VHS Series 816 Series Vertical Stack Water Source Heat Pumps Installation, Operation & Maintenance Instructions 69197312 Revision: 03/30/05 TABLE OF CONTENTS Model Nomenclature 2 General Information 3 Inspection 3 Introduction 3 Storage 3 Unit Protection 3 Pre-Installation 3 Installation 4 Supply and Return Piping 4 Condensate Piping 4 Riser Connections 4 Wall Board Installation 5 Optional Duct Installation 5 Supply Grille Installation 6 Electrical Wiring 7 Typical Wiring Diagram - CXM 8 Typical Wiring Diagram - DXM 9 Installation of Optional Wall Mounted Thermostat 10 Shipping Bracket Removal 11 Chassis Installation 12 Start-Up Preparation 13 Hose Kit Installation 14 System Checkout 18 Unit Start-Up 19 Balancing Water Flow 20 Adjusting Fan Speed 20 Operating Controls 20 Maintenance 21 Revision Log 22 Warranty 23
DECODERS Chassis 1 2 3 8 1 6 4 5 6 7 8 9 10 11 12 13 1 0 G S P S S C O Q Model Type 816 Chassis Unit Size 10, 15, 20, 28, 30, 36 Voltage E = 265/60/1 G = 208-230/60/1 Refrigeration Schraders S = Standard Front Access Controls P = Standard for use with CXM or DXM Automatic Flow Regulator (US gpm) S = No AFR C = 1.5, D = 2.0, E = 2.5, F = 3.0, G = 3.5, H = 4.0 J = 5.0, K = 6.0, L = 7.0, M = 8.0, N = 9.0, P= 10.0 Standard O = Standard Water Coil C = Copper N = Cupro-Nickel, RV Energized in Cooling H = Copper (Replacement Only) Water Valve & Pump Option S = No Water valve M = Standard Water Valve H = High MOPD Water Valve P = Secondary Circulating Pump Revision Level Q = Current Revision Level Rev.: 10/01/04D Unit Size 10, 15, 20, 28, 30, 36 Cabinet Style A = Standard.625 Flange C = Master.625 Flange D = Slave.625 Flange B = Standard 1.250 Flange E = Master 1.250 Flange F = Slave 1.250 Flange 1 2 3 4 5 6 8 9 10 11 12 13 14 15 1 0 A G O N "H" Panel "G" Panel Voltage G = 208-230/60/1 E = 265/60/1 Options O = No Options H = High Static Motor M = Manual Air Vents B = High Static Motor And Manual Air Vents Controls A = CXM w/remote Tstat & Internal Secondary Pump Wiring. B = DXM w/remote Tstat & Internal Secondary Pump Wiring. C = CXM w/remote Tstat & MPC D = Dxm W/Remote Tstat & MPC L = CXM w/remote Tstat & LON M = DXM w/remote Tstat & LON N = CXM w/remote Tstat R = DXM w/remote Tstat P = CXM w/surface Mounted Tstat S = DXM w/surface Mounted Tstat 7 A Cabinet A 1 A O O O O P Cabinet Height A = 88 Power Termination Front Left Return & Supply Air No Supply = 0A, 0B, 0C Single Supply = 1A - 1M Double Supply = 2A - 2T Triple Supply = 3A - 3M Quadruple Supply = 4A - 4C B = 80 C = 88 w/8 Cabinet Stand D = 80 w/8 Cabinet Stand A = Disconnect Switch Only C = Breaker - HACR O = No Disconnect Right Revision Level P = Current Standard O = Standard Supply Air Opening Sizes A = 10 W x 6 H B = 10 W x 8 H C = 10 W x 10 H D = 12 W x 10 H E = 12 W x 12 H F = 12 W x 6 H G = 14 W x 6 H H = 14 W x 8 H M = 16 W x 6 H P = 16 W x 10 H Q = 16 W x 12 H R = 16 W x 14 H O = No Front Or Side Openings Rev.: 10/07/04D Page 2
GENERAL INFORMATION Inspection Upon receipt of shipment, carefully check the shipment against the bill of lading. Verify that all VHS units have been received. Inspect each unit for damage. Assure that the carrier makes proper notation on the delivery receipt of all shortages and damage identified and that he completes a Carrier Inspection Report. Concealed damage not discovered during unloading must be reported to the carrier within fifteen (15) days of receipt of shipment. NOTE: It is the responsibility of the purchaser to file all necessary claims with the carrier. Notify the ClimateMaster Traffic Department within fifteen (15) days of receipt of shipment of all damage. VHS Units are shipped in three cartons: one for the cabinet assembly, one for the chassis assembly and one for the return air panel. Introduction ClimateMaster Vertical Hi-Rise Water Source Heat Pump units are decentralized room terminals designed for field connection to a closed-circuit piping loop. VHS Units are typically installed in perimeter zones and are usually framed in place. A discharge plenum with single or multiple air discharge options eliminates the need for duct work in most applications. Unit electrical data is provided in the project submittal drawings. Storage DO NOT store or install VHS units in a corrosive environment or in locations subject to temperature or humidity extremes (e.g., attics, garages, rooftops, etc.). Corrosive conditions and high temperature or humidity can significantly reduce performance, reliability, and service life. Upon the arrival of the equipment at the job site, immediately store units in their shipping cartons in a clean, dry area. Always move chassis in an upright position. Tilting chassis on their sides may cause equipment damage. Store chassis in an upright position at all times. Do not stack equipment. Do not remove equipment from shipping cartons until equipment is required for installation. Cabinets should be stored as shipped. Unit Protection Cover VHS units on the job site with either shipping cartons, vinyl film, or an equivalent protective covering. Cap the open ends of pipes stored on the job site. In areas where painting, plastering, or the spraying of fireproof material has not been completed, all due precautions must be taken to avoid physical damage to the units and contamination by foreign material. Physical damage and contamination may prevent proper start-up and may result in costly equipment clean-up. Examine all pipes, fittings, and valves before installing the system components. Remove any dirt found on these components. All cabinets may not be equipped with the same size riser or the same air supply grille arrangement. Carefully inspect each unit before delivery to the installation site. In some cases each cabinet may be individually tagged for a specific location in the building. To avoid equipment damage, do not use these units as a source of heating or cooling during construction process. The mechanical components and filters used in these units quickly become clogged with construction dirt and debris which may cause system damage and necessitate costly unit clean-up. Pre-installation Installation, operation and maintenance instructions are provided with each unit. Before unit start-up, read all manuals and become familiar with the unit and its operation. Thoroughly check out the system before operation. Complete the inspections and instructions listed below to prepare a VHS unit for installation. 1. Compare the electrical data on the unit nameplate with ordering and shipping information to verify that the correct unit has been shipped. 2. Keep the equipment covered with the shipping carton until all plastering, painting and finish work is complete and it is time to install the cabinet and chassis. 3. Match unit chassis to proper cabinets. 4. Verify that the refrigerant tubing is free of kinks or dents, and that it does not touch other unit components. 5. Inspect all electrical connections. Connections must be clean and tight at the terminals. 6. Inspect blower assembly and manually rotate fan wheel to assure that it turns freely. NOTE: Compressors of VHS Units are all spring mounted. See bracket removal instructions for proper installation. The installation of Vertical Hi-Rise Water Source Heat Pumps and all associated components, parts, and accessories that make up the installation shall be in accordance with the regulations of ALL Authorities having jurisdiction and MUST conform to all applicable Codes. It is the responsibility of the Installing Contractor to determine and comply with ALL applicable Codes and Regulations. Page 3
RISER/CABINET INSTALLATION To avoid damage from clogged coil surfaces, clogged motor ventilation openings, seized fan blades and potential unit failure, DO NOT OPERATE UNIT without complete enclosure, supply grille, return air grille and filter in place. Supply and Return Piping 1. Install a drain valve, shut-off/balancing valves, flow indicators and drain tees at the base of each supply and return riser to enable system flushing at start-up, balancing and during servicing. 2. Install strainers at the inlet of each circulating pump. 3. Insulate loop water piping which runs through nonconditioned areas or outside the building. Because loop temperature is normally between 60 F and 90 F, piping does not sweat or suffer heat loss under ambient conditions. Condensate Piping Condensate connection between the drain pan assembly and condensate riser is factory installed and trapped in VHS units. Riser Connections Install Cabinet Risers as follows: 1. In applications supplemented with factory (or field) supplied between the floor riser extensions, assemble and install extensions before installing cabinet. NOTE: Riser assemblies are designed to accommodate a maximum of 1-1/2 " expansion and contraction up to a total movement of 3". If the total calculated riser expansion exceeds 3", expansion devices must be provided. NOTE: All riser modifications necessitated by variations in floor-to-floor dimensions including cutting off or extending risers is the sole responsibility of the installing contractor. 2. Move cabinet into position. CAUTION: Keep risers off the floor while moving cabinet. 3. Raise the cabinet upright and lower it into the riser from the floor below. NOTE: The top of each riser is equipped with a 3" swagged section. There is sufficient extension at the bottom to allow insertion of approximately 2" of the riser into the swaged top of the riser below.! CAUTION To ensure correct riser positioning and to compensate for variations in floor-to-floor dimensions, do not allow the unit to unit riser joint to bottom out. 4. Center risers in the pipe chase and shim the cabinet level. Plumb risers in two planes to assure proper unit operation and condensate drainage. 5. Attach the cabinet assembly to the floor and the building structure on at least two sides using sheet metal angles. A base vibration dampening pad is recommended to help eliminate transfer of any vibration to the structure. Material of 0.070 to 0.125 inches thick should be applied to the perimeter of the cabinet base. Additional anchorage can be provided by installing brackets at the top of the cabinet. Brackets also simplify wall board installation around the cabinet. 6. DO NOT attach drywall studs to cabinet When all units on a riser are anchored into place, complete riser joints as follows: 1. Center the horizontal supply and return runouts in the expansion slots provided in the back panel of the cabinet assembly. Assure that runouts are perpendicular to the back panel. 2. Verify that all riser joints are vertically aligned and that risers penetrate at least one inch into the swaged joint of the riser below. DO NOT let riser joint bottom out. 3. Braze riser joints with a high-temperature alloy (such as Phos-copper or Silfos). Soft solder (50-50, 60-40 or 85-15) or low-temperature alloys are not suitable for this application. 4. Anchor built-in risers to the building structure with at least one contact point. To accommodate vertical expansion and contraction DO NOT fasten risers rigidly within the unit. 5. Verify that unit shut-off valves are closed. DO NOT OPEN VALVES until the system has been cleaned and flushed. 6. To facilitate cleaning and flushing, install the hose kit at the end farthest from the pump and connect the ends of the hoses with the riser flush adapter. Then open both valves before pumping fresh water through the system, close the valves when the system is clean. Remove the flush adapter before installing the chassis. NOTE: Refer to System Flushing Section of this manual for more information. 7. Install vents in piping loop as required to bleed the system of air accumulated during installation. Optional factory installed air vents may be ordered. Page 4
RISER/CABINET INSTALLATION Figure 1: Vertical Stack Unit Components 1 4 1 Supply, Return, and Condensate Risers 2 Return Air Panel 2 3 Chassis 4 Cabinet 3 Wallboard Installation Install wallboard using conventional construction methods. Secure drywall to studs with low profile, panhead sheet metal screws. Wallboard must not be fastened to drain pan edges or control box enclosure. Do not attach drywall studs to cabinet. Do not install wallboard using adhesive alone. Vacuum all drywall dust and construction debris from coils, drain pans and blower discharge plenum after cutting out supply and return holes for grilles. Insulation should be placed between the drywall and the cabinet for sound attenuation. WARNING To prevent electrical shorts and drain pan leaks, assure that screws do not penetrate unit components when driving screws near the unit control box or drain pan. Do not allow screws or nails to penetrate chassis, risers, electrical junction boxes, raceways or to interfere with chassis removal. To avoid motor or compressor damage, keep drywall dust out of the unit. When installation is complete, cover cabinet supply and return air openings. (Cardboard from unit shipping cartons can be used). Do not allow paint or wall texture over-spray to contact coil, fan or other unit components. Warranties are void if paint or other foreign debris is allowed to contaminate internal unit components. Do not adjust the Sight and Sound baffle (see Figure 2). It is not designed to be used as a damper. Optional Duct Installation When return air is required to enter the unit through openings in a stud wall, supply and field install an optional duct. Seal duct against the return air grille. Add a blockoff above and below the chassis to ensure that all air entering the unit passes through the filter and refrigerantto-air coil. Sheet metal ductwork must not be attached to the cabinet. A canvas type flexible connection should be used between the cabinet and the ductwork. The Sight and Sound baffle should be removed when the system is ducted (see Figure 2). Page 5
CABINET INSTALLATION Figure 2: Sight and Sound Baffle Sight and Sound Baffle Supply Grille Installation Refer to Table 1 to determine grille size based on the type and size of the supply air grille. Install supply grilles over the cabinet discharge openings as follows: a. Insert the grille into the cabinet discharge opening. Assure that the grille flange rests against the drywall covering the cabinet. b. Secure the grille to the cabinet with the screws provided. Table 1: Supply Grille Sizes and Arrangements (3) Unit Single Double Triple Size Discharge (1) Discharge (2) Discharge (3) VHS-10 12" x 10" 10" x 6" Not Recommended VHS-15 12" x 12" 10" x 6" Not Recommended VHS-20 16" x 12" 14" x 8" 14" x 6" VHS-28 Not Recommended 16" x 10" 16" x 6" VHS-30 Not Recommended 16" x 12" 12" x 10" VHS-36 Not Recommended 16" x 14" 16" x 10" (1) Side to front (2) Any combination of top-ducted, side or front (3) Grille sizes and arrangements are based on an equal CFM through each grille Page 6
ELECTRICAL WIRING WARNING To avoid possible injury or death due to electrical shock, open the power supply disconnect switch and secure it in an open position during installation. CAUTION: Use only copper conductors for field installed electrical wiring. Unit terminals are not designed to accept other types of conductors. All field installed wiring, including the electrical ground, MUST comply with the National Electrical Code as well as applicable local codes. In addition, all field wiring must conform to the Class II temperature limitations described in the NEC. Consult the unit wiring diagram located on the outside of the control box door to ensure proper electrical hookup. Route power wiring to the unit control panel through the factory installed conduit at the top of the cabinet. Size wiring to handle circuit ampacity marked on the unit nameplate. Units are shipped wired for 208 Volts. Rewire the control transformer (if supplied) if the actual voltage is 230 Volts. Refer to the unit wiring diagram for details of this procedure. Consult the unit wiring diagram located on the outside of the control box door to ensure proper electrical hookup. Table 2: Operating Voltages Operating Range 208/230/60/1 197 Volts min - 250 Volts max 265/60/1 238 Volts min - 292 Volts max Page 7
Page 8 TYPICAL WIRING DIAGRAM - VHS WITH CXM
TYPICAL WIRING DIAGRAM - VHS WITH DXM Page 9
THERMOSTAT INSTALLATION Installation of Optional Wall-Mounted Thermostat The unit can be furnished with a 24-volt surface mounted ACO or MCO control circuit or a remote 24-volt ACO or MCO thermostat. A typical field connection diagram is shown in Figure 3. Refer to instructions provided with remote thermostat for wiring instructions. WARNING Zone integrity must be maintained to efficiently control units or groups of units. Unless zones of control are considered and accounted for, adjacent units may operate in heating and cooling modes simultaneously. Low-voltage wiring between the unit and the wall thermostat must comply with all applicable electrical codes (i.e., NEC and local codes), and be completed before the unit is installed. Use of four-wire, color-coded, low-voltage cable is recommended. ACO wall thermostats may require field installation of two jumper wires between terminals RC and RH and between W2 and Y1. Check the wiring diagram to determine if jumpers are required. Table 3 below lists recommended wire sizes and lengths to install the thermostat. The total resistance of lowvoltage wiring must not exceed 1 ohm. Any resistance in excess of 1 ohm may cause the control to malfunction because of high voltage drop. Table 3: Recommended Thermostat Wire Sizes WIRE SIZE MAX. WIRE LENGTH* 22-Gauge 30 Feet 20-Gauge 50 Feet 18-Gauge 75 Feet 16-Gauge 125 Feet 14-Gauge 200 Feet *Physical distance from thermostat to unit. Figure 3: Typical VHS Field Connections for units with Wall-Mounted 24V Thermostat WARNING Disconnect electrical power source to prevent injury or death from electrical shock. CAUTION Use copper conductors only to prevent equipment damage Legend: A = Two power wires on single-phase units B = 1H/1C MCO or ACO thermostat - 4 wires MCO = Manual changeover thermostat ACO = Automatic changeover thermostat NOTE: All customer-supplied wiring to be copper only, and must conform to NEC and local electrical codes. Wiring shown with dashed lines must be fieldsupplied and field-installed. Page 10
CHASSIS INSTALLATION VHS Series Compressor Shipping Bracket Removal for Size 10 and 15 Fig 4 Directions The VHS size 10 and 15 Rev Q includes a spring compressor mounting upgrade. This upgrade requires the removal of a compressor shipping bracket prior to installation. Unlike the 20 thru 36 this bracket will not prevent the installation of the Chassis so care must be taken to insure that this bracket has been removed. The bracket will have a red label attached by a nylon wire tie. 1. First loosen the TWO nuts holding the compressor tight using either a ratchet and socket or an end wrench. 2. Next, using the nylon wire tie pull the bracket out from under the compressor. DO NOT RE-TIGHTEN THE NUTS! The chassis is now ready for installation. VHS Series Compressor Shipping Plate Removal for Size 20-36 Step 2) Remove (A) bolts using drill guns as shown in Figure 5. Bolt A Fig 5 Directions The VHS size 20-36 Rev Q includes a spring compressor mounting upgrade. This upgrade requires the removal of a compressor shipping plate that MUST BE REMOVED prior to installation. Step 1) Verify in Figure 4, Chassis 20-36 shown as shipped from the factory at time of printing and locate the compressor shipping bracket. Page 11
CHASSIS INSTALLATION Step 3) Remove (B) bolts using drill gun as shown Figure 6. Fig 6 Step 5) Insert flat head screw driver in bracket 1 hole and disengage bracket 1 using chassis base as pivot point shown in Figure 8a and 8b. Discard bracket 1. Fig 8a Bolt B Pivot Point Step 4) Remove bracket 2 (Bracket 2 location shown in Figure 7). Discard bracket 2. Fig 8b Fig 7 Step 6) Remove (C) screws using drill gun and cover rectangular hole up with label plate shown in Figure 9. Fig 9 Bolt C The chassis is now ready for installation. Page 12
START-UP PREPARATION System Cleaning and Flushing Cleaning and flushing the unit is the single most important step to ensure proper start-up and continued efficient operation of the system. Follow the instructions below to properly clean and flush the system: WARNING To prevent injury or death due to electrical shock or contact with moving part, open unit disconnect before servicing unit. 1. Verify that electrical power to the unit is disconnected and that the heat rejector is de-energized. 2. Verify that supply and return riser service valves are closed at each unit. 3. Fill the system with water, leaving the air vents open. Bleed all air from the system but do not allow the system to over flow. Check the system for leaks and make any required repairs. 4. Adjust the water and air level in the expansion tank. 5. With strainers in place, start the pumps. Systematically check each vent to ensure that all of the air is bled from the system. 6. Verify that make-up water is available and adjusted to properly replace any space remaining when all air is evacuated. Check the system for leaks and make any additional repairs required. 7. Set the boiler to raise the loop temperature to approximately 85 F. Open the drain at the lowest point in the system. Verify that make-up water replacement rate equals rate of bleed. Continue to bleed the system until the water appears clean or for at least three hours whichever is longer. 8. Completely drain the system. Flush risers as follows: (Refer to Figure 10). 1. Close shut-off valves at each unit on the riser except the shut-off valve on the top floor. 2. At the top floor, install the hose kit and connect the ends of the hoses with the factory riser flush adapter. 3. Flush solution through supply riser. Note: The solution passes through the top floor connection down the return riser. 4. When the building has more than 10 floors, connect the supply and return runouts on the top two floors to divide the water flow and reduce pressure drop at the pump. 5. Repeat flushing procedure for each set of risers in the building. 6. Refill the system and add in a proportion of trisodium phosphate approximately one pound per 150 gallons of water. Reset the boiler to raise the loop temperature to about 100 F. CAUTION: To avoid possible damage to piping systems constructed of plastic piping, DO NOT allow loop temperature to exceed 110 F. 7. Circulate the solution for between 8 to 24 hours. At the end of this period, shut off the circulating pump and drain the solution. Repeat system cleaning if desired. 8 Open the supply and return riser service valves at each unit. Refill the system and bleed off all air. 9. Test the system ph with litmus paper. The system water should be slightly alkaline (ph 7.5 to 8.5). Add chemicals as appropriate to maintain acidity levels. CAUTION: Do Not use "Stop-Leak" or any similar chemical agent in this system. Addition of these chemicals to the loop water can foul the system and can inhibit unit operation. 10. When the system is successfully cleaned, flushed, refilled, and bled, check the main system panels, safety cutouts, and alarms. Set controls to properly maintain loop temperature. Figure 10: Typical piping arrangement for flushing risers. Page 13
HOSE KIT AND CHASSIS INSTALLATION VHS Series Hose Kit Installation After cabinets are installed, remove the upper and lower panels. SAVE THESE FOR RE-INSTALLATION AFTER THE CHASSIS IS INSTALLED! The cabinet has one or two shipping braces across the front (Figure 11) remove and discard both braces. Fig 12 Step 1: Remove (2) Panels and Shipping Braces Fig 11 Remove Locate the valves inside the unit cabinet marked WATER IN and WATER OUT (Figure 13). Apply Teflon tape to the male pipe thread end of each hose (Figure 14). Attach the hoses to the water valve. Always use a back-up wrench when tightening the hose to the valve (Figure 15).! WARNING! Under no circumstances should any part of the hose itself be gripped or twisted by hand, pliers, channel locks or any other tool. LEAKAGE OR BURSTING MAY OCCUR! Always use a back-up wrench when tightening the hose. 13 Step 2: Attach the Flex Hoses Unpack and examine hose kit. Remove all shipping and/ or packing material such as rubber bands, plastic caps, and styrofoam. Hose kit should contain (2) hoses (Figure 12).! CAUTION If the risers are under pressure, do not open shut off valves until installation is complete! Water In Water Out Page 14
HOSE KIT AND CHASSIS INSTALLATION Fig 14! WARNING! Do Not Remove Valve without first draining the risers below cabinet level. Step 2: Attach Flex Hoses (continued) Fig 15 Let the universal ends of the hoses hang inside the cabinet for now. (Figure 17). Note: Be sure the valve handles are in a position that enables them to be opened and closed. Check the swivel ends of the hoses (Figure 18). Gaskets must be in the hose for proper seal. Fig 17 Option to Step 2 If you remove the valves to attach the hoses, be sure the 0-ring is in the valve before attaching to the union in the cabinet. Note: The valve union is to be hand tight plus a 1/4 turn. Fig 18 Fig 16 Page 15
HOSE KIT AND CHASSIS INSTALLATION Step 3: Attach to the Chassis Slide the chassis part way into the cabinet. Match the WATER IN hose to the WATER IN tube on the chassis and the WATER OUT hose to the WATER OUT tube. Tighten the swivel connection keeping the copper tube parallel to the sides of the chassis, then tighten the hose to the copper making sure the hose hangs straight without twisting or turning (Figure 19). NOTE: The approximate rule for tightening the copper union and the hose union is hand tight plus 1/4 turn. Under no circumstances should any part of the hose itself be gripped or twisted by hand, pliers, channel locks or any other tool. Leakage or bursting may occur! Always use a back-up wrench when tightening the hose. Fig 19 This!! WARNING! Not This! Fig 20 Check all connections for tightness including the ones above the installed valves (valve union). The chassis should slide into the cabinet without restriction (Figure 20). Chassis and Hose Kit Installation Install the VHS Chassis as follows: 1. Verify that the shut-off/balancing valve in the return line and the shut-off valve in the supply line are closed. 2. Flush system following the procedure in Preparation for Start-up Section of this manual. 3. When the system is clean and flushed, open the unit water valves and check piping for leaks. 4. A flexible electrical cable terminating in quickconnect plugs is provided in chassis. 5. Complete electrical connections between cabinet and chassis by mating the quick-connect plugs on the chassis cable to the plugs located in the bottom surface of the blower deck, directly under the control box. 6. Install the air filter in the chassis by inserting the bottom edge of the filter into the bottom filter bracket. Push filter down until the top can be pushed into place, then latch the filter in place with the two top latches. 7. Before installing the return air/access panel, perform the following checks: a. Ensure that fan wheel rotates freely and does not rub against housing. If rough handling during shipping has caused fan wheel to shift, adjust as necessary. b. Verify that water piping connections to the chassis are complete and that unit service valves which were closed during flushing have been opened. c. Verify that power between the cabinet and chassis is properly connected. d. Assure that the unit drain is properly positioned, secured and not blocked. e. Verify that the nuts used to secure the blower assembly to the fan deck are tight. Page 16
HOSE KIT AND CHASSIS INSTALLATION f. After the system has been filled and system pump is started, all connections should be re-checked for water leaks. ClimateMaster WILL NOT be responsible or liable for damage caused by water leaks at any field water connections! 8. Re-attach the upper and lower panels as shown in Figure 21. 9. Install the cabinet return air/access panel. See installation instructions shipped with return air/access panel for detailed information.! WARNING! Do Not Open Valves to chassis until system has been Purged! Fig 21! IMPORTANT! After the system has been filled and system pump is started, all connections should be rechecked for water leaks. ClimateMaster WILL NOT be responsible or liable for damage caused by water leaks at any field water connections! Page 17
SYSTEM CHECKOUT When the installation is complete and the system is cleaned and flushed, follow the System Checkout procedure below. Record systems parameters. 1. Voltage Check: Ensure that voltage is within the utilization range specifications of the unit compressor and fan motor. 2. System Water Temperature: Referring to Table 4, ensure that system water temperature is within an acceptable range to facilitate start-up; (When conducting this check, be sure to verify the proper heating and cooling set-points as well). 3. System Water ph: Verify that system water exhibits an approximately neutral balance (i.e., a ph of 7.5 or 8.5); this extends the life of the hoses and heat exchangers. 4. System Flushing: Properly clean and flush system periodically. Ensure all supply and returns are connected end-to-end to facilitate system flushing and prevent fouling of the heat exchanger by system water. Water used in the system must be of potable quality and clean of dirt, piping slag, and chemical cleaning agents. 5. Closed-Type Cooling Tower (or Open Tower w/heat Exchanger): Required to ensure continued cleanliness of the system water, while providing the means for removing excess heat from the building. Check equipment for proper temperature set points and operation. 6. Balanced Water Flow Rate to Heat Pump: Verify that as each heat pump unit is installed, inlet and outlet water temperatures are recorded. Refer to the "WSHP System Start-Up/Inspection Sheet." This check eliminates nuisance unit trip-outs resulting from water velocities that are either too low or too high. It can also prevent the occurrence of erosive water flow rates. 7. Standby Pump Installed: Each system must have a standby pump for proper sequencing and operation. 8. System Controls Operational: Verify that the system controls are functioning and providing the proper sequencing; this check is necessary to ensure that no catastrophic system failures occur (e.g., frozen cooling towers or heat exchangers, nuisance system shutdowns, etc.). 9. Freeze Protection from Water System: Ensure that freeze protection is provided for the outdoor portion of the loop water system. Inadequate freeze protection can lead to extremely expensive tower and system piping repairs. NOTE: A problem commonly associated with this type of system occurs when it is filled during construction for the purpose of cleaning, flushing and testing. After testing is complete and the system is drained, the building is often left without heat during winter conditions. Since the condenser coils never fully drain by themselves, they can freeze unless glycol is added to the system. Add glycol in areas where winter conditions prevail. 10. System Water Loop Free of Air: Verify that all air is removed from the system. (Air in the system impairs unit operation and can cause corrosion in the system piping.) 11. Unit Filters Clean: Check to ensure that unit filter is clean. This contributes to the proper operation of the unit by ensuring adequate airflow across the coil. ClimateMaster recommends that the contractor clean or install a new filter in each unit shortly after initial unit start-up. In addition, use a vacuum to remove any debris or dirt lodged in or on the units. 12. Check Unit Fans for Free Rotation: Manually rotate fans to make sure that they rotate freely, and that they are secured properly to the fan shaft. Fan motors are factory lubricated. Do not oil on start-up. 13. System Control Center Installed: A system control and alarm panel is a necessity to ensure control of the temperature set points for operation of the system's heat rejector and boiler. Ideally, the panel should also contain, both audio and visual indicators for abnormal loop water temperatures or lack of water flow. Provide indicator lights for the primary and standby loop circulator pumps when used. 14. Miscellaneous: Note any questionable aspects of the installation. Page 18
UNIT START-UP Use the procedure outlined below to initiate proper unit start-up: NOTE: This equipment is designed for indoor installation ONLY. 1. Adjust all valves to the full open position and verify that the return air/access panel is installed on all units. 2. Adjust thermostat to OFF position. Close disconnect switches on all units to provide line power. WARNING High voltage is present in some areas of the electrical panels with the disconnect switch(es) closed. Be sure to exercise caution when working with energized equipment. 3. Operate each unit first in the cooling mode. Room temperature should be in the normal range (i.e., approximately 70 to 75 F DB, and 61 to 65 F WB). Loop water temperature entering the heat pumps should be at least 40 F, but not in excess of 110 F. Refer to Table 4 for more specific information on the operating parameters of VHS units. NOTE: Three factors determine the operating limits of a VHS unit - (1) return air temperature, (2) water temperature, and (3) ambient temperature. Whenever any one of these factors is at a minimum or maximum level, the other two factors must be at normal levels to ensure proper unit operation. a. Adjust the unit thermostat to the coolest position and set the selector switch to cool. Both the fan and compressor should run. b. Check for cool air delivery at the unit grille a few minutes after the units have begun to operate. List the identification number of any machines that do not function at this time. c. Check the elevation and cleanliness of the condensate lines. 4. Operate each heat pump in the heating cycle after checking cooling cycle operation. A time delay prevents the compressor from re-starting for approximately 5 minutes. a. Adjust the unit thermostat to the warmest setting and set the selector switch to heat. The blower should start immediately and the compressor should activate after the time delay is complete. b. Once the unit has begun to run, check for warm air delivery at the unit grille. Again the installing contractor must list the serial number of any machine that does not function. 5. Log the unit operating conditions at initial start-up for each unit to establish a permanent operating record. Trouble Shooting If the unit fails to operate, conduct the following checks: 1. Check the voltage and current; it should be in accordance with the electrical specifications described on the unit nameplate. A voltage variation of +/- 10% of nameplate utilization voltage is acceptable. 2. Look for wiring errors; check for loose terminal screws where wire connections have been made on both the line and low-voltage terminal boards. 3. Check for dirty filters; a clogged filter can cause the unit's safety cutouts to stop unit operation. 4. Verify that the supply and return piping is properly connected to the inlet and outlet connections on the unit. When the unit is in the cooling mode under ARI conditions, the leaving water temperature is approximately 10 F warmer than the entering water temperature at 3 GPM/ ton. 5. If the fan fails to operate, check to see that the fan wheel turns freely and that it is secured to the shaft. Also, determine whether the fan operates during both the heating and cooling modes. 6. If the checks described above fail to reveal the problem and the unit still fails to operate, contact a trained service technician for proper diagnosis and repair of the equipment. NOTE: VHS heat pumps are designed to start heating and operate in an ambient of 40 F, with entering air at 40 F, entering water at 50 F, a minimum return air temperature of 50 F and both entering air and water at the flow rates used in the ARI Standard 320 rating test, for initial start-up in winter. To cold start, increase boiler temperature to 80 F. When space temperature reaches desired level, return boiler control to 70 F. Page 19
UNIT START-UP Table 4: VHS Operating Limits Air Limits Cooling Heating Minimum Ambient Air 50 F 50 F Rated Ambient Air 80 F 70 F Maximum Ambient Air 100 F 85 F Minimum Entering Air 50 F 50 F Rated Entering Air db/wb 80/67 F 70 F Maximum Entering Air db/wb 100/83 F 80 F Water Limits Min Entering Water 40 F 50 F Normal Entering Water 85 F 70 F Max. Entering Water 110 F 90 F Note: Minimum Air and Water conditions can only be used at ARI fl ow rates. Only one maximum or minimum value may be used with VHS Units. All other parameters must be at normal conditions. Balancing Water Flow On VHS units with a combination shut-off/balancing valve in the supply or return line, adjust water flow rate through the water coil as follows: 1. Fasten one sensor of a dual-temperature test instrument to the supply (or inlet) water pipe inside the unit. Attach the other sensor to the return pipe. 2. Install the return air/access panel. Use care to avoid damaging the sensor leads of the test instrument. 3. Start the unit in cooling mode using the instructions in Unit Start-Up section of this manual. 4. Note the temperature rise of the water flowing through the unit. Gradually close the balancing/ shut-off valve until the desired temperature rise is achieved - typically, 10 F. NOTE: This water flow rate results in a 6-7 F drop in temperature in the heating mode. Adjusting Fan Speed Adjust fan speed on units not equipped with a fan speed selector switch as follows: 1. Open the unit electrical disconnect switch. For sizes 10, 28, 30, and 20, standard, this lead in attached to Pin (2). Move it to Pin (3) for low speed. NOTE: To ensure proper air delivery in units provided with top-duct supply air connections, the fan must be wired to run at high speed. Control Operation Units with wall-mounted thermostats. OperateVHS units from a remotely located, 24-Volt, wall thermostat as follows: a. Move the heating and cooling set point levers to the position of the desired comfort level. NOTE: the minimum temperature differential between heating and cooling is 3 F. b. Adjust the thermostat system to switch to the desired mode of operations. c. Switch positions include: OFF: Both heating and cooling systems are off. Fan is de-energized if the fan switch is in the AUTO position. AUTO: Unit automatically heats or cools depending upon the relationship between room temperature and thermostat setpoint. HEAT: Heating system is automatically controlled by the thermostat. Cooling system is locked out. COOL: Cooling system is automatically controlled by the thermostat. Heating system is locked out. d. Position the fan switch in either the ON or AUTO position as desired. NOTE: When the switch is in the ON position, fan operation is continuous regardless of system switch position. When the switch is in the AUTO position, fan operation cycles with the compressor during heating and cooling operation. WARNING To prevent injury or death due to electrical shock or contact with moving parts, open and lock unit disconnect. 2. Remove the unit front panel and open the control panel. 3. Locate the black fan motor lead. 4. For sizes 15, 36, and 20 high static, this lead is attached to Pin (1). Move it to Pin (2) for low speed. Page 20
MAINTENANCE Perform the maintenance procedures outlined below at the intervals indicated. WARNING To prevent injury or death due to electrical shock or contact with moving part, open unit disconnect switch before servicing unit. 1. Inspect filters every three months. Establish a regular maintenance schedule. Clean filters frequency. Maintenance as needed. CAUTION: To avoid fouled machinery and extensive unit clean-up, do not operate units without filters in place or use as a temporary heat source during construction. To remove the filter from the VHS unit, move the filter latches at the top out of the way and pull the filter out at the top and up to remove. Replace with a new filter by sliding the new filter into the bottom filter bracket, then push the top in place and drop the filter laches down to hold. 2. Check condensate drain pans for algae growth every three months. If algae growth is apparent, consult a water treatment specialist for proper chemical treatment. The application of an algaecide every three months typically eliminates algae problems in most locations. 3. Check fan motors annually. All ClimateMaster heat pumps utilize permanently lubricated fan motors when shipped from the factory. Do not oil fan motors. 4. Visually inspect units at least once a month. During inspection, give special attention to hose assemblies. Note any signs of deterioration or cracking, and repair leaks immediately. 5. Conduct an amperage check annually on the compressor and fan motor. Amperage draw on this equipment should not exceed normal full load or rated load amps by more than 10 percent of the values noted on the unit nameplate. Maintain a log of amperage to detect deterioration prior to component failure. 6. Inspect heat exchangers at least once each year (or more frequently if the unit is located in a "dirty" environment). A dirty heat exchanger can reduce operating capacity and can result in serious equipment problems. Safety Control Reset All ClimateMaster heat pumps are furnished with highpressure, low-pressure and low-temperature cutouts to prevent the machine from operating at abnormal conditions of temperature or water flow. The high-pressure control used on VHS units is designed to open its contacts at 380 psi and automatically re-close them at 300 psig. The contacts of the low-temperature switch open at 33 F and re-close at 40 F. A lockout electrically linked with these cutouts, interrupts unit heating or cooling operation. The unit must be reset manually. Reset is accomplished adjusting the control (or system) switch to the OFF position and then back to the HEAT or COOL (or AUTO) position as desired. NOTE: the VHS may also be reset by opening and closing the circuit breaker. NOTE: If the unit must be reset more than twice, check the unit for a dirty filter, abnormal entering water temperature, inadequate or excessive water flow, and internal malfunctions. If the unit continues to cutout, contact a trained service technician. Page 21
IOM Revision Log: Date Page # Description 02/17/05 8 & 9 Updated CXM & DXM wiring diagrams 02/17/05 4-6 Added additional requirements to installation for sound attenuation 02/17/05 Various Updated fi gure numbers for consistency 02/17/05 22 Added revision log Page 22
CLIMATE MASTER, INC. LIMITED EXPRESS WARRANTY / LIMITATION OF REMEDIES AND LIABILITY (WITH EXTENDED COMPRESSOR WARRANTY) It is expressly understood that unless a statement is specifically identified as a warranty, statements made by Climate Master, Inc., a Delaware corporation, ( CM ) or its representatives, relating to CM s products, whether oral, written or contained in any sales literature, catalog or this Agreement, are not express warranties and do not form a part of the basis of the bargain, but are merely CM s opinion or commendation of CM s products. EXCEPT AS SPECIFICALLY SET FORTH HEREIN, THERE IS NO EXPRESS WARRANTY AS TO ANY OF CM S PRODUCTS. CM MAKES NO WARRANTY AGAINST LATENT DEFECTS AND CM MAKES NO WARRANTY OF MERCHANTABILITY OF THE GOODS OR OF THE FITNESS OF THE GOODS FOR ANY PARTICULAR PURPOSE. GRANT OF LIMITED EXPRESS WARRANTY CM warrants CM products purchased and retained in the United States of America and Canada to be free from defects in material and workmanship under normal use and maintenance as follows: (1) All complete air conditioning, heating, and/or heat pump units built or sold by CM for 12 months from date of unit start-up or 18 months from date of shipment (from factory), whichever comes first; (2) Repair and replacement parts, which are not supplied under warranty, for 90 days from date of shipment (from factory); and, (3) If such extended warranty is purchased, the compressors on all complete air conditioning, heating and/or heat pump units built or sold by CM shall extend for 60 months from the date of shipment (from factory). All parts must be returned to CM s factory in Oklahoma City, Oklahoma, freight prepaid, no later than 60 days after the date of the failure of the part; if CM determines the part to be defective and within CM s Limited Express Warranty, CM shall, when such part has been either replaced or repaired, return such to a factory recognized dealer, contractor or service organization, F.O.B. CM s factory, Oklahoma City, Oklahoma, freight prepaid. The warranty on any parts repaired or replaced under warranty expires at the end of the original warranty period. This warranty does not cover and does not apply to: (1) Air filters, fuses, refrigerant, fluids, oil; (2) Products relocated after initial installation; (3) Any portion or component of any system that is not supplied by CM, regardless of the cause of the failure of such portion or component; (4) Products on which the unit identification tags or labels have been removed or defaced; (5) Products on which payment to CM is or has been in default; (6) Products which have defects or damage which result from improper installation, wiring, electrical imbalance characteristics or maintenance; or are caused by accident, misuse or abuse, fire, flood, alteration or mis application of the product; (7) Products which have defects or damage which result from a contaminated or corrosive air or liquid supply, operation at abnormal temperatures, or unauthorized opening of refrigerant circuit; (8) Mold, fungus or bacteria damages; (9) Products subjected to corrosion or abrasion; (10) Products manufactured or supplied by others; (11) Products which have been subjected to misuse, negligence or accidents; (12) Products which have been operated in a manner contrary to CM s printed instructions; or (13) Products which have defects, damage or insufficient performance as a result of insufficient or incorrect system design or the improper application of CM s products. CM is not responsible for. (1) the costs of labor, refrigerant, materials or service incurred in removal of the defective part or in obtaining and replacing the new or repaired part; or, (2) transportation costs of the defective part from the installation site to CM or of the return of any part not covered by CM s Limited Express Warranty. Limitation: This Limited Express Warranty is given in lieu of all other warranties. If, notwithstanding the disclaimers contained herein, it is without limitation any express warranties or any implied warranties of fitness for particular purpose and merchantability, shall be limited to the duration of the Limited Express Warranty. LIMITATION OF REMEDIES In the event of a breach of the Limited Express Warranty, CM will only be obligated to CM s option to repair the failed product or to furnish a new or rebuilt product in exchange for the product which has failed. If after written notice to CM s factory in Oklahoma City, Oklahoma of each defect, malfunction or other failure and a reasonable number of attempts by CM to correct the defect, malfunction or other failure and the remedy fails of its essential purpose, CM shall refund the purchase price paid to CM in exchange for the return of the sold good(s). Said refund shall be the maximum liability of CM. THIS REMEDY IS THE SOLE AND EXCLUSIVE REMEDY OF THE BUYER OR PURCHASER AGAINST CM FOR BREACH OF CONTRACT, FOR THE BREACH OF ANY WARRANTY OR FOR CM S NEGLIGENCE OR IN STRICT LIABILITY. LIMITATION OF LIABILITY CM shall have no liability for any damages if CM s performance is delayed for any reason or is prevented to any extent by any event such as, but not limited to: any war, civil unrest, government restrictions or restraints, strikes, or work stoppages, fire, flood, accident, shortages of transportation, fuel, material, or labor, acts of God or any other reason beyond the sole control of CM. CM EXPRESSLY DISCLAIMS AND EXCLUDES ANY LIABILITY FOR CONSEQUENTIAL OR INCIDENTAL DAMAGE IN CONTRACT, FOR BREACH OF ANY EXPRESS OR IMPLIED WARRANTY, OR IN TORT, WHETHER FOR CM s NEGLIGENCE OR AS STRICT LIABILITY. OBTAINING WARRANTY PERFORMANCE Normally, the contractor or service organization who installed the products will provide warranty performance for the owner. Should the installer be unavailable, contact any CM recognized dealer, contractor or service organization. If assistance is required in obtaining warranty performance, write or call: Climate Master, Inc. Customer Service 7300 S.W. 44th Street Oklahoma City, Oklahoma 73179 (405) 745-6000 NOTE. Some states or Canadian provinces do not allow limitations on how long an implied warranty lasts, or the limitation or exclusion of consequential or incidental damages, so the foregoing exclusions and limitations may not apply to you. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state or Canadian province to Canadian province. Please refer to the CM Installation, Operation and maintenance Manual for operating and maintenance Instructions. *LC080* Rev.: 3/03 LC080 Page 23
*69197312* Part #: 69197312 7300 S.W. 44th Street Oklahoma City, OK 73179 Phone: 405-745-6000 Fax: 405-745-6045 www.climatemaster.com ClimateMaster works continually to improve its products. As a result, the design and specifications of each product at the time of order may be changed without notice and may not be as described herein. Please contact ClimateMasterʼs Customer Service Department at 1-405-745-6000 for specific information on the current design and specifications. Statements and other information contained herein are not express warranties and do not form the basis of any bargain between the parties, but are merely ClimateMasterʼs opinion or commendation of its products. ClimateMaster, Inc. 1992 Rev.: 03/30/05D