and checked according to respective manufacturers in structions Any defective components should be replaced only with identical original parts 53 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 below may result in damage and will void unit warranty 1 Unit must be stored indoors in a clean dry and tempered 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 Storing units outdoors is contraindicated and will void our warranty 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 lf applicable a certified qualified Refrigeration Technician should record refrigerant
69. led correctly and filled Check at all unit split sections that all factory internal high and low voltage wiring connections have been properly re connected Check that all shipped loose or field supplied com ponents 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 settings of control are in accordance with the wiring schematic 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 10 of rated or 2 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 If the unit is equipped with an electric coil the instal lation and pre start up checks must be completed per Appendix E Check that all safety switches overloads or other manual reset devices are reset If the unit is equipped with compressors power must be turned on with t
70. lling a plug for cleaning of the trap is recom mended Fill the P traps with water before starting the unit Check and clear drains annually at start of cooling 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 Refrigerant Systems On assembled units which are split for shipment or by customer request where the refrigeration system is split the refrigerant lines are capped at the splits factory leak tested and charged with nitrogen The type of refrigerant and charge is based on calculated volumetric capacity and stamped on the nameplate The Installing Contrac tor is responsible for connecting the refrigerant lines leak testing evacuation charging the refrigerant system and adjusting the charge VCES V CUBE IOM 1C On assembled units with split refrigerant systems where the condenser or condenser compressor sections are remotely installed the Installing Contractor is responsible for designing and completing the refrigerant system cal culating the charge leak testing evacuation charging the refrigeration and adjusting the charge Refer to Appendix L for information on adjusting the refrig erant charge 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 checkl
71. neeeeeseaaes 59 Appendix J Filter Resistance and 0 0 0 seen 60 Appendix K Troubleshooting 61 Appendix L Adjusting Refrigerant Charge eeeccccccesseceeeesenneeeeeeeeaeeeeeeeaaeeeeeeeaaeeeeeeeaaeeseeseaeeeeeeesaeeeeeeseaaeeeeeeenaaeeeeneeaaes 63 VCES V CUBE IOM 1C 2 Nomenclature Model Indicator V V Cube Volume Control V Variable air volume C Constant air volume Condenser 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 0 1 0 Heating Type E Electric H Hot water S Steam X No heat Frame Size 5 Small M Medium L Large T Tall Control Panel Location L Left handed unit R Right handed unit V V Y 000 o IG S M IL LISTED Intertek 2015 Nortek Air Solutions Canada Inc All rights reserved throughout the world Illustrations cover the general appearance of Venmar CES products at the time of publication and Nortek Air Solutions reserves the right to make changes in design and construction at any time without notice The following are trademarks or registered trademarks of their respective companies V Cube and FANWALL from Nortek Air Solutions LLC Nortek Air Solutions LLC d b a Venmar CES furnishes equipment pursuant to
72. ng elements 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 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 300V 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
73. nk off plate Step 3 4 Inlet sid 4 4 s Airflow straightener panel frame 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 Figure 31 Blank off plate Step 4 32 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 clean 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 surrounding 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 Filters Ensure the motor is operating at the current indi cated on the nameplate If not a physical or electri cal restriction is working against the motor and it must be repaired Ensure the motor is not vibrating too much A si
74. nt 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 installation Installation and Assembly Materials for Multi section Modular Units All materials for assembling a multi sectional unit as de tailed below and per the instructions that follow are sup plied by Mammoth and located inside one or more of the unit sections where this yellow label as shown below is applied on the door VCES V CUBE IOM 1C e ADBOND 1465 acoustical butyl sealant or equiva lent applied to top perimeter of structural steel sup port housekeeping pad or to the top perimeter joint of a horizontally split indoor unit lower section just prior to unit installation The use of ADBOND 1465 acoustical butyl sealant or equivalent is required to create a proper seal to minimize the risk of water in filtration and or to ease section movement when pull ing modules together Do not use the butyl sealer on the exterior split section joints or exposed surfaces as remains pliable sticky and should it become smeared is difficult to clean e Polyvinyl gasket with adhesive strip 2 1 13 x 38 mm x required length applied between unit sections for split section joints and duct opening connections e 3 8 7 Grade 5 1 thread length zinc plated bolts with two washers and one nut each to secure sections toget
75. oles made by the Installing Contractor in the casing partitions or floor been well sealed to prevent air and or water infiltration 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 isolation bases been removed a Do all the fan impellers rotate freely 5 b Are all fan impellers and drive set screws tight c Are all the fan bearing set screws or locking collars tight d Are all fan belts aligned and have proper tension e 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 6 b Doall sliding filters have a retainer at the end track and well attached blank offs c Are the filter pressure differential gauges switches or sensors free of dirt and set at a value satisfactory to the end user to trigger a filter change VCES V CUBE IOM 1C 43 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 not applicable to brazed aluminum heat exchangers a Are all pipe connections tight and have they been checked for damage that may have occurred during shipping or installation b Has the piping to the coils and WSHP WCC been comple
76. 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 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 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 VCES V CUBE IOM 1C 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 reduc ing valve open Check vents in sequence to bleed off any trapped air to provide circulation through all components of the system 5 While circulating water check and repair any leaks in the piping Drains at the lowest point s in the system should b
77. oned spaces must be insulated and covered with a vapor barrier Flexible connectors should be installed close to the unit in the duct leading to occu pied spaces to minimize noise transmission 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 Eloows with a turning radius equal to or greater than one 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 NFPA7O 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 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 fac
78. operative as 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 21 Fan wheel cone alignment Step 2a VCES V CUBE IOM 1C Figure 22 Fan wheel cone alignment Step 20 FANWALL cube 3 If the optional airflow straighteners are furnished on the inlet side of the fan it must be removed next Re move all tek screws on the airflow straightener panel frame and remove it from the cube Figure 23 Fan wheel cone alignment Step 3 30 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 Figure 24 Fan wheel cone alignment Step 4 Gently rotate fan wheel 5 To make adjustment loosen do not remove all the cone retaining fasteners Figure 25 Fan wheel cone alignment Step 5 VCES V CUBE IOM 1C 6 Using a rubber mallet gently tap around the cone until desired clearance is acquired between fan wheel and inlet cone Figure 26 Fan wheel cone alignment Step 6 7 Gently rotate the fan wheel to verify cone adjustment for proper clearance from wheel Gently tap cone Figure 27 Fan wheel cone ali
79. permanently suspended the units must be set on structural steel beams that are sup ported by vertical rods Mammoth 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 9 Single section unit shown for multi sectional unit suspension consult factory Figure 9 Indoor suspended installation Anchor min Field Fabricated Ductwork On indoor horizontal or indoor vertical duct connections make connections to the casing by applying Adseal 1800 silicone based sealant or equivalent around the connec tion and screwing flanged ducts directly to the casing and or flange with self drilling sheet metal screws It is im portant 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 accor dance with applicable codes Ductwork running through roof decks must comply with local fire codes Ducts pass VCES V CUBE IOM 1C ing through unconditi
80. pressor 9 Compressor 10 Compressor 11 Compressor 12 Compressor 13 Compressor 14 Compressor 15 Compressor 16 VCES V CUBE IOM 1C 47 Table C6 Start up Readings Water Source Heat Pump WSHP Water Cooled Condenser WCC Serial Number Waterside Cooling Mode Waterside Heating Mode Entering F C Leaving Temperature Temperature F C Temperature Entering Difference Temperature F C F C Leaving Temperature F C Temperature Difference F C Entering Pressure PSI Leaving Pressure PSI US GPM Condenser 1 Condenser 2 Condenser 3 Condenser 4 Condenser 5 Condenser 6 Condenser 7 Condenser 8 Condenser 9 Condenser 1 4 Condenser 4 Condenser 4 Condenser 4 Condenser 4 0 1 2 Condenser 13 4 5 6 Condenser Table C7 Start up Readings Electric Heating Coil Stage L1 Amps L2 Amps L3 Amps Check for Hot Pots gt This unit has been checked out and started according with the above procedures and completed forms and is operating satisfactorily After 24 hours of satisfactory op eration shut down the unit and check all foundation bolts shaft bearings drive set screws valve tra
81. pressures on all compressors at time of storage Each compressor must maintain refrigerant pressure in the system 5 If applicable a certified qualified Refrigeration Technician 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 holding pressure must then be re installed 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 Nortek Air Solutions Canada Service De partment 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 before operating the unit Refer to the V Cube Start up Form 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 VCES V CUBE IOM 1C Please note that if the unit is bein
82. 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 VCES V CUBE IOM 1C 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 CAUTION Electrical components and contacts must be protected from damaging metal shavings before drilling holes into the control panel Use liquid tight connections through the control panel and unit casing eliminating any water and air penetration 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 electro mechanical interference Ensure the power feed cable ground is securely connected to the terminals located in the control panel 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 option field wiring entry points may only be field extended through the cabinet within desig nated areas The unit cabinet and or floor must be wisely penetr
83. r correct pressure and differential VCES V CUBE IOM 1C 62 Appendix L Adjusting Refrigerant Charge CAUTION The Clean Air Act of 1990 bans the intentional vent ing of refrigerant CFCs and HCFCs as of July 1 1992 Approved methods of recovery recycling or reclaiming must be followed Fines and or incarceration may be lev ied for non compliance CAUTION It is very important to make certain that the recycle or re covery equipment used is designed for R410a The pres sure of R410a refrigerant is approximately 60 greater than that of R22 Pressure gauges require a range up to 800 psig high side and 250 psig low side Recovery cyl inders require a 400 psig rating Adjusting the refrigerant charge of a system in the field must be based on determination of liquid sub cooling and evaporator superheat On a system with a TXV liquid sub cooling is more representative of the charge than evapo rator superheat but both measurements must be taken Before Charging 1 Unit being charged must be at or near full load con ditions before adjusting the charge 2 Units equipped with hot gas re heat must be charged with the hot gas re heat valves closed while the unit is in cooling mode to get the proper charge After charging unit must be operated in re heat de humidification mode to check for correct operation 3 Units equipped with heat pump options must be charged in heating mode to get the proper charge Aft
84. rapping AAA A Removable plug v4 Cleanout Minimum 0 5 13 mm 0 5 13 mm maximum total static pressure 1 9375 49 mm if unit has a 6 152 mm tubular steel base H K pipe diameter insulation X low uu CXIX Negative Pressure Trapping Removable plug J Y 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 H y pipe diameter insulation gt 1 fou ot a VCES V CUBE IOM 1C 41 This page intentionally left blank VCES V CUBE IOM 1C 42 Appendix C V Cube Start up Form and Checklist IMPORTANT Complete this form for each unit and email fax or mail to Nortek Air Solutions Canada immediately after start up to validate warranty and to provide valuable information for personnel performing future maintenance or for factory assis tance to address below Read the Installation Operation and Maintenance Instructions Manual and the Venmar CES Control 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
85. re 15 Remove safety screen on motor end LH tit 8 Disconnect the four wire electrical cable from the motor junction box Make note of wire locations for reinstallation later see Figure 16 Figure 16 Remove electrical cable 27 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 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 17 Figure 17 Remove motor pedestal retaining bolts 5 After removing the motor pedestal 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 removed 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
86. ressor Compressor Compressor Compressor 0 1 2 Compressor 13 4 5 Compressor Compressor 16 Rotate blower impellers every two months Date Date Date Date Date Date Supply Other Grease fan bearings as required Supply Other VCES V CUBE IOM 1C 56 Appendix G V Cube Maintenance Summary Chart Table G1 V Cube Maintenance Summary Chart Item No Description Monthly Quarterly Semi annually Annually Inspect the general condition of the unit X Remove any dirt or debris X General Check for unusual noise or vibration X Lubricate the door latch mechanisms Clean fans with stream of water Align or replace belts and drives Adjust belt tension Fans 6 4 Check motor voltage and current O Lubricate the motor and shaft bearings e o Lubricate motor base adjusting screws x lt lt X Visual inspection for dirt or leakage Dampers Nm Lubricate damper linkage mare w Clean and replace prefilters A Air filters Clean and replace final filters E al Inspect holding frames sliding rack E O Clean the coils Coils a Winterize the water coil wo K Verify all electrical connections tighten if necessary
87. sed by Mammoth Other types of compres sors are available upon request if required Maintenance and service on compressors must be completed by a licensed service mechanic Provincial or state regula tions frequently require such qualifications for compressor maintenance If a compressor cycles leaks or has any defects contact the factory as soon as possible See Appendix A for compressor maintenance and trouble shooting refrigerant circuits and Appendix L for adjusting refrigerant charge Additional refrigerant troubleshooting issues can be found in Appendix K 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 sys tem will require new gaskets in order to retain the water tight seal required for correct system operation VCES V CUBE IOM 1C Evaporator Section Th
88. sing all lifting lugs provided will compromise the structural integrity of the unit or unit section Never lift rig or ceiling suspend from the top of the unit or unit sec tions 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 fork lifted 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 12 805 mm beyond the sides Mammoth will not be responsible for any damage caused to the unit casing during 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
89. ssor 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 Customer Service Department at Nortek Air Solutions Canada 3 If steps 1 and 2 have not clearly identified a com pressor failure it will be necessary to meg the com pressor motor refer to the respective compressor manual or contact the Customer Service Department at Nortek Air Solutions Canada 37 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 comparison purposes after the cleaning operation is complete Suitable two ounce bottles are available at any drug store AA 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
90. st The complete fan section non compressorized unit or the bottom half compressor condenser section base must be fastened to the structural steel or pad to pre vent this end section from moving when pulling sections together Fastening method must be determined by the Installing Contractor The lifting lugs on the outside pe rimeter may be used or removed with bolts and internal nuts used to fasten unit to structural steel or pad All bolts should be returned and sealed 2 For a horizontally split indoor unit or section a Apply a continuous Y 13 mm bead of ADBOND 1465 acoustical butyl sealant on the top perimeter of the lower or bottom section 1 38 1 mm from the outer edge as shown in Figure 2a VCES V CUBE IOM 1C Figure 2a Apply a continuous 12 bead of butyl sealer on the top perimeter of the lower or bottom section Y 13 mm bead of ADBOND 1465 acoustical butyl sealant b Set the upper or top section over the lower sec 3 Set the second or DX evaporator cooling coil section tion lining up the bolt holes in the junction plates approximately 6 152 mm from the first section see for a horizontally split indoor unit or section see Figure 3 If second section has a horizontal split Figure 2b the top section must be installed as per procedure 1 above before proceeding Remove the yellow Figure 2b Set the upper or top section over the lower lifting lugs located on the section jo
91. sulating materials Use special air intake louvers of weatherproof con struction for pre heat 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 1C 2 Electrical Installation of Electric Coil Heaters 2 1 Disconnect Power Source Disconnect all power sources before opening the control box and working within 2 2 Read Nameplate 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 knockouts 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 con
92. ted and have the piping lines been flushed filled vented and tested at 1 25 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 and or installation 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 Are all motorized damper control arms control rods and shafts tight a Do all non motorized dampers rotate freely Is the ductwork connected complete and free of obstructions Have all condensate drain connections been trapped installed correctly and filled Have all factory internal high and low voltage wiring connections been properly re connected at all unit split sections Are all shipped loose or field supplied components correctly installed and wired Has the wiring diagram been marked up accordingly and left with the unit Has the power supply and control wiring been inspected and approved by the Local Authorities Have factory and field wiring connections been checked and tightened Check that all settings of control are in accordance with the wiring schematic Check that all
93. ter 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 WISE coils 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 applicable 4 Awaterside economizer coil along with dual two way modulating water economizer valves and a tempera ture sensor shall be supplied with the unit The water temperature sensor is input to the DDC control sys tem which determines when to divert water to the economizer coil for energy conservation in cooling mode VCES V CUBE IOM 1C 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 bal ancing valves pressure relief valves or other safety or con trol 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 back flow preventers strainers valves flow temperature and pressure measuring fr
94. the completed Start up Form and Checklist to Nortek Air Solutions Canada to validate warranty Maintain a copy of the report at the unit for future reference 23 Once completed return setpoints to original or re quired values return the unit to the correct mode of operation and adjust the time clock if required Airflow Balancing IMPORTANT Before measuring airflows the building must be in its normal state Hermetically 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 specified airflow rates as shown in the mechanical draw ings Unit fan speed s and damper positions are theo retically 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 suggested methods This would normally be a velocity traverse measurement or flow measuring station FMS installed in the ducts 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 VCES V CUBE IOM 1C Flow measuring stations FMS and magnehelic gauges can also be used to measure airflow It is important to locate the FMS in the warm side duc
95. through the water to refrigerant heat ex changer Check the incoming line water pressure to ensure it is within design and acceptable limits Enable the cooling mode of operation Check if the sound of the compressor is normal or if there is ex cessive vibration Check all field and factory refrigerant and water pip ing connections for leaks and correct Operate the refrigerant system near full load condi tions in both heating and cooling modes and check sub cooling and superheat against values in Appen dix L Table L1 If readings do not match adjust the refrigerant charge Refer to Appendix L for informa tion on adjusting the refrigeration charge On units with WCC after a few minutes of operation a Check the supply discharge temperature status on the keypad for cooling air delivery Measure the temperature difference between entering and leaving water In cooling mode the temperature 20 difference should be approximately 1 5 times greater than the heating mode temperature dif ference For example if the cooling temperature difference is 15 F 8 3 C the heating tempera ture difference should be approximately 7 F to 10 F 8 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 rea
96. 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 placed 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 for ward to the line that you previously marked Line the four pedestal bolt holes up with the bolt holes on the mounting angles Insert four Y 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 forward or backward Fan wheel should not be rubbing on the inlet cone If cone alignment is required see instruc tions for Fan
97. tion and airflow restriction Too high of x Reduced or no airflow f i external static Check static vs blower performance curve 0 GRAS water f w Check pump operation or valve operation setting Check water flow Adjust to proper flow rate High head pressure x nlet water too hot Check load loop sizing loop backfill ground moisture x Air temperature out of range Bring return air temperature within design parameters x Scaling in Waterside heat Perform scaling check and clean if necessary exchanger x x Unit overcharged Check superheat and sub cooling x x Non condensable in system Vacuum system re weigh in charge O iow Check pump operation or valve operation setting Check water flow Adjust to proper flow rate x Water temperature out of range Bring water temperature within design parameters Check for dirty air filter and clean or replace Check Low suction pressure Reduced airflow in cooling fan motor operation and airflow restriction Too high of external static Check static vs blower performance curve x Air temperature out of range Bring entering air temperature within design parameters x x Insufficient charge Check for refrigerant leaks Low discharge air Xx Too high of airflow Check fan s motor speed selection and airflow temperature in heating Poor performance See insufficient capacity VCES V CUBE IOM 1C 40 Appendix B Positive and Negative Pressure Trapping Positive Pressure T
98. to reduce pressure loss and to use less electricity to achieve proper ventilation Duct work must be in accordance with ducting mechani cal rules to prevent sound issues and system effects VCES V CUBE IOM 1C e Theunit should be mounted on a level foundation to allow condensation to flow into internal drains The foundation 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 recom mendations a Structural Engineer must be involved to properly size supporting structural elements e Once the unit is in place within the mechanical equipment room mount the unit on a housekeep ing 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 in structions 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 Mammoth unit All local codes and fire regulations must be
99. to the end user to trigger a filter change Check coils if fins have been damaged in ship ping installation or building construction and are clean Straighten fins with fin comb and clean coil if required not applicable to brazed aluminum heat exchangers a Check all pipe connections are tight and that no damage has occurred during shipping or installation b Check that the piping to the coils and WSHP WCC have been completed piping lines have been flushed filled vented and tested at 1 25 times the operating pressure Refer to Appen dix A for piping installation and check that it is complete VCES V CUBE IOM 1C 8 20 21 22 23 24 Scroll compressor RIS vibration isolator bolts are fac tory tightened to the correct torque setting for opera tion 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 and or installation b Check that the refrigerant lines are spaced at least 1 apart and from the compressor after shipping and installation c Check that the refrigerant line clamps are still se cure and have their rubber lining 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 instal
100. tory installed door interlocking disconnect in the control panel 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 and high voltage wiring be tween unit sections at the junction boxes or extend coiled wiring IMPORTANT Wire nuts and electrical butt connectors if required must be supplied by the Electrical Contactor e Check nameplate for correct power supply requirements e See electrical schematics and sequence of control located in the control panel pocket for field wiring of power connections shipped loose sensors items or remote control interlocks The Electrical Contrac tor must locate install and wire sensors items or remote control interlocks as per electrical schematics and sequence of control e Numbered terminals strips are included in the control panel for 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 Mounting of field provided components in the control panel is allowed as long as their space was consid ered during the submittal
101. trolled 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 marked for fan interlock or air sensing device connection Remove jumper between terminals I 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 52 sure the heater is properly interlocked to prevent it from being energized before the damper is fully open 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 suit able airflow sensing device or interlock the heater with fan An insufficient airflow will lead to the opening of the auto reset thermal cut out or damage to the heati
102. turn lines for service and removal b Manual shut off valves in supply and return water lines for isolation and service 35 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 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 gauge 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 sec onds 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 damage 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
103. twork to minimize the effect of differences in air density especially when bal ancing during extremely cold outside conditions or to take temperature readings and make the necessary corrections if installed in the cold side ductwork Air density varia tions can affect the FMS by more than 15 The FMS should be located downstream in straight sections of duct and not immediately after fans or obstructions 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 21 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 for maintenance instructions to follow the unit is to be stored for a period of time ex ceeding one month Following the instructions in this ap pendix will assist in preventing potential unit damage that may result from an extended storage period Maintenance Summary Chart Please refer to Appendix G for a recommended list of rou tine maintenance items and time intervals A more detailed description of maintenance items follows Refrigerant Systems Compressors Scroll type compressors are the most common type of compressor u
104. ty and run tested prior to shipment with the type of refrigerant and charge stamped on the nameplate As part of the start up procedure oper ate the refrigerant system near full load conditions in both heating and cooling modes and check sub cooling and superheat against values in Appendix L Table L1 If readings do not match adjust the refrigeration charge Refer to Appendix L for infor mation on adjusting the refrigerant charge A WARNING Electric shock can cause personal injury or death Only qualified service personnel should install and service this equipment The keypad must be used to check operation ac cording to sequence and to adjust setpoints while power is on for start up and while performing service All units are factory run tested Fans compressors and condenser fans if equipped and refrigerant pip ing is not split for shipment are set up to run correct when power is connected If any one fan is running backwards or compressor is making loud noises disconnect power and switch two leads on three phase power to ensure proper rotation and avoid damage With multi section units with split wiring connections check rotation of fans compressors and condenser fans for correct rotation to ensure wiring connections are correct VCES V CUBE IOM 1C a4 Before proceeding complete the pre start up checklist Check that all access panels or doors are closed If units are equipped with compressors feel the compressor
105. uide and the Sequence of Operation Disable the heating and cooling functions and set the unit to the occupied mode to bump start the fan wheel s to check their operation If units are equipped with dampers check that dampers are operating properly Check that the fan wheel s are rotating in the correct direction Adjust the fan motor VFD s to the correct air volume Hertz For occupied mode adjust outside and mixed or recirculation air damper positioners to achieve the required air volumes Re check the voltage at the disconnect switch against the nameplate and against phase to phase readings on three phase with all blower s operating If the voltage is not within 10 of rated or 2 of phase to phase have the condition corrected before continuing start up Check amperage draw to each motor on each phase against motor nameplate FLA If significantly different check ductwork static and or take corrective action Before activating the compressor s ensure that any water shut off valves are open and that water is circulating through the water to refrigerant heat exchanger Check the incoming line water pressure to ensure it is within design and acceptable limits Enable the cooling mode of operation Check if the sound of the compressor is normal or if there is excessive vibration Check all field and factory refrigerant and water piping connections for leaks and correct Operate the refrigerant system ne
106. ur 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 Figure D2 Place leg extensions over the frame tabs then pull back to lock the leg extension into place Pull leg extension back to lock it into place Repeat Step 1 with each of the four corners The frame with leg extensions should look like Figure D3 Figure D3 Frame with leg extensions installed a a 49 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 Figure D4 Insert HEPA filter into frame until the gasket comes in contact with the holding frame Insert filter until the gasket material contacts A the filter frame The filter should now be resting inside of the holding frame as shown to the left When installing the filters into a frame bank of multiple frames install the lower filters first so that the upper filters can rest on the lower filters VCES V CUBE IOM 1C 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 extension and tighten using the hexkey Tighten t
107. xceeds 35 F 19 4 C then the water flow rate is inadequate or the airflow rate may be low and a second check may be required after airflow balancing 16 On units with electric heating coils check supply air proving interlock switch setting to ensure minimum supply airflow prior to operation 17 Enable heating options and check the operation according to sequence for electric coils see electric heating coil and controls information in Appendix E 18 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 19 Check the operation of the control options provided on the unit 20 Check the setpoints on the DDC Points Reference adjust and record changes as required 21 Check that air balance has been completed for both occupied and unoccupied operation 22 When unit has achieved steady state take measurements and complete readings section of the Start up Form and Checklist in Appendix C Send copy of the completed Start up Form and Checklist to Nortek Air Solutions Canada to validate warranty Maintain a copy of the report at the unit for future reference 23 Once completed return setpoints to original or required values return the unit to the correct mode of operation and adjust the time clock if required VCES V CUBE IOM 1C 45 Start up Readings Serial Number e Allow unit to reac
108. y iii ai A Ritu Sues avoid Guwahati tes 27 MOTOS ica A e A A agatha dere o ied ten 33 FIGS oe det ae e ark do 33 COIS 2 2 E E Hsescebeees cea leridvet N atti edd ei A eet aed ae 34 A eisai eek A E E T Meare hones E TAA ac cecametieeniecutvnes ud oer ieee et edesaety 34 ee el pane A A ii 34 Appendix A Water Cooled Condenser WCC Piping Installation Maintenance and Troubleshooting cccoocccnccnnno 35 Appendix B Positive and Negative Pressure Trapping occcccccccccncccccccconnnnnnnnnnnncnnnonccnnnnnnnnnnnnnnnn eee nn nn seen nn rre nnnn rra nn rnnnnnnnnes 41 Appendix C V Cube Start up 7 43 Appendix D HEPA Filter installati iriiri pin 7 49 Appendix E Electric Heating Coil and Controls Information ooooonnnnnnncccocccccnnnnncconnnnnnnannncnnnnnnnnnnnnnnnnnn nn nnncccnn nana nnnnnnnnnns 52 Appendix F Extended Dormant Unit Maintenance Procedure ooccccccnnnonococcnccccncnnccnnnnnnnnonnncnnnnnnnnnnnnnnnnnnnnnnnnccn rra rn rnnannnnnns 54 Appendix G V Cube Maintenance Summary Chal Eooooccncccccccnncnnnnnnnnnnonnnnnnnncnnnnnnennnnn nn nn n enn nn eee nn nennnnnnnnnnnnnnnnnrnnnnrennnnnnnnes 57 Appendix H Measuring and Adjusting V belt Tension oooooccccccnnnnnccccconanonanannncconnnncnnnnnnnnnn nro nnnn cnn nn nnnnn nan n nn cnn nc cnn nn rn rrnnnnnnnnes 58 Appendix FANWALL Inlet Cone Alignment cccscccccssssseeceeessneeeeessseeneeeesecaeeeeescceaeeseesaaeeeeeseseaeeesessceaseeeesse

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