How it Works
Mammoth
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V-Cube
User Manual
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Mammoth V-Cube User Manual

V-Cube™
Floor-by-floor, Vertical Self-contained System
Installation, Operation and Maintenance Instructions Manual
Capacities: 9–150 tons
©2012 Venmar CES Inc.
Table of Contents
Nomenclature ......................................................................................................................................................................3
Safety Considerations .........................................................................................................................................................4
General Information ...........................................................................................................................................................4
Recommended Spare Parts ........................................................................................................................................... 4
Unit Application Limitations ........................................................................................................................................5
Installation ...........................................................................................................................................................................5
Unit Location Requirements .........................................................................................................................................5
Rigging, Lifting and Assembling .................................................................................................................................. 6
Suspended Unit Installation .......................................................................................................................................11
Electrical Connections ................................................................................................................................................. 11
Coil or Water Cooled Condenser (WCC) Piping Connections ................................................................................... 13
Condensate Drain Trap and Lines ..............................................................................................................................13
Start-up .............................................................................................................................................................................. 14
Start-up Procedure ...................................................................................................................................................... 15
Maintenance ......................................................................................................................................................................16
Long-term Storage Maintenance Procedures ............................................................................................................16
Maintenance Summary Chart .....................................................................................................................................16
Refrigerant Systems ....................................................................................................................................................17
Dampers .......................................................................................................................................................................18
FANWALL® Array .........................................................................................................................................................21
Coils ..............................................................................................................................................................................26
Troubleshooting ..........................................................................................................................................................27
Appendix A: Water Cooled Condenser (WCC) Piping Installation, Maintenance and Troubleshooting .....................28
Appendix B: Positive and Negative Pressure Trapping ................................................................................................... 32
Appendix C: V-Cube™ Start-up Report and Checklist ....................................................................................................33
Appendix D: HEPA Filter Installation ...............................................................................................................................40
Appendix E: Electric Heating Coil and Controls Information .........................................................................................42
Appendix F: Extended Dormant Unit Maintenance Procedure ......................................................................................44
Appendix G: V-Cube™ Maintenance Summary Chart ....................................................................................................45
Appendix H: Measuring and Adjusting V-belt Tension ..................................................................................................46
Appendix I: FANWALL® Inlet Cone Alignment ................................................................................................................47
Appendix J: Filter Resistance and Latches .......................................................................................................................48
Appendix K: Troubleshooting ..........................................................................................................................................49
Manufacturer reserves the right to discontinue or change specifications or designs without notice or obligation.
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2

Nomenclature

VV Y
GSM
000 0
L
Model Indicator
ol Panel Location
V − V-Cube
Volume Control
V − Variable air volume C − Constant air volume
Condenser
N − No cooling X − Dx without WiSE coil W − Dx with WiSE coil Y − Chilled water cooling Z – Remote condenser A − Airside economizer
Nominal Tonnage
Number of Compressors
0 − Air handler T − Tandem compressors H − Heat pump
Voltage
F − 208-230/3/60 L − 220-240/3/60 G − 460-480/3/60 K − 575/3/60 J − 380-415/3/50
Heating Type
E − Electric H − Hot water S − Steam X − No heat
Frame Size
S − Small M − Medium L − Large T − Tall
Contr
L – Left handed unit R – Right handed unit
CES Group, LLC d/b/a Venmar CES furnishes equipment pursuant to its then-current Terms and Conditions of Sale and Lim­ited Warranty, copies of which can be found under the Terms & Conditions of Sale and Warranty link at www.ces-group.com. Extended warranties, if any, shall be as offered and acknowledged in writing by Venmar CES.
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Safety Considerations

!
!
Warning, Caution and Important notes appear through­out 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 in­structions that must be followed as outlined below.
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 se­verely damage the unit, its components, the assembly or final installation.
IMPORTANT
Indicates supplementary information needed to fully complete an instruction or installation.

General Information

This manual is designed to provide general information on the common operation of all standard and optional components that may have been installed in the unit. Note that some sections of this manual may not apply to your unit. This manual has been designed for a general purpose and describes all options offered by Venmar CES Inc. that could be included in the unit. Consult the manual from the component manufacturer if more detailed technical information about a specific component is required.
All documentation that was specifically designed for your unit has been included in the pocket of the control panel, including (and if applicable):
Hazards may exist within this equipment because it con­tains electrical and powerful moving components. Only qualified service personnel should install or service this equipment. Untrained personnel can perform basic main­tenance such as maintaining filters. Observe precautions marked in literature and on labels attached to the unit. Follow all safety codes.
WARNING
Disconnect the main power switch to the unit before per­forming service or maintenance. Electric shock can cause personal injury or death.
• Warranties
• Mechanical drawings
• Unit nomenclature
• Electrical schematics
• Sequence of control
• DDC controller documentation (when supplied) – Controller user’s manual – Communication protocol documentation – Hardware documentation – Keypad documentation

Recommended Spare Parts

Spare parts should be ordered at the time the installa­tion 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 equip­ment is essential may require more spare parts than listed. Please contact the service department at Venmar CES for recommendations.
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Minimum spare parts include:
• One matching set of fan belts (belt driven fans only)
• One set of filters
• One set of shell and tube condenser head gaskets
per condenser (water cooled units only)
4

Unit Inspection on Arrival

Inspect the equipment exterior 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, heat exchanger, dampers and drains.

Unit Application Limitations

CAUTION
Venmar CES equipment is not designed to be used for temporary heating, cooling and/or ventilation during con­struction.
Using Venmar CES 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.

Installation

Unit Location Requirements

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.
Fine dust, larger particulate matter, solvents, varnishes and other chemicals may cause filter clogging and elevated cabinet pressures, higher power consumption and possible irreparable damage to a variety of other key components that may be present in the system. Potential damages in­clude, but are not limited to, these examples.
Consult local building codes and electrical codes for spe­cial installation requirements and note additional require­ments listed in this manual. In choosing the installation location of the unit, consider the following factors:
• The unit should be installed to allow easy access for maintenance and for systems operation.
• Clearance around the unit should be per the recom­mended 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.
• Locate the unit in an area requiring the least amount of ductwork and direction changes to allow optimum performance, to reduce pressure loss and to use less electricity to achieve proper ventilation. Ductwork must be in accordance with ducting mechanical rules to prevent sound issues and system effects.
• The unit 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 recommendations, a Structural Engineer must be involved to properly size supporting structural ele­ments.
• Once the unit is in place within the mechanical equipment room, mount the unit on a housekeeping pad of sufficient height in order to allow for drain trap height and condensate lines to slope toward the building drain; install condensate pumps to reduce height of the housekeeping pads or drill holes in the concrete pad or mechanical room floor for sufficient trap height.
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Rigging, Lifting and Assembling

IMPORTANT
• Carefully read all the instructions contained herein. Before proceeding with any work, correlate these instructions with the information provided on the curb and equipment shop drawing for the specific project.
• These instructions outline the suggested method of rigging, lifting and installing a Venmar CES unit. All local codes and fire regulations must be verified and adhered to by the Installing Contractor.
• Before assembling, hoisting or setting any pieces of the supporting curbs or units, verify that the proper unit is being directed to the correct location, as des­ignated by the architectural and engineering design drawings.
• Safety first: Ensure that all safety practices recom­mended by local safety associations are continu­ously in use.
• If any questions arise during the installation proce­dure, please contact the factory.
• The Installing Contractor is responsible for the unit being air and water-tight including all section joints on the unit.
• All holes that have been made by the Installing or Electrical Contractor after receiving and installing the unit must be well sealed to prevent air and/or water infiltration.
All rigging equipment and labor (as applicable) is provided by the Installing Contractor as detailed below. It is highly recommended that extra quantities of all items listed be on hand. The rigging procedure and/or equipment used to lift the unit may differ depending on the physical dimen­sions 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.).
• All construction equipment and labor required to complete the work according to local codes.
• Condensate and/or P-trap piping hardware.
• All tools and materials required for level unit installa­tion.
Installation and Assembly Materials for Multisection (Modular) Units
• Polyvinyl gasket with adhesive strip (½” x 1½” [13 x 38 mm] x required length) applied between unit sec­tions (for split section joints and duct opening con­nections).
• 3/8” x 2½” Grade 5 full thread zinc plated bolts, with two washers and one nut each (to secure sec­tions together).
• Adseal 1800 series (from Adchem Adhesives) clear silicone based sealant or equivalent (for side and top joints).
Rigging, Lifting and Assembling Instructions
Depending on size, the unit or unit sections of a multi-sec­tion (modular) unit will arrive at the jobsite on a standard flatbed or special low bed trailer. Each unit or unit section is identified with labels, as per the mechanical drawings. At ground level, ensure that any crating used for shipping purposes is removed if there is a possibility that it will in­terfere with the placing or assembling of the unit or unit sections on the structural steel or housekeeping pad.
Unit or unit sections shall be lifted by cables attached to all the lifting lugs. Consult the mechanical drawings located in the pocket of the control panel for the number of lift­ing lugs, number of sections and unit weight. For multi­section (modular) unit check for additional lugs located between split sections. Lifting lugs are factory bolted to the unit or unit section base.
CAUTION
All lifting lugs provided must be used when rigging units or unit sections. Rigging and lifting unit or unit sections without using all lifting lugs provided will compromise the structural integrity of the unit or unit section. Never lift, rig or ceiling suspend from the top of the unit or unit sections. Using a forklift or similar device for moving, lifting or rigging unit or unit sections is prohibited. The use of a forklift or other similar device is only allowed for modular unit sections that are mounted on wooden skids within the factory prior to shipment. The sections must be forklifted individually along its longest side only.
When lifting the unit or unit sections, use adjustable spreader bars, pulleys, cables (straps or chains) in order to properly distribute the load, applying an even vertical lifting force only at all the lifting lugs to prevent structural damage to the unit or unit section or prevent cables from rubbing against the cabinet (see Figure 1). Provide ad­ditional blocking and coverings (as required) to prevent damage to the unit finish and/or components. The adjust­able spreader bars are required to maintain a clearance between the cables and the unit or unit section of at least 12” [305 mm] beyond the sides. Venmar CES will not be responsible for any damage caused to the unit casing 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 and prior to setting. When com­mencing 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 sud­den, jerking movements. Do not permit the unit or unit
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section to be suspended by the lifting lugs for an extended
See Detail A
period of time. Once the unit or unit section leaves the trailer, ensure it is level at all times.
Adjustable spreader bars (typ.)
Pulleys (typ.)
Detail A
Use clevis and clevis pin to attach cable to lifting lugs.
12” 12”
Pulleys
Adjustable spreader bars
12” min.
6” max.
Figure 2: Set the next section approximately 6” [152 mm] from the first section.
3. Corner reinforcement brackets or angle bars may have been used to support multi-section (modular) unit walls during transportation, rigging and lifting at the split. The brackets shown in Figure 3 are for larger units. Simple angle bars are used for smaller units (not shown). The corner reinforcement brackets or angle bars are no longer required after rigging and lifting and must be removed.
IMPORTANT
After the corner reinforcement brackets or angle bars have been removed from the split section, set the screws along with the rubber washers that were holding the brackets or angle bars back in place for water-tightness.
Figure 1: Use adjustable spreader bars, pulleys and cables attached to all lifting lugs to apply an even lifting force.
Assembling a Multi-section (Modular) Unit
Special attention must be taken to ensure that a multi­section (modular) unit has an air and water-tight seal at every section split. Follow the next set of instructions for assembling a multi-section (modular) unit.
1. Remove the yellow lifting lugs located on the section joint (if any) once the first section is set in place.
IMPORTANT
Yellow lifting lugs located on the section joint (if any) must be removed once the first section is set in place to allow the next section to be pulled to the first.
2. Set the second section approximately 6” [152 mm] from the first section (see Figure 2). Remove the yellow lifting lugs located on the section joints (if any) from the second section to allow sections to be pulled together.
VCES-V-CUBE-IOM-1A
Figure 3: Corner reinforcement brackets or angle bars to be removed from the split section. Reset the screws with rubber washer in place for water-tightness.
4. Verify that these two sections are aligned square at the joint in all three directions.
7
5. For modular integrated water cooled units, the
acoustical butyl sealant
1½”
Detail at A
5b
½” x 1½” polyvinyl gasket
compressor/condenser section should first be mated to the coil section as outlined in Figure 2 prior to mounting the fan section. The internal water and re­frigerant piping must then be completed in the field by the Installing Contractor. Once the field piping is complete a bead of Adcoustik butyl sealer should be applied to the top of the condenser/compressor section as illustrated in Figure 4a. The fan/blower as­sembly should then be gently lowered on top of the compressor/condenser section as shown in Figure 4b. Finally the top and bottom sections should be joined together with bolts, nuts and washers as per Figure 4c. After reassembly, the unit will require pump down (evacuation) and refrigerant charging. Factory shall provide dry nitrogen “holding” charge only. Re­frigerant, additional copper piping and insulation for field connections shall be supplied by others. Filter drier shall be shipped loose for field installation.
½” [13 mm] bead of ADBOND 1465
Figure 4c: Secure the top and bottom sections together with bolts, nuts and washers. Do not over tighten.
6. Install the ½” x 1½” [13 x 38 mm] 6. polyvinyl gasket with adhesive strip directly on one side of the split section perimeter frames and middle interior parti­tions as shown in Figure 5a through Figure 5d.
Figure 4a: Apply a ½” bead of Adcoustik butyl sealer atop of the condenser/compressor section prior to placing the fan/blower section above it.
Figure 4b: Gently lower the fan/blower section atop of the compressor/condenser section.
1½”
A
5a & 5c
5d
Figure 5: General gasket layout
IMPORTANT
Make sure to have full contact between strips wherever a discontinuity is present, for air- and water-tightness.
¼”
Figure 5a: Install a polyvinyl gasket strip on each vertical outside wall ¼” [6.4 mm] from the outside side edge from top to bottom of the side joint. When compressed, a small gap will remain which will allow the Adseal 1800 series silicone based sealant or equivalent to seal the vertical side edges (explained in Figure 8).
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8
Bottom of frame
Top of frame
7. Use tools (chains, chain blocks, 7. chain type come along, etc.) connected to the side lifting lugs (at­tached 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 ¼” [6.4 mm] apart on the full joint perimeter as in Figure 6. Remove any yellow side lifting lugs that interfere with the chains for pulling sections together. When joining sections together, always apply the pulling force to the lifting lugs attached to the unit structural base, never to the corner posts and pull uniformly from both sides of the unit section.
Figure 5b: Install two horizontal polyvinyl gasket strips along the base frame, one at the top and one at the bottom of the base frame between the two vertical side gasket strips so there is full contact between gasket strips for air- and water-tightness.
Figure 5c: Install one horizontal polyvinyl gasket strip along the top frame between the two vertical side gasket strips so there is full contact between gasket strips for air­and water-tightness.
IMPORTANT
Unit sections must be drawn together using the lifting lugs attached to the unit structural base only.
CAUTION
Do not use the vertical side casing framing or bolt holes to pull sections together as this may cause the corner posts to warp and break their air- and water-tight seal.
Displacement
Tools supplied by others
Figure 6: Use tools (chains, chain blocks, chain type come along, etc.) hooked to the unit lifting lugs attached to the structural base on both sides of the unit to pull the second or next section to the first section evenly.
Middle internal partition(s)/divider(s)
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.
VCES-V-CUBE-IOM-1A
8. With the sections pulled together, use the 3/8” x 2½” bolts, nuts and washers to secure the sections together along the sides as in Figure 7. Start at the bottom and gradually tighten all bolts to apply an even load along both sides and along the top (not at one place) until sections or gasket is compressed within ¼” [6.4 mm].
9
Figure 7: Secure the sections pulled together with bolts,
1/8” x 1” neoprene SOFT SEAL gasket
nuts and washers. Do not over tighten.
CAUTION
Do not over tighten the side bolts as this may cause the corner posts to warp and break their air- and water-tight seal.
9. After two sections are assembled, verify that the assembly is level and square. If an adjustment is re­quired, make certain to address it immediately, not at the end of the final assembly.
10. If multi-section unit has more than two sections fol­low Steps 1 through 9 for each additional section, always pulling the next section from the first end sec­tion.
11. Apply a generous bead of Adseal 1800 series clear silicone based sealant (or equivalent) to the exterior side frame joint seams to completely cover the sec­tion split gasket and in such a way that the silicone bead meets with both frames as in Figure 8. The bead of clear silicone based sealant should fill the ¼” gap, as shown in Figure 8.
12. All lifting lugs removed on the exterior of the base for pulling sections together must be returned or if not desired the bolts must be set back in place. Once removed the bolts must be returned and sealed with clear silicone based sealant for water-tightness. All other 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.
Bead of Adseal 1800 clear silicone based sealant
Figure 9: a) Install the gasket strips on the inside edges of the inside caps; b) Install caps in place with self-drilling screws; c) Apply a continuous bead of Adseal 1800 clear silicone based sealant (or equivalent) to the inside cap seams and partition(s)/divider(s).
Figure 8: Apply a continuous bead of Adseal 1800 clear silicone based sealant (or equivalent) to the exterior side frame joints and for indoor units along the top frame joints.
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¼” bead Adseal 1800 clear silicone based sealant
10

Suspended Unit Installation

min.
!
To install units that will be permanently suspended, the units must be set on structural steel beams that are sup­ported by vertical rods. Venmar CES recommends beams under the full perimeter and all cross members requiring support. In addition to these recommendations, a Struc­tural Engineer must be involved to properly size the sup­porting structural elements. Note that the locations of the beams shall be coordinated with the location of access doors to prevent any interference (see Figure 10). Single section unit shown; for multi-sectional unit suspension, consult factory.

Field Fabricated Ductwork

Anchor
40”
Figure 10: Indoor suspended installation
40” min.
On indoor or indoor vertical duct connections, make con­nections to the casing by applying Adseal 1800 silicone based sealant or equivalent around the connection and screwing flanged ducts directly to the casing and/or flange with self-drilling sheet metal screws. It is important to seal all duct connections to prevent air leakage and system performance problems. Ductwork must be supported by the building structure.
For duct connection sizes, see the mechanical drawings. Insulate and weatherproof all external ductwork, joints and roof openings with counter-flashing and mastic in accordance with applicable codes. Ductwork running

Electrical Connections

WARNING
When installed, the unit must be electrically grounded in accordance with local codes or, in the absence of local codes, with the National Electrical Code, ANSI/NFPA70, and/or the Canadian Electrical Code CSA C22.1. Unit cabinet must have an uninterrupted, unbroken electrical ground to minimize the possibility of personal injury if an electrical fault should occur. Failure to follow this warning could result in the installer being liable for personal injury of others.
The unit is factory wired (unless otherwise specified) except for power connections, shipping split locations, shipped loose sensors/items or remote control options as indicated in the electrical schematics and sequence of control. The unit may or may not have an optional factory installed door interlocking disconnect in the control panel.
through roof decks must comply with local fire codes. Ducts passing through unconditioned spaces must be in­sulated and covered with a vapor barrier.
The ventilation system should be designed according to maximum airflow needs. To minimize noise level and loss of pressure, ducts should be designed for a maximum air velocity of 1,200 feet per minute, keeping the direction and transition changes to a minimum. To further reduce noise transmission, line the first 15 feet [4,572 mm] of duct with acoustic insulation. Elbows with a turning radius equal to or greater than 1, or 90º elbows with turning vvanes, should also be used.
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.
• For multi-section (modular) units, the Electrical Con­tractor must join the low voltage wiring between unit sections using quick connections supplied by Venmar CES and join the high voltage wiring between sec­tions at the junction boxes or extend coiled wiring.
• Check nameplate for correct power supply require­ments.
• See electrical schematics and sequence of control lo cated in the control panel pocket for field wiring of power connections, shipped loose sensors, items or remote control interlocks. The Electrical Contractor must locate, install and wire sensors, items or remote
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11
control interlocks as per electrical schematics and se­quence of control.
• Numbered terminals strips are included in the control panel for ease of connection and service.
• 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.
• 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 con­sidered during the submittal process. Non considered electrical components are not allowed in the control panel. It is the responsibility of the Control Contrac­tor to provide his own power source(s) for any field added electrical components. The control panel mounted transformers are not rated for external components power supply unless otherwise listed on the electrical schematics.
Electrical Field Connections
Shipped loose sensors, items or remote control wiring can be located next to the power feed cable provided it is inserted in shielded cable that will protect it from elec­tromechanical 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 sup­plied. 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 des­ignated areas. The unit cabinet and/or floor must be wisely penetrated in order to keep their integrity. Access openings in the floor can only be cut or drilled for piping and wiring (high and low voltage) in the designated rect­angular areas within an upturned 1” [25.4 mm] flange as provided during the submittal process and located on the mechanical drawings. Access openings must be sized, field cut or drilled by the Installing Contractor within the rectangular flanged area then sealed air- and water-tight. If insulation was removed to create floor access openings, insulation must be put back in place to avoid condensa­tion. 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.
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Coil or Water Cooled Condenser (WCC) Piping Connections

CAUTION
Internal coil (water, steam or non-integrated direct ex­pansion), WCC piping connections within the unit may only be field extended through the cabinet within desig­nated areas. Connections to the unit coil (water, steam or nonintegrated direct expansion, WCC) are by others. External supply and return piping connection, provision, design and all other safety (such as dielectric couplings or other), freeze protection or electrical control require­ments for system operation are the sole responsibility of the Installing Contractor and/or Design Engineer. Refer to ASHRAE handbooks and local building codes for correct piping and electrical control for proper installations. Refer to the mechanical drawings for coil performance design information.
Connections to the unit coil (water, steam or non-inte­grated direct expansion, WCC or humidifier) are by others. Refer to the mechanical drawings and the instructions on the casing for correct orientation of external piping. External supply and return piping connection, provision, design and all other safety, freeze protection or electrical control requirements for system operation are the sole responsibility of the Installing Contractor and/or Design Engineer. Refer to ASHRAE handbooks and local building codes for correct piping and electrical control for proper installations. Refer to the mechanical drawings for coil per­formance design information.
For WCC units, see Appendix A. See the piping schematics for optional piping components and sequence of opera­tion 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 damage.
IMPORTANT
A hydrostatic test must be performed in the field by the Installing Contractor at 1.25 times the operating pressure on all equipment involving piping connections to verify that the installed unit and its connections to the network are free of leaks prior to the unit being set in operation. This test shall be performed after the unit is completely piped to the network and shall cover the connections between the unit and the network, as well as all internal components of the unit.

Condensate Drain Trap and Lines

Cooling coils, humidifiers or other options that can pro­duce condensation are provided with a drain pan with a 1¼” [32 mm] MPT (Male Pipe Thread) drain connection. A drain trap and condensate line of equal size must be field provided by the Installing Contractor on the drain connections and coupled to the building drainage system to prevent air or sewer gases from being pulled into the unit caused by the negative (suction) pressure and forcing water out of the pan into the unit or from air escaping into the drain caused by positive pressure. See Appendix
B for illustrations and dimensional information on positive
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 requirements. Installing a plug for cleaning of the trap is recommended. Fill the P-traps with water before starting the unit. Check and clear drains annually at start of 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.
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Start-up

Pre Start-up Check

Before requesting start-up, check that the installation is complete and unit is ready. Complete the pre start-up below (if items are applicable) and the checklist in Appen-
dix C for each unit. For torque values on set screws, belt
tension, etc. check under Operation and Maintenance.
1. Check the electrical disconnect is in 1. the ‘Off’ posi­tion.
2. Check the split section joints are properly installed on multi-section units.
3. Check that all holes that have been made by the Installing Contractor after receiving the unit in the casing, partitions or floor have been well sealed to prevent air and/or water infiltration.
4. Check the unit for obstructive packaging, objects near or in fans, dampers, etc.
5. Remove all retaining bolts on fan bases. a. Check that the fan impellers are rotating freely. b. Check fan impeller and drive set screws. Tighten
if required.
c. Check the fan bearing set screws or locking col-
lars. Tighten if required.
d. Check fan belt alignment and tension.
6. Check that the air filters are installed and clean. Replace if necessary. See Appendix D for optional downstream high efficiency HEPA filter installation (if supplied). a. Check all face-mounted filters are attached with
four clips each.
b. Check each sliding filter has a retainer at the end
track and well attached blank-offs.
c. Check that the filter pressure differential gauges,
switches or sensors are free of dirt and set at a value satisfactory to the end user to trigger a fil­ter change.
7. Check coils if fins have been damaged in shipping, installation or building construction and are clean. Straighten fins with fin comb and clean coil if re­quired. 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 WCC have
been completed, piping lines have been flushed, filled, vented and tested at 1.25 times the oper­ating pressure.
c. Refer to Appendix A for WCC piping installation
and check that it is complete.
8. Scroll compressor RIS vibration isolator bolts are fac­tory tightened to the correct torque setting for op­eration and do not require field adjustment. a. Check that refrigerant components and piping
are in good condition and have no damage or leaks from shipping or installation.
b. Check that the clearance around the water
cooled condenser (WCC) is in accordance with minimum recommended clearances.
9. Check motorized damper control arms, control rods and shafts for tightness. a. Check that non motorized dampers rotate freely.
10. Check that ductwork is connected, complete and free of obstructions.
11. Check that condensate drain connections have been trapped, installed correctly and filled.
12. Check that all shipped loose or field supplied compo­nents have been correctly installed and wired.
13. Check that the wiring diagram has been marked up accordingly and left with the unit.
14. Check that all power supplies and control wiring have been inspected and approved by the Local Au­thorities having jurisdiction.
15. Check all factory and field wiring connections for tightness. Tighten if necessary.
16. Check that all fuses are properly installed in holders.
17. 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.
18. Check that all field piping and venting installation and connections for the heating and cooling options have been completed and tested.
19. Set the heating and cooling enable switches to the ‘Off’ position.
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14

Start-up Procedure

!
To ensure proper operation of each unit, qualified person­nel should perform the start-up as outlined below (based on options included with unit) and complete the Start-up Report and Checklist in Appendix C for permanent record. A completed report and checklist will provide valuable in­formation for personnel performing future maintenance.
IMPORTANT
• A completed copy of the Start-up Report and Checklist must be sent back to the factory for war­ranty validation and for factory assistance.
• General information on the factory installed and programmed DDC control system regarding the navigation 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 crankcase heaters to be energiz­ing to prevent possible damage.
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 ac­cording 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 pip­ing 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.
7. Recheck the voltage at the disconnect switch against the nameplate and against phase-to-phase readings on three-phase with all fans operating. If the voltage is not within 10% of rated or 2% of phase-to-phase have the condition corrected before continuing start­up.
8. Check amperage draw to each motor on each phase against motor nameplate FLA. If significantly differ­ent check ductwork static and/or take corrective ac­tion.
9. Feel the compressor crankcases. They should be warm if the disconnect has been on for at least 24 hours. This will assure that no refrigerant liquid is present in the crankcase which could cause compres­sor damage or failure to occur on start-up.
10. 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.
11. Enable cooling and check that compressors and con­denser fans are rotating in the correct direction.
12. Check if the sound of the compressor is normal or if there is excessive vibration.
13. Check all field and factory refrigerant and water pip­ing connections for leaks and correct.
14. Check the operation of the control options provided on the unit.
15. Check the reference setpoints on the keypad opera­tion guide against the sequence of operation, adjust and record changes as required.
16. When unit has achieved steady state take measure­ments and complete the readings section of the start-up report in Appendix C.
17. Set the keypad to each mode of operation and check the operation according to sequence.
18. For recirculation scheduling mode the outside air and exhaust air dampers must be adjusted during start-up to achieve the required outside and exhaust air vol­umes. See Airflow Balancing for further information.
19. Send copy of the completed start-up reports to Ven­mar CES to validate warranty. Maintain a copy of the reports at the unit for future reference.
1. Before proceeding complete the Pre 1. Start-up Checklist.
2. Check that all access panels or doors are closed.
3. Open the access door to the main control panel to access the keypad interface device.
4. Bump-start the unit to verify that the fan wheel(s) are rotating in the correct direction.
5. Set the keypad to occupied mode with heating and cooling disabled and fan(s) enabled.
6. Check that dampers are operating properly.
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Airflow Balancing
!
IMPORTANT
Before measuring supply and exhaust flows, 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 supply and exhaust flow rates as shown in the me­chanical drawings. Unit fan speed(s) and damper positions are theoretically set at the factory based on the ductwork static pressures and flow rates specified in the mechanical drawings. If conditions change or verification is required, airflow measurements should be taken using AMCA sug­gested methods. This would normally be a velocity traverse measurement or flow measuring station (FMS) installed in the ducts. Where space is limited in the outdoor air and exhaust air, pressure drop readings can be taken across the energy recovery heat exchanger (with economizer heat recovery bypass dampers closed, if equipped) and com-
pared to the submittal documents. Heat recovery perfor­mance is tested in accordance to AHRI Standard 1060 and is accurate to within +/− 5% if there is no dirt buildup in the heat recovery heat exchanger. Should flow rates need to be reset, adjust the outside air, exhaust air or mixed air dampers, variable speed sheaves, VFD fan speed setpoint positions or change the sheaves.
Flow measuring stations (FMS) and magnahelic gauges can also be used to measure supply and exhaust flow. It is im­portant to locate the FMS in the “warm side” ductwork to minimize the effect of differences in air density, especially when balancing during extremely cold outside conditions or to take temperature readings and make the necessary corrections if installed in the “cold side” ductwork. Air density variations can affect the FMS by more than 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.

Maintenance

Long-term Storage Maintenance Procedures

WARNING
Many of the following steps need to be performed with the unit powered off and locked out. Disconnect the main power switch to the unit before performing service and maintenance procedures.

Maintenance Summary Chart

Please refer to Appendix G for a recommended list of routine maintenance items and time intervals. A more de­tailed description of maintenance items follows.
Please refer to Appendix F: Extended Dormant Unit Main­tenance Procedure and Checklist, for maintenance instruc­tions to follow if the unit is to be stored for a period of time exceeding one month. Following the instructions in this appendix will assist in preventing potential unit dam­age that may result from an extended storage period.
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