Mammoth K Vintage User manual

MAMM-WSHP-IOM-1KA (September 2011)
Vertical Water-to-Water Heat Pumps With
R-410A
Installation, Operation and Maintenance Manual
Sizes: 064 to 480
Model: K Vintage
P/N 71144912

2
MAMM-WSHP-IOM-1KA (September 2011)
Model Nomenclature················································································································3
Transportation and Storage ····································································································3
Installation ································································································································4
Unit Location ····························································································································5
Piping ········································································································································6
Cleaning and Flushing·············································································································7
Start-up······································································································································8
Operating Limits·······················································································································9
Controls···································································································································10
Inputs/Outputs························································································································13
General Maintenance ·············································································································14
Parts and Service Support·····································································································14
Troubleshooting·····················································································································15
Performance Troubleshooting ·····························································································16
Unit check-out sheet ·············································································································17
Table of Contents
K Vintage Water-to-Water
Sizes 064 to 480

3
MAMM-WSHP-IOM-1KA (September 2011)
“Mammoth” is a registered trademark of Mammoth, Inc.
©Mammoth, Inc. 2011. All rights reserved throughout the world.
Illustrations cover the general appearance of Mammoth products at the time of publication and Mammoth, Inc. reserves the right to make changes
in design and construction at anytime without notice.
Model Nomenclature
F-170- W- H- K
Voltage BTU/hr Cooling Unit Type Temperature Range Vintage
F = 208-230/60/3 064 = 58,437 W = Water-to-Water H = Standard Range
G = 460/60/3 120 = 127,792 L = Low Temp Operation
J = 380-415/50/3 170 = 172,906
K = 575/60/3 270 = 257,319
S = 380/60/3 360 = 350,047
480 = 459,580
Transportation and Storage
Upon receipt of the equipment, check for visible dam-
age. Make a notation on the shipper’s delivery ticket
before signing. If there is any evidence of rough han-
dling, immediately check for concealed damage. If any
damage is found, notify the carrier within 48 hours to
establish your claim and request their inspection and a
report. Then contact the Mammoth Service department
at [phone] or [email protected]
for a warranty claim number.
Do not stand or transport the unit on its side. In the
event that elevator transfer makes horizontal position-
ing unavoidable, absolutely ensure that the unit is in
the normal upright position for at least 24 hours before
operating.
Temporary storage at the job site must be indoors,
completely sheltered from rain, snow, etc. High or low
temperatures naturally associated with weather pat-
terns will not harm units. But excessively high tempera-
tures, 140°F (60°C) and higher, may deteriorate certain
plastic materials and cause permanent damage.

4
MAMM-WSHP-IOM-1KA (September 2011)
Installation
General
1. To prevent damage, this equipment should not be
operated during the construction period.
2. Inspect the unit for any specific tagging numbers
indicated by the factory per a request from the in-
stalling contractor.
3. Check the unit nameplate for the size and voltage
rating and confirm against the plans that the unit is
being installed in the correct location.
4. Verify the installation location with the piping and
electrical contractors prior to installation.
5. Verify all clearances are available for the unit prior
to installation.
6. Note the location and routing of water piping and
electrical wiring. The locations of these items are
clearly marked on the submittal drawings.
7. Mammoth recommends the unit be covered during
construction to protect components from dust and
other harmful materials. This is critical while spray-
ing fireproofing material on bar joists, sandblasting,
spray painting and plastering.
NOTE:
Check the unit name plate for correct voltage with the
plans before installing the equipment. Make sure all
electrical ground connections are made in accordance
with local code.
IMPORTANT:
Mammoth water source heat pumps should be in-
stalled only by qualified personnel, experienced in the
installation of this equipment and related systems.
Read these instructions carefully before unpacking,
installing and operating this unit.

5
MAMM-WSHP-IOM-1KA (September 2011)
Unit Location
Locate the unit in an area that allows for easy removal
of the compressor and control box access panels. The
diagram below shows minimum suggested clearances.
Any additional clearances would be beneficial, but not
always necessary.
The requirements on any specific unit may increase or
be reduced depending on several factors such as
maintenance requirements and mechanical or electrical
installation codes.
The electrical connections are accessible from the
front. The compressor can be accessed from either
side. There are no air filter, ductwork or ventilation air
requirements for K-Vintage water-to-water units.
Service Clearances

6
MAMM-WSHP-IOM-1KA (September 2011)
Unit Piping
1. All K-Vintage heat pumps should be connected to
supply and return piping in a two-pipe reverse
return configuration. A reverse return system is
inherently self-balancing and requires only trim
balancing where multiple quantities of heat pumps
with different flow and pressure drop characteristics
exist in the same loop. Check for proper water
balance by measuring differential temperature
reading across the water connections. To verify
proper water flow, the differential temperature
should be between 7°F to 10°F for heat pumps in
the cooling mode or heating mode.
2. The piping may be steel, copper, or PVC. Avoid
dissimilar metal fittings as they may corrode. If the
use of dissimilar metals is unavoidable, use
dielectric isolation at that connection point. We
recommend a 30 mesh strainer (supplied by
others) be mounted prior to the water inlet to the
unit.
3. Supply and return run-outs usually join the heat
pump via short lengths of flexible hose which that
can be sound attenuators for hydraulic pumping
noise. Make sure hoses and pipes are suitable for
system water pressure and sized for proper flow
rate. Never use flexible hoses that are smaller
(inside diameter) than that of the water connection
on the unit. One end of the hose should have a
swivel fitting to facilitate removal for service. Hard
piping can also be brought directly to the heat
pump. This option is not recommended since no
vibration or noise attenuation can be accomplished.
The hard piping must have a union to facilitate heat
pump removal.
4. The supply and the discharge pipes should be
insulated to prevent condensation damage caused
by low water temperature in the pipes.
5. Make sure that threaded fittings are sealed. Teflon
tape can be used to provide a tight seal.
6. Supply and return shutoff valves are required at
each heat pump. All flow valves should be ball
type. The return valve is used for balancing and
should have a “memory stop” so that it can always
be closed off but can only be reopened to the
proper position for the flow required. To avoid
water hammer during start-up or shut down,
solenoid vales of the slow closing diaphragm type
should be used. Placing the solenoid valve on the
outlet side of the system helps relieve this situation.
Due to high pressure drop or poor throttling
characteristics, globe and gate valves should not
be used.
7. No heat pump should be connected to the supply
and return piping until the water system has been
cleaned and flushed completely. After the cleaning
and flushing has taken place, the initial connection
should have all valves wide open in preparation for
the water system flushing.

7
MAMM-WSHP-IOM-1KA (September 2011)
1. If the K-Vintage units are equipped with optional
water shutoff valves, either electric or pressure op-
erated, the supply and return run-outs must be con-
nected at each heat pump location. This will pre-
vent the introduction of dirt into the heat pump.
2. Fill the system at the city water makeup connection
with all air vents open. After filling, close all air
vents.
3. The contractor should start the main circulator with
the pressure reducing valve open. Check vents in
sequence to bleed off any trapped air, providing
circulation through all components of the system.
4. While circulating water, the contractor should check
and repair any leaks in the piping. Drains at the
lowest point(s) in the system should be opened for
the initial flush and blow down, making sure city
water fill valves are set to make up water at the
same rate. Check the pressure gauge at the pump
suction and manually adjust the makeup to hold the
same positive steady pressure both before and
after opening the drain valves. Flush should con-
tinue for at least two hours, or longer if required,
until the drain water is clear and clean.
Cleaning and Flushing
5. Shut off the circulator pump and open all drains
and vents to completely drain down the system.
Short circuited supply and return runouts should
now be connected to the heat pump supply and
return connections. Do not use sealers at the
swivel flare connections of the hoses.
6. Refill the system with clean water. Test the water
using litmus paper for acidity and treat as required
to leave the water slightly alkaline (pH 7.5 to 8.5).
The specified percentage of antifreeze may also be
added at this time. Use commercial grade anti-
freeze designed for HVAC systems only. Do not
use automotive grade antifreeze.
7. Once the system has been filled with clean water
and antifreeze (if used), precaution should be taken
to protect the system from dirty water conditions.
Dirty water will result in system wide performance
degradation and solids may clog valves, strainers,
flow regulators, etc. Additionally, the heat exchang-
ers may become clogged which reduces compres-
sor service life or causes premature failure.
8. Set the loop water controller heat add setpoint to
70°F and the heat rejection setpoint to 85°F. Sup-
ply power to all motors and start the circulation
pumps. After full flow has been established through
all components including the heat rejecter
(regardless of season) and air has been vented
and loop temperatures have been stabilized, each
of the heat pumps will be ready for check, test and
start-up, and water balancing.
IMPORTANT:
Prior to first operation of K-Vintage units, the water
circulation system must be cleaned and flushed of all
construction dirt and debris. After the cleaning
and flushing has taken place, the initial connection
should have all valves wide open in preparation for
the water system flushing.

8
MAMM-WSHP-IOM-1KA (September 2011)
Before powering up any K-Vintage unit, check the
following:
1. The high voltage supply matches the nameplate.
2. Field wire size, breakers and fuses are the correct
size.
3. Water piping is complete and correct.
4. The closed loop system is flushed and purged.
5. Loop pumps are correctly wired.
6. Access panels on the unit are in place and
secured.
7. Temperature controller is in the “Off” position.
Once the above items have been verified, you are now
ready to begin start-up.
1. Set temperature controller to highest position.
2. Set temperature controller to “cool”. Compressor
should not operate. The source water pump should
energize.
3. Slowly lower the temperature controller setting until
the compressor is energized. Measure the water
flow using pressure and temperature (P/T) ports
until the temperature difference is 7 to 10°F
between the entering and leaving water
temperature.
Start-up
4. Check the cooling high and low refrigerant
pressures.
5. Turn temperature controller to the “off” position.
The unit will stop running and the reversing valve
should de-energize.
6. Leave unit “off” for approximately five minutes to
allow pressure to equalize.
7. Adjust temperature controller to lowest setting.
8. Set temperature controller to “heat”.
9. Slowly adjust temperature controller to higher
temperature until the compressor energizes.
10. Check the heating high and low refrigerant
pressures.
11. Check for vibrations, noise, water leaks, etc.
12. Adjust temperature controller to correct mode and
set to maintain desired temperature.
13. If the unit does not operate, check the following
points:
a) Is supply voltage to the unit compatible?
b) If the unit operates but stops after a brief period:
i) Is there proper water flow rate within
temperature limits? Check water balancing;
backflush unit if dirt clogged.
ii) See troubleshooting guide on page 15 for
more tips.
Once the unit is up and running, instruct the equipment
owner/operator of correct temperature controller and
system operation.
IMPORTANT NOTE:
Avoid starting any electrical equipment for the first time
alone. Always have another person located away from
the unit that can turn off main power immediately.

9
MAMM-WSHP-IOM-1KA (September 2011)
Operating Limits
Environment
Operating voltages
208-230/60/3. . . . . . . . . 187 volts min.; 253 volts max.
460/60/3 . . . . . . . . . . . . 414 volts min.; 506 volts max.
380-415/50/3. . . . . . . . . 342 volts min.; 456 volts max.
575/60/3 . . . . . . . . . . . . 518 volts min.; 632 volts max.
380/60/3 . . . . . . . . . . . . 342 volts min.; 418 volts max.
Additional Information For Initial Start-up Only
This equipment is designed for indoor installation only.
Sheltered locations such as attics, garages, etc., gen-
erally will not provide sufficient protection against ex-
tremes in temperature and/or humidity, and equipment
performance, reliability, and service life may be ad-
versely affected.
Note:
Voltages listed are to show voltage range. However,
units operating with over- or under-voltage conditions
for extended periods of time will experience premature
component failure. Three phase system imbalance
should not exceed 2%.
APPLICATIONLIMITS
StandardrangeLowTempGeothermal
COOLINGHEATINGCOOLINGHEATING
MINIMUMENTERINGWATERTEMPERATURE50˚ 40˚25˚** 25˚**
MAXIMUMENTERINGWATERTEMPERATURE110˚110˚110˚110˚
*Applicationlimitsapplyatorabovestandardflowratesspecifiedforsizeofunit.
**Requiresglycolinthesystem

WATERTEMPERATURES/DegreesF*

10
MAMM-WSHP-IOM-1KA (September 2011)
MAMMOTH CONTROLS
HP 5 Microprocessor Control Board
The standard HP 5 microprocessor control board
provides complete control of a compressor, reversing
valve and offers numerous safety features and
troubleshooting fault indicators. The HP 5 unit is
designed to operate with Mammoth’s existing series of
wall thermostats and arrives factory-installed and wired.
Operation and maintenance (OM) instructions for the
HP 5 control board are contained in a separate
document (MAMM-WSHP-IOM-1HP5). This document
is available on the Mammoth website at
www.mammoth-inc.com under Literature.
Key Features and Benefits
 Low and high voltage protection
 Check microprocessor at startup – self-diagnostic
 Random start time delay from 5 to 35 seconds
 Compressor anti-short cycle protection for 300 seconds (5 minutes)
 Compressor and reversing valve control
 Compressor lockout with selectable intelligent/manual reset
 LED status on the board
 Lockout alarm signal to the temperature controller in the event of a safety circuit fault
 Operable on 50 and 60 cycle power
 Emergency shutdown from a field-supplied signal
 Unoccupied (night setback and night setup) mode from a field-supplied signal
 Dry contact alarm signal for connection of a fault signal to a DDC controller.
 Auxiliary dry contact for tie-in of a motorized valve when the compressor is on (or optional compressor status)
 Night heating or cooling operation from temperature controller
 Override of the unoccupied mode from the temperature controller
 Low and high pressure compressor protection
 Low pressure bypass with 0, 1, 2 and 3 minute selections

11
MAMM-WSHP-IOM-1KA (September 2011)
I/O 560 Controller
Mammoth I/O Zone 560 controller delivers powerful
control and communications features all in a compact,
economical package. Fully capable of operating in a
100% stand-alone control mode, the I/O Zone 560 can
connect to a Building Automation System (BAS) using
any of today’s most popular protocols, such as BACnet,
Modbus, N2, LonTalk. The I/O Zone 560 also supports
communication to the Mammoth line of intelligent space
sensors and keypad/display units.
Key Features and Benefits
 I/O point count: 5 digital outputs (relayed), and 6 universal imputs.
 Built-in protocol support: BACnet (ARCNET and MS/TP), Modbus RTU, and N2. Optional plug-in communica-
tions boards: LonTalk
 On-board battery-backed real-time clock is standard, thus enabling full stand-alone scheduling capabilities as
well as historical trend data storage and alarm event time-stamping.•
 Powerful, high-speed 16-bit processor with 1MB Flash memory and 512KB of battery-backed RAM - plenty of
room for even demanding and complex applications.

12
MAMM-WSHP-IOM-1KA (September 2011)
Mammoth I/O Zone 583 controller delivers powerful
control and communications features all in a compact,
economical package. Fully capable of operating in a
100% stand-alone control mode, the I/O Zone 583 can
connect to a Building Automation System (BAS) using
any of today’s most popular protocols, such as BACnet,
Modbus, N2, and LonTalk,. The I/O Zone 583 also sup-
ports communication to Mammoth’s line of intelligent
space sensors and keypad/display units.
Key Features and Benefits
 I/O point count: 5 digital outputs (relayed), 8 inputs and 3 analog outputs.
 Built-in protocol support: BACnet (ARCNET and MS/TP), Modbus RTU, and N2. Optional plug-in communica-
tions boards: LonTalk
 On-board battery-backed real-time clock is standard, thus enabling full stand-alone scheduling capabilities as
well as historical trend data storage and alarm event time-stamping.•
 Powerful, high-speed 16-bit processor with 1MB Flash memory and 512KB of battery-backed RAM - plenty of
room for even demanding and complex applications.
I/O 583 Controller

13
MAMM-WSHP-IOM-1KA (September 2011)
I/O 560 & 583—Example of I/Os
Point
UI #1
UI #2
UI #3
UI #4
UI #5 Compr Lockout (Waterflow) Compr #1 HP4 Alarm Compr #2 HP4 Alarm
UI #6 Emergency Shut Down Remote Start (External Clock) Htg/Clg Changeover ****
Point
DO #1
DO #2
DO #3
DO #4
DO #5
INPUTS
Description
Reversing Valve*
Compressor Call #2
Pump Start*
Common Alarm
OUTPUTS
Dry Contact
for 24VAC
Compressor Call #1
Thermistor/
Dry Contact Load Supply Water Temperature (Outlet) Load Return Water Temperature (Inlet)
Thermistor/
Dry Contact
Source Leaving Water Temperature (Outlet)
Source Entering Water Temperature (Inlet)
Description
Notes:
1. Multiplexed inputs 5, 6 use 10K/4.99K/2.49K resistors for contact inputs. 1.24K resistor not used.
* Could do more stages if cooling call and pump started externally.
** A minimum of one keypad display must be ordered per project to set required set-points (Part #71027956).
*** A protocol will be a cost add option.
**** Load Shed will be a cost add option.

14
MAMM-WSHP-IOM-1KA (September 2011)
Proper maintenance is important to provide the most
efficient operation and longest life for your equipment.
The following points are to serve as a general guide.
Always consult with your maintenance contractor with
regard to the specific requirements of your own installa-
tion.
The following should be checked only by a competent
contractor.
Contactor Points: Check contactor points twice a year
to see that they are not burned or pitted as a result of
low voltage, lightning strikes, or other electrical difficul-
ties.
Water System: The water circulating pump should be
checked and cleaned so that it is operating normally.
The 30 mesh strainer should also be cleaned at this
time. Clogged coils lead to high head pressures and
inefficient operation. If coil is limed, a cleaning treat-
ment may be necessary. Water coils should be
checked yearly for liming or clogging.
Brazed Plate Heat Exchanger Cleaning: When the
likelihood of fouling is high (for instance, when hard
water is used), clean the exchanger by circulating a
cleaning liquid through it. Use a tank with a weak acid
General Maintenance
for this clean-in-place (CIP) process. A five-percent
solution of phosphoric acid is an effective choice for
most units. If the exchanger is cleaned frequently, use
a five-percent solution of oxalic acid.
For best results, the cleaning solution flow rate should
be at least 1.5 times the normal flow rate, preferably in
backflush mode. Before restarting, flush the unit with
plenty of fresh water to purge any remaining acid.
Clean at regular intervals.
Improper Unit Functioning: If unit is not performing
properly, several readings of temperature, pressure
and electrical characteristics need to be taken. The
normal required troubleshooting information is listed on
the Check, Test and Start Form on page 16.
Performance Measurements: Recording of perform-
ance measurements of volts, amps, and water tem-
perature differences (both heating and cooling) is rec-
ommended. A comparison of logged data with start-up
and other annual data is useful as an indicator of gen-
eral equipment condition.
Periodic lockouts almost always are caused water
problems. The lockout (shutdown) of the heat pump is
a normal protective result. Check for dirt in the water
system, water flow rates, and water temperatures.
DANGER!
Electric shock hazard. Turn of all power before
servicing. Failure to do so may result in severe
personal injury or death.
NOTE:
DO NOT place refrigeration gauges on system for
Check, Test and Start procedure. They should be
used for major service only.
Mammoth brand products are serviced by Authorized
Service Providers. For service support, contact Mam-
moth at 952-358-6618 or [e-mail].
Parts and Service Support
Parts for Mammoth brand products are available by
contacting your local representative. For assistance
locating your Mammoth representative, call 952-358-
6600 or e-mail [e-mail].

15
MAMM-WSHP-IOM-1KA (September 2011)
Troubleshooting
R-410A
The In’s and Out’s of R-410A
R-410A is a non-ozone depleting blend of two
Refrigerants — HFC-125 and HFC-32 in a fifty percent
mixture. Refrigerant 410A exhibits higher operating
pressure and refrigeration capacity than R-22.
Although R-410A is non-flammable at ambient tem-
perature and atmosphere pressure, it can become
combustible under pressure when mixed with air.
(NOTE: R-410A should not be mixed with air under
pressure for leak testing. Pressure mixtures of dry nitro-
gen and R-410A can be used for leak testing.)
Lubrication
R410A should be used only with polyolester (POE) oil.
The HFC refrigerant components in R-410A will not be
compatible with mineral oil or alkylbenzene lubricants.
R-410A systems will be charged with the OEM recom-
mended lubricant, ready for use with R-410A.
Charging
Due to the zeotropic nature of R-410A, it should be
charged as a liquid. In situations where vapor is nor-
mally charged into a system, a valve should be in-
stalled in the charging line to flash the liquid to vapor
while charging.
All Mammoth K-Vintage units are designed
for commercial use. Units are designed for the
cooling mode of operation and fail safe to heating.
.
Troubleshooting Refrigeration Circuit
Symptom Head
Pressure Suction Pressure Compressor Amp Draw Super Heat Subcooling
Water
(Loops)
Temp
Differential
Safety
Lock
Out
Charge
Undercharge
System
(Possible Leak)
Low Low Low High Low Low Low Pressure
Overcharge Sys-
tem
Pressure High High High Normal Low Normal High Pressure
Low Water Flow
Heating Low Normal Low Normal Low Low High High Low Temp
Low Water Flow
Cooling High High High High Low High High Pressure
High Water Flow
Heating Normal Low Low Low Normal Low High Pressure
High Water Flow
Cooling Low Low Low Low HIgh Low Low Temp
TXV Restricted High Low Normal Low High High Low
WARNING!
It is very important to make certain that the recycle or
recovery equipment used is designed for R-410A. The
pressure of R-410A refrigerant is approximately 60
percent greater than that of R-22. Pressure gauges
require a range up to 800 PSIG high side and 250
PSIG low side. Recovery cylinders require a 400 PSIG
rating.

16
MAMM-WSHP-IOM-1KA (September 2011)
Performance Troubleshooting
Performance
Troubleshooting Heating Cooling Possible Cause Solution
Unit doesn’t operate in cooling X X Low refrigerant charge Check superheat and subcooling
X X
Restricted metering de-
vice Check superheat and subcooling– replace
X Defective reversing valve Perform RV touch test
X X Unit undersized
Recheck loads & sizing. Check sensible, cooling load and heat pump ca-
pacity
X X
Scaling in waterside heat
exchanger Perform scaling check and clean if necessary
X X Inlet water too hot or cold Check load, loop sizing, loop backfill, ground moisture
High head pressure X Reduced or no water flow
in cooling Check pump operation or valve operation/setting. Check water flow; adjust to proper flow rate
X Inlet water to hot Check load, loop sizing, loop backfill, ground moisture
X
Scaling in waterside heat
exchanger Perform scaling check and clean if necessary
X X Unit overcharged Check superheat and subcooling
X X
Non-condensable in
system Vacuum system, reweigh in charge
Low suction pressure X Reduced water flow in
heating Check pump operation or valve operation/setting. Check water flow adjust to proper flow rate
X
Water temperature out of
range Bring water temp within design parameters
X X Insufficient charge Check for refrigerant leaks

17
MAMM-WSHP-IOM-1KA (September 2011)
UNIT CHECK-OUT SHEET
Customer Data
Customer Name ________________________________________ Date _________________________________________
Address ________________________________________________________________________________________________
Phone ________________________________________________ Unit Number___________________________________
Unit Nameplate Data
Make _______________________ Model Number ________________________ Serial Number _______________________
Compressor(s):
# 1: RLA_______ LRA _______ Refrig, Charge (oz.) _______ # 2: RLA_______ LRA _______ Refrig, Charge (oz.) ______
Maximum Fuse Size (Amps) __________ _____________ Minimum Circuit Ampacity (Amps) __________________
Operating Conditions
Unit Conditions Cooling Mode Heating Mode
Entering Fluid Temperature _____________ _____________
Leaving Fluid Temperature _____________ _____________
Fluid Flow (gpm) _____________ _____________
Fluid Side Pressure Drop _____________ _____________
Compressor # 1 # 2
Mode Cooling Heating Cooling Heating
Suction Pressure (psig) _______ _______ _______ _______
Discharge Pressure (psig) _______ _______ _______ _______
Suction Temp (at compressor) _______ _______ _______ _______
Discharge Temp (at compressor) _______ _______ _______ _______
Suction Superheat (at compressor) _______ _______ _______ _______
Liquid Line Leaving Condenser Temp _______ _______ _______ _______
Liquid Subcooling _______ _______ _______ _______
Volts/Amps # 1 # 2
Phase L1 L2 L3 L1 L2 L3
Compressor Volts _____ _____ _____ _____ _____ _____
Compressor Amps _____ _____ _____ _____ _____ _____

18
MAMM-WSHP-IOM-1KA (September 2011)
Notes

19
MAMM-WSHP-IOM-1KA (September 2011)
Notes

Mammoth, Inc. has a policy of continuous product improvement and reserves the right to
change design and specifications without notice.
© 2011 Mammoth, Inc.
MAMM-WSHP-IOM-1KA
September 2011
[email protected]
www.mammoth-inc.com