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.....................................................................................................................
Nomenclature Model Indicator V − V-Cube Volume Control V − Variable air volume C − Constant air volume Condenser N − No cooling Y − Chilled water cooling X − Dx without WiSE coil W − Dx with WiSE coil Z – Remote condenser A − Airside economizer Nominal Tonnage Number of Compressors 0 − Air handler T − Tandem compressors Voltage F − 208-230/3/60 K − 575/3/60 L − 220-240/3/60 J − 380-415/3/50 H − Heat pump G − 460-480/3/60 Heating Type E − Electric H − Hot water S − Steam X − No heat Frame Size S − Sma
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.
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. File a claim with the shipping company if the unit is damaged. Check the packing slip against all items received.
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.
section to be suspended by the lifting lugs for an extended period of time. Once the unit or unit section leaves the trailer, ensure it is level at all times. 6” max. Adjustable spreader bars (typ.) Pulleys (typ.) Detail A Use clevis and clevis pin to attach cable to lifting lugs. See Detail A 12” 12” Pulleys Adjustable spreader bars Figure 2: Set the next section approximately 6” [152 mm] from the first section. 3.
5. For modular integrated water cooled units, the compressor/condenser section should first be mated to the coil section as outlined in Figure 2 prior to mounting the fan section. The internal water and 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.
Top of frame Bottom of frame 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. 7. Use tools (chains, chain blocks, 7. chain type come along, etc.
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.
Suspended Unit Installation 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.
• • • • 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.
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.
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 Appendix 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.
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.
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.
Refrigerant Systems ! Distributor 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. Compressors Scroll-type compressors are the most common type of compressor used by Venmar CES. Other types of compressors are available upon request, if required. Maintenance and service on compressors must be completed by a licensed service mechanic.
Dampers ! 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. Units from Venmar CES may or may not incorporate the use of dampers. If dampers are present within the unit, the following maintenance should occur in order to prevent the unit from working under too much pressure and to prevent any other issues.
! 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.
! 6. Fan, wheels, housings and drive assemblies 6. should be checked for dirt buildup annually and cleaned if necessary to keep them from becoming unbalanced 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.
FANWALL® Array ! WARNING Many of the following steps need to be performed with the unit powered off and locked out. Disconnect the main power switch to the unit before performing service and maintenance procedures. Maintenance Schedule FANWALL array of multiple direct driven plenum fan and motor “cubes” are equipped with permanently sealed bearings and do not require lubrication. The following maintenance schedule is recommended. 1. Monthly a.
! 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. 5. After removing the motor pedestal 5. retaining bolts, slide the motor/fan/pedestal assembly out to the point where the motor lifting ring is clear of the cube frame enough to use. If a mechanical device is available for use, attach it to the motor lifting ring.
! 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. 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). ward or backward. Fan wheel should not be rubbing on the inlet cone.
! 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. 7. Gently rotate the fan wheel to verify cone adjustment for proper clearance from wheel. 4. Gently rotate the fan wheel to verify location of adjustment required. Figure 28: Fan wheel/cone alignment – Step 7a and Step 9a Figure 25: Fan wheel/cone alignment – Step 4 5.
! 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. 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. Blank-off Plate (if applicable) 1.
Motors ! • 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.
! 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. Cleaning Procedure 1. Shut down the unit by closing the main disconnect at the power inlet. 2. Open panels or doors to gain access to both sides of the coil section. 3. Remove soft debris from both sides of the coil with a soft brush. 4.
Appendix A: Water Cooled Condenser (WCC) Piping Installation, Maintenance and Troubleshooting Units have the WCC supply and return line internally coupled (manifold) and piped to the unit exterior. The WCC connections shall have copper IPS connections. See the submittal drawings for size, location, flow rate, type of fluid, pressure drop information and components included and factory installed for the supply and return connections.
air in order to avoid unexpected high head pressure 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/connections 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 economizer coil (if equipped) and water-to-refrigerant condenser for conservation when the unit is off.
Monthly • Check water cooled condensers for scaling and proceed with brushing and cleansing if necessary. Quarterly • Check oil level in compressor (half site glass). Semi-annually • • • Check operation of crankcase heaters. Check for broken or loose pipe clamps. 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.
4. Install the recommended size suction 4. 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 recovered refrigerant). See unit’s nameplate for proper refrigerant charge. 5. Start the compressor and put the system in operation. As the contaminants in the system are filtered out, the pressure drop across the suction line filter drier will increase.
Appendix B: Positive and Negative Pressure Trapping Positive Pressure Trapping Removable plug Cleanout X K H L K H X L = = = = Minimum 0.5” [13 mm] 0.5” [13 mm] + maximum total static pressure 3.9375” [100 mm] if unit has a 6” [152 mm] tubular steel base H + K + pipe diameter + insulation − X Negative Pressure Trapping Removable plug Cleanout H J X L = = = = VCES-V-CUBE-IOM-1A X H L J 1” [36 mm] (for each 1“ [25 mm] of maximum negative static pressure) + 1” [25 mm] Half of H 3.
Appendix C: V-Cube™ Start-up Report and Checklist IMPORTANT • Complete this form for each unit and email, fax or mail to Venmar CES immediately after start-up to validate warranty and to provide valuable information for personnel performing future maintenance or for factory assistance to address below. Read the Installation, Operation and Maintenance Instructions Manual and the EPiC™ System Keypad Operation Guide and the Sequence of Operation before proceeding.
Serial Number:______________________________________ Table C1: Pre Start-up Checklist Checklist Item 7 8 9 Is the ductwork connected, complete and free of obstructions? 11 Have all condensate drain connections been trapped, installed correctly and filled? 12 Are all shipped loose or field supplied components correctly installed and wired? 13 Has the wiring diagram been marked up accordingly and left with the unit? 14 Has the power supply and control wiring been inspected and approved by the Loca
Serial Number:______________________________________ Table C2: Start-up Checklist Checklist Item 1 2 3 20 Before proceeding, complete the Pre Start-up Checklist. Close all access panels or doors. Turn the main disconnect to the ‘On’ position. The unit can be started by using the keypad and selecting the mode of operation from the Keypad Operation Guide and the Sequence of Operation. Run through the complete sequence of operation of the unit, adjusting setpoints and documenting as required.
Serial Number:______________________________________ Nameplate voltage Input voltage L1–L2 L2–L3 L1–L3 Table C3: Start-up Readings – Supply Fans Rotation Nameplate Correct Amps Amp Draw L1 L2 L3 Full Load Amps O/L Amp Setting RPM Min. Hertz O/L Set at Min. Hertz Max. Hertz O/L Set at Min. Hertz L3 Full Load Amps O/L Amp Setting RPM Min. Hertz O/L Set at Min. Hertz Max. Hertz O/L Set at Min.
Serial Number:______________________________________ Table C5: Start-up Readings – Condenser Fans Rotation Correct Amp Draw Nameplate Amps L1 L2 L3 Full Load Amps O/L Amp Setting Fan 1 Fan 2 Fan 3 Fan 4 Fan 5 Fan 6 Fan 7 Fan 8 Fan 9 Fan 10 Fan 11 Fan 12 Fan 13 Fan 14 Fan 15 Fan 16 Table C6: Start-up Readings – Compressors Amp Draw Nameplate Amps L1 L2 L3 After compressor has been running for 15 minutes, check for the following: Outdoor Ambient Full Hot Gas Temperature Load Suction Discharge Sup
Serial Number:______________________________________ Table C7: Start-up Readings – Water Source Heat Pump (WSHP)/Water Cooled Condenser (WCC) Waterside Cooling Mode Waterside Heating Mode Entering Leaving Temperature Entering Leaving Temperature Entering Temperature Temperature Difference Temperature Temperature Difference Pressure (°F/°C) (°F/°C) (°F/°C) (°F/°C) (°F/°C) (°F/°C) (PSI) Leaving Pressure (PSI) US GPM Condenser 1 Condenser 2 Condenser 3 Condenser 4 Condenser 5 Condenser 6 Condenser 7 Conde
Serial Number:______________________________________ Item Description Refrigerant pressure at storage Compressor #1 Inspection Date/Reading Date PSIG Date PSIG Date PSIG Date PSIG Date Date Date Date Date Date Compressor #2 4 Compressor #3 Compressor #4 Compressor #5 Compressor #6 Compressor #7 Compressor #8 Refrigerant pressure every 3 months Compressor #1 Compressor #2 5 Compressor #3 Compressor #4 Compressor #5 Compressor #6 Compressor #7 Compressor #8 Rotate blower impellers every 2 m
Appendix D: HEPA Filter Installation These instructions are for installing AAF HEPA filters (11½” depth) into AAF HEPA holding frames. The holding frames are available in multiple sizes and materials, but include the PN series of 30619XX-XXX, where the X’s vary with frame size and material. All frames, latches, extension legs and filters are sold separately. Please read the entire installation instructions before beginning the installation process.
a frame bank of multiple frames, install the lower filters first so that the upper filters can rest on the lower filters. Step 4 Once all four corner latches have been tightened within ¼” 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 D5: Filter placed inside of frame Step 3 Place a latch so that it overlaps the leg extension, as shown below in Figure D6.
Appendix E: Electric Heating Coil and Controls Information This electric heating coil module covered by this appendix 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 Installation and Operation Instructions. The information provided in this appendix applies to the electric heating coil module, installed in the appliance and to its operation, maintenance and service.
3 – Operating Electric Coil Heaters 4.2 – Electrical Inspection 3.1 – Minimum Airflow Two weeks after start-up, all electric connections to contactors 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 recommended monthly during the first four months of operation.
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.
Appendix G: V-Cube™ Maintenance Summary Chart Table G1: Maintenance Summary Chart – V-Cube Item General Fans No. Description Monthly Quarterly 1 Inspect the general condition of the unit. x 2 Remove any dirt or debris. x 3 Check for unusual noise or vibration. x 4 Lubricate the door latch mechanisms. 5 Clean fans with stream of water. x 6 Align or replace belts and drives. x 7 Adjust belt tension. x 8 Check motor voltage and current. x 9 Lubricate the motor and shaft bearings.
Appendix H: Measuring and Adjusting V-belt Tension Table H1: Measuring V-belt Tension V-belt Cross Section Small Sheave Diameter Range (Inches) 3.00 to 3.40 3.60 to 4.20 4.60 to 6.00 4.60 to 5.40 5.60 to 7.40 8.60 to 9.40 7.00 to 8.50 9.00 to 12.00 13.00 to 16.00 12.00 to 15.50 16.00 to 18.00 22.00 to 27.00 17.70 to 23.60 23.70 to 31.50 31.60 to 39.60 2.10 to 3.40 3.60 to 4.20 4.60 to 6.00 3.70 to 5.40 5.60 to 7.40 8.60 to 9.40 5.80 to 8.50 9.00 to 12.00 13.00 to 16.00 2.65 to 3.35 3.65 to 4.12 4.50 to 5.
Appendix I: FANWALL® Inlet Cone Alignment Table I1: 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.
Appendix J: Filter Resistance and Latches Table J1: Prefilters (MERV 8) Depth Nominal Size 2” [51 mm] 4” [102 mm] Capacities (CFM) Resistance @ Capacity (in. w.g.) Medium High Medium High Final 12” x 24” x 2” [305 x 610 x 51 mm] 24” x 24” x 2” [610 x 610 x 51 mm] 600 1,250 1,000 2,000 0.12 0.12 0.23 0.23 1.00 1.00 12” x 24” x 4” [305 x 610 x 102 mm] 24” x 24” x 4” [610 x 610 x 102 mm] 600 1,200 1,200 2,400 0.12 0.12 0.27 0.27 1.00 1.
Appendix K: Troubleshooting Table K1: Troubleshooting – V-Cube™ Symptom Possible Cause Corrective Action General Air supply too cold. Noisy unit. Bearings wear down too quickly. Blower wheel is rubbing on other parts. Check filters and enthalpy wheel for blockage. Balance flow of supply and exhaust air so that exhaust air is equal or greater than supply air. Install a post-heat module. Adjust wheel or replace defective part. Blower wheel is out of alignment. Remove the motor/blower assembly.
Table K1: Troubleshooting – V-Cube™ Symptom Prefilter is wet. Solenoid valve does not open. Too much refrigerant is being fed to the evaporator and the superheat is too low (cannot be adjusted). Possible Cause Corrective Action Outside air hood is shipped loose and was not well Reinstall hood, ensuring the flange is properly sealed. sealed when installed. Airflow exceeds design conditions and sucks water Redesign the hood or lower the cfm of the unit. into the unit. Refrigerant Issues No power to coil.
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info@venmarces.com www.venmarces.com Venmar CES Inc. has a policy of continuous improvement and reserves the right to change design and specifications without notice. FANWALL TECHNOLOGY® and FANWALL® are trademarks of Huntair, Inc. Products in this literature are covered by one or more of the patents listed on www.ces-group.com/patents. ©2014 Venmar CES Inc.
