Liebert® DS™ User Manual–28-105kW, 8-30 Tons, Upflow and Downflow, 50/60Hz
TABLE OF CONTENTS IMPORTANT SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 SAVE THESE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 1.0 LIEBERT DS COMPONENTS AND NOMENCLATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 2.0 COOLING CONFIGURATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 3.
7.5 Disassembly—Upflow Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 7.5.1 7.5.2 Remove Compressor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Remove Blower and Electric Box Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 7.6 Reassembly—Upflow Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13.0 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 13.1 Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 13.1.1 Filter Replacement Procedure—Downflow Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 13.1.2 Filter Replacement Procedure—Upflow Units . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURES Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 Figure 18 Figure 19 Figure 20 Figure 21 Figure 22 Figure 23 Figure 24 Figure 25 Figure 26 Figure 27 Figure 28 Figure 29 Figure 30 Figure 31 Figure 32 Figure 33 Figure 34 Figure 35 Figure 36 Downflow model component locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 37 Figure 38 Figure 39 Figure 40 Figure 41 Figure 42 Figure 43 Figure 44 Figure 45 Figure 46 Figure 47 Figure 48 Figure 49 Figure 50 Figure 51 Figure 52 Figure 53 Figure 54 Figure 55 Figure 56 Figure 57 Figure 58 Figure 59 Figure 60 Figure 61 Figure 62 Figure 63 Figure 64 Figure 65 Figure 66 Figure 67 Figure 68 Figure 69 Figure 70 Figure 71 Using rigging to lift Liebert DS off skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 72 Figure 73 Figure 74 Figure 75 Figure 76 Figure 77 Figure 78 Figure 79 Figure 80 Figure 81 Figure 82 Figure 83 Figure 84 Figure 85 Figure 86 Figure 87 Figure 88 Figure 89 Figure 90 Figure 91 Figure 92 Figure 93 Figure 94 Figure 95 Figure 96 Figure 97 Figure 98 Figure 99 Figure 100 Figure 101 Figure 102 Figure 103 Figure 104 Figure 105 Piping schematic—GLYCOOL semi-hermetic compressor models . . . . . . . . . . . . . . . . . . . . . . . Piping schematic—GLYCOOL with scroll compressor models . . . .
Figure 106 Canister plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 Figure 107 Circuit board diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 37 Table 38 Table 39 Table 40 Table 41 Table 42 Table 43 Table 44 Table 45 Table 46 Table 47 Table 48 Table 49 Table 50 Table 51 Table 52 Table 53 Table 54 Table 55 Table 56 Table 57 Table 58 Table 59 Table 60 Table 61 Table 62 Table 63 Table 64 Table 65 Table 66 Table 67 Component weights—downflow, water/glycol/GLYCOOL, 105kW (30 ton), all compressors *; forward-curved and EC fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Important Safety Instructions IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This manual contains important safety instructions that should be followed during the installation and maintenance of the Liebert DS™. Read this manual thoroughly before attempting to install or operate this unit. Only qualified personnel should move, install or service this equipment. Adhere to all warnings, cautions and installation, operating and safety instructions on the unit and in this manual.
Important Safety Instructions ! CAUTION Risk of contact with hot surfaces. Can cause injury. The compressors, refrigerant discharge lines, humidifiers and reheats are extremely hot during unit operation. Allow sufficient time for them to cool before working within the unit cabinet. Use extreme caution and wear protective gloves and arm protection when working on or near hot compressors, discharge lines, humidifiers and reheats. ! CAUTION Risk of handling heavy and lengthy parts.
Liebert DS Components and Nomenclature 1.0 LIEBERT DS COMPONENTS AND NOMENCLATURE Figure 1 Downflow model component locations 14 3 17 11 2 1 9 13 15 7 4 16 10 12 6 8 5 1. Liebert iCOM 2. Electric Box 3. Filters 4. Evaporator Coil 5. Motor 6. Blower 7. Fan Pulley 8. Motor Sheave and Belts 9. Compressor Section 18 10. Infrared Humidifier, optional 11. Disconnect, optional 12. Condensate Pump, optional 13. Smoke Sensor, optional 14. Condenser Cleanout Plugs, fluid-cooled units only 15.
Liebert DS Components and Nomenclature Figure 2 Upflow model component locations 18 14 6 11 7 8 9 1 2 5 4 15 16 17 12 1. Liebert iCom Control Display 2. Electric Box 3. Filters - not shown for clarity 4. Evaporator Coil 5. Motor 6. Blower 7. Fan Pulley 8. Motor Sheave and Belts 9. Compressor Section 10. Infrared Humidifier (optional) 13 10 11. Disconnect (optional) 12. Condensate Pump (optional) 13. Smoke Sensor (optional) 14. Condenser Cleanout Plugs (fluid-cooled units only) 15.
Liebert DS Components and Nomenclature Figure 3 Liebert DS model number nomenclature 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 D S 0 3 5 A U A 0 E I * * * * Air Distribution DS = Downflow Standard VS = Upflow Standard Factory Configuration Number Nominal kW 028, 035, 042, 053, 070, 077, 105 (8, 10, 12, 15, 20, 22, 30 tons) Humidification 0 - None I - Infrared S - Steam Generating Canister Cooling Type A = Air-Cooled D = Dual-Cooling, Air-Cooled W = Water/Glycol K = GLYCOOL H = D
Cooling Configurations 2.0 COOLING CONFIGURATIONS NOTE All field-installed piping must comply with applicable local, state and federal codes. AIR-COOLED Air-cooled unit piping is spun closed from the factory and contains a nitrogen holding charge. Each installation requires field-supplied refrigerant piping to a condenser. GLYCOL-COOLED Glycol-cooled units are factory-charged and tested.
Pre-Installation Guidelines 3.0 PRE-INSTALLATION GUIDELINES 3.1 Room Preparation • Verify that the floor is level, solid and sufficient to support the unit. See Table 2 for unit weights. • Confirm that the room is properly insulated and has a sealed vapor barrier. • For proper humidity control, keep outside or fresh air to an absolute minimum (less than 5% of total air circulated in the room). • Do not install Liebert DS units in an alcove or at the end of a long, narrow room.
Pre-Installation Guidelines 3.3 Air Distribution—Upflow Units Various configurations are available: • Front return • Rear return • Top-front supply • Top-rear supply For in-room applications with supply and return grilles, several feet of clearance must be maintained at the intake and discharge of the unit. Upflow rear-return configurations use a filter box attached to the back of the Liebert DS. Allow 25" (635 mm) on one side of the unit for access to the rear return filter box.
Pre-Installation Guidelines 3.4 Connections and System Setup • Plan the routing of wiring, piping and ductwork to the unit. See Figures 61 and 62 and Figures 77 through 97 for unit connection locations. • Water/glycol and GLYCOOL units utilizing a drycooler may require an optional aquastat setting. See Tables 64 through 67 for aquastat setting guidelines. Applications with the optional stat setting require field piping to be insulated to prevent condensation.
Liebert DS Dimensions and Weights 4.
Liebert DS Dimensions and Weights Figure 6 Cabinet and floor planning dimensions—downflow, air-cooled, 28-42kW (8-12 ton), semi-hermetic compressor models Secondary Refrigerant Piping Entrance Filters are accessible through top of unit only. Downflow electrical connections can be made from top or bottom of unit.
Liebert DS Dimensions and Weights Figure 7 Cabinet and floor planning dimensions—downflow, air-cooled, 28-42kW (8-12 ton), scroll compressor models Secondary Refrigerant Piping Entrance 56-7/8" Opening (1445mm) 33" (838mm) Filters are accessible 24-3/8" through top of unit only. (619mm) Downflow electrical Opening connections can be made from top or bottom of unit.
Liebert DS Dimensions and Weights Figure 8 Cabinet and floor planning dimensions—downflow, water/glycol/GLYCOOL, 28-42kW (8-12 ton), all compressor models Condenser Cleanout Access 56-7/8" Opening (1445mm) 33" (838mm) Air Inlet Opening 35" (889mm) Secondary Condenser TOP VIEW Fluid Piping Entrance Secondary Entrance High-Volt Connection(s) 24-3/8" (619mm) Opening Filters are accessible through top of unit only. Downflow electrical connections can be made from top or bottom of unit.
Liebert DS Dimensions and Weights Figure 9 Cabinet and floor planning dimensions—downflow, air-cooled, 53-77kW (15-22 ton), semi-hermetic compressor models Second Refrigerant Piping Entrance 33" (838mm) 80" Opening (2032mm) Notes: Filters are accessible through top of unit only. 24-5/8" (625mm) Opening AIR INLET OPENING 35" (889mm) Downflow electrical connections can be made from top or bottom of unit.
Liebert DS Dimensions and Weights Figure 10 Cabinet and floor planning dimensions—downflow, air-cooled, 53-77kW (15-22 ton), scroll compressor models Digital scroll compressor not available on 077 models. Second Refrigerant Piping Entrance 80" Opening (2032mm) 33" (838mm) 35" (889mm) Secondary Entrance High-Volt Connection(s) Notes: Filters are accessible through top of unit only. 24-5/8" (619mm) Opening AIR INLET OPENING Downflow electrical connections can be made from top or bottom of unit.
Liebert DS Dimensions and Weights Figure 11 Cabinet and floor planning dimensions—downflow, water/glycol/GLYCOOL, 53-77kW (15-22 ton), all compressor models Digital scroll compressor not available on 077 models. Condenser Cleanout Access 80" (2032mm) Opening 33" (838mm) 24-5/8" (625mm) Opening Air Inlet Opening 35" (889mm Notes: Filters are accessible through top of unit only. Downflow electrical connections can be made from top or bottom of unit.
Liebert DS Dimensions and Weights Figure 12 Cabinet and floor planning dimensions—downflow, 105kW (30 ton), all compressor models Secondary Refrigerant Piping Entrance Notes: Filters are accessible through top of unit only. Downflow electrical connections can be made from top or bottom of unit.
Liebert DS Dimensions and Weights Figure 13 Cabinet and floor planning dimensions—downflow, water/glycol/GLYCOOL, 105kW (30 ton), all compressor models Condenser Cleanout Access 102-13/16" (2611mm) Opening 33" (838mm) 35" (889mm) AIR INLET OPENING TOP VIEW Secondary Entrance High-Volt Connection(s) Secondary Condenser Fluid Entrance Notes: Filters are accessible through top of unit only. Downflow electrical connections can be made from top or bottom of unit.
Liebert DS Dimensions and Weights Figure 14 Cabinet and floor planning dimensions—upflow, air-cooled 28-42kW (8-12 ton), semi-hermetic compressor models Alternate Refrigerant Piping Entrance Note: Front air return unit shown. For rear Note: Front unit to shown. return unit,air inreturn addition frontFor service area rear return unit, in addition front service shown, also include 25" to (635mm) on one side area shown, also include 25"return (635mm) onbox.
Liebert DS Dimensions and Weights Figure 15 Cabinet and floor planning dimensions—upflow, air-cooled 28-42kW (8-12 ton), scroll or digital scroll compressor models Alternate Refrigerant Piping Entrance Note: Front air return unit shown. For rear Note: Front return unit For return unit, air in addition toshown. front service area rear return unit, in addition to front service shown, also include 25" (635mm) on one side area shown, also include (635mm) on of unit for access to rear25" return filter box.
Liebert DS Dimensions and Weights Figure 16 Cabinet and floor planning dimensions—upflow, water/glycol/GLYCOOL, 28-42kW (8-12 ton), all compressor models Condenser Cleanout Access Note: Front air return unit shown. For rear Note: Front unit shown. return unit,airinreturn addition to frontFor service area rear return unit, in addition front service shown, also include 25"to(635mm) on one side area shown, also include 25"return (635mm) on box.
Liebert DS Dimensions and Weights Figure 17 Cabinet and floor planning dimensions—upflow, air-cooled, 53-77kW (15-22 ton), semi-hermetic compressor models Alternate Refrigerant Piping Entrance 33" (838mm) 35" (889mm) 3/4" (19mm) Bezels High-Volt Connection(s) 1-1/2" (38mm) TOP VIEW Low-Volt Connection(s) Minimum required for blower replacement 109" (2769mm) 24" (610mm) 76" (1930mm) 34" (864mm) Shaded area indicates a recommended minimum clearance for component access.
Liebert DS Dimensions and Weights Figure 18 Cabinet and floor planning dimensions—upflow, air-cooled, 53-77kW (15-22 ton), scroll or digital scroll compressor models Digital scroll compressor not available on 077 models.
Liebert DS Dimensions and Weights Figure 19 Cabinet and floor planning dimensions—upflow, water/glycol/GLYCOOL, 53-77kW (15-22 ton), all compressor models Condenser Cleanout Access Digital scroll compressor not available on 077 models.
Liebert DS Dimensions and Weights Figure 20 Cabinet and floor planning dimensions—upflow, air-cooled, 105kW (30 ton), all models Alternate Refrigerant Piping Entrance 33" (838mm) 35" (889mm) 3/4" (19mm) Bezels High-Volt Connection(s) TOP VIEW 1-1/2" (38mm) Minimum required for blower replacement Low-Volt Connection(s) 132" (3353mm) 24" (610mm) 76" (1930mm) 34" (864mm) 2" (51mm) 131" (3327mm) FRONT VIEW Note: Front air return unit shown.
Liebert DS Dimensions and Weights Figure 21 Cabinet and floor planning dimensions—upflow water/glycol/GLYCOOL 105kW (30 ton), all models Alternate Refrigerant Piping Entrance 33" (838mm) 35" (889mm) Alternate Condenser Fluid Piping Entrance TOP VIEW High-Volt Connection(s) 1-1/2" (38mm) 3/4" (19mm) Bezels Required for condenser cleanout Minimum required for blower replacement Low-Volt Connection(s) 132" (3353mm) 24" (610mm) 76" (1930mm) 2" (51mm) Shaded area indicates a recommended minimum clea
Liebert DS Dimensions and Weights Figure 22 Floor stand dimensions—downflow, 28-42kW (8-12 ton) models A+1-1/2" (38mm) (with feet) A 47-15/16" (1218mm) B 4-1/2" (114mm) 33" (838mm) 16-3/4" (425mm) 34-1/2" (876mm) (with feet) Supply air discharge opening Supply air discharge opening 1" (25mm) TYP. Gussets supplied on floor stands 12" (305 mm) tall and greater Optional turning vane shown as front air discharge.
Liebert DS Dimensions and Weights Figure 23 Floor stand dimensions—downflow, 53-77kW (15-22 ton) models B A+1-1/2" (38mm) (with feet) A 69-3/4" (1772mm) 34-1/2" (876mm) (with feet) 16-3/4" (425mm) Supply air discharge opening 33" (838mm) 1" (25mm) TYP. Gussets supplied on floor stands 12" (305 mm) tall and greater Supply air discharge opening 7/8" (23mm) Optional turning vane shown as front air discharge.
Liebert DS Dimensions and Weights Figure 24 Floor stand and floor planning dimension, downflow 53-77kW (15-22 tons) models with EC fans A B Piping Access Area 3/4" (19mm) 32" (813mm) Center Feet 31-1/2" (800mm) C Support Feet Centers 3/4" (19mm) 32-3/4" (832mm) D 3/4" (19mm) 7/8" (23mm) See Note 4 3" (76mm) 1" (25mm) E 1. This floor stand should be used when EC fans are intended to be lowered under a raised floor.
Liebert DS Dimensions and Weights Figure 25 Floor stand dimensions—downflow, 105kW (30 ton) models 132-1/2" (3366mm) (with feet) 131" (3327mm) 91-3/4" (2330mm) 26" (660mm) 4-1/2" (114mm) 34-1/2" (876mm) (with feet) 33" (838mm) 16-3/4" (425mm) 1" (25mm) TYP. Supply air discharge opening Supply air discharge opening Gussets supplied on floor stands 12" (305 mm) tall and greater 7/8" (23mm) Optional turning vane shown as front air discharge.
Liebert DS Dimensions and Weights Figure 26 Floor stand and floor planning dimension, downflow 105kW (30 tons) models with EC fans 132-1/2" (3366mm) (with feet) 131" (3327mm) 25" (635mm) 34-1/2" (876mm) 33" (with feet) (838mm) 74" (1880mm) 1" (25mm Typ.) Gussets supplied on floor stands 12" (305mm) tall and greater. 3" (76mm) NOTE: 1) This floor stand should be used when EC fans are intended to be lowered under a raised floor.
Liebert DS Dimensions and Weights Figure 27 Blower outlet and deck dimensions—upflow, 28-42kW (8-12 ton) 73" (1854mm) or 86" (2184mm) Ref E Blower Outlet * C A 35" (889mm) Ref B Blower Outlet Location - Top View Front of Unit * Duct flange not provided Top of Unit Blower Deck 1-1/2" (38mm) D 76" (1930mm) Ref Front or Rear Throw Air Supply Table 24 DPN001120 Rev. 3 Blower outlet and deck dimensions for upflow, 28-42kW (8-12 ton) with forward-curved fans Dimensions, in.
Liebert DS Dimensions and Weights Figure 28 Blower outlet and deck dimensions—upflow, 53-77kW (15-22 ton) with forward-curved fans 98" (2449mm) or 109" (2769mm) F E Blower Outlets * C A A 35" (889mm) Ref B B Blower Outlet Location - Top View Front of Unit * Duct flanges not provided. Top of Unit Blower Deck D 1-1/2" (38mm) 76" (1930mm) Ref. DPN001191 Rev.
Liebert DS Dimensions and Weights Figure 29 Blower outlet and deck dimensions—upflow 105kW (30ton) 132" (3353mm) G Blower Outlets * F E A A A 35" (889mm) Ref B B B C BLOWER OUTLET LOCATION - TOP VIEW Front of Unit * Duct flanges not provided TOP OF UNIT Blower Deck 1-1/2" (38mm) 76" (1930mm) Ref DPN001192 Rev. 1 Front or Rear Throw Air Supply Table 26 Blower outlet and deck dimensions—upflow 105kW (30ton) Dimensions, in.
Liebert DS Dimensions and Weights Figure 30 Rear return filter box dimensions Filter Access Door Filter Access Door 7-15/16" (202mm) 76" 40" (1930mm) (1016mm) 38-1/4" (971mm) Duct Size 3-1/2" (89mm) D Duct Size C A B NOTES: 1. Filters can be accessed from either side. 2. 25" (635mm) minimum clearance provided on one side for filter access. 3. Filter boxes are shipped flat and must be field assembled. Table 27 DPN001196 Rev.
Liebert DS Dimensions and Weights Figure 31 Upflow unit plenum dimensions FRONT VIEWS REAR VIEWS WITH GRILLE WITH GRILLE Panel removable for condenser clean out access (Water/Glycol/GLYCOOL models only) WITHOUT GRILLE 34" (864mm) LEFT SIDE VIEWS CHECK ONE (1): B WITHOUT GRILLE A 1" (25mm) H RIGHT SIDE VIEWS CHECK ONE (1): WITH GRILLE 76" (1930mm) WITHOUT GRILLE SIDE VIEW - UNIT WITH PLENUM FRONT VIEW - UNIT WITH PLENUM Notes: 1.
Equipment Inspection and Handling 5.0 EQUIPMENT INSPECTION AND HANDLING Upon arrival of the unit and before unpacking it, verify that the labeled equipment matches the bill of lading. Carefully inspect all items for damage, either visible or concealed. For initial access use a 7/32" Allen wrench for panel removal. Damage should be immediately reported to the carrier and a damage claim filed with a copy sent to Emerson Network Power or to your sales representative. 5.
Equipment Inspection and Handling If possible, transport the Liebert DS with a forklift or pallet jacks. If that is not possible, use a crane with belts or cables, slings and spreader bars. • If using a forklift or pallet jack, make sure that the forks (if adjustable) are spread to the widest allowable distance that will fit under the skid. Ensure the fork length is suitable for the unit length.
Equipment Inspection and Handling 5.2.1 Removing the Unit from the Skid With a Forklift 1. Align a forklift with either the front or rear side of the unit. ! WARNING Risk of improper moving. Can cause equipment damage, injury or death. Use the center of gravity indicators on the unit to determine the entry points for the tines (see Figure 36). The center of gravity varies depending on the unit size and selected options.
Equipment Inspection and Handling 5.2.2 Moving the Unit to the Installation Location with Piano Jacks 1. With the Liebert DS elevated, place two piano jacks into position—one at either end of the unit. 2. Lower the unit to a height suitable for the piano jacks and place protective material between the Liebert DS and the piano jacks. 3. Secure the unit to the piano jacks and remove the forklift. 4. Use the piano jacks to move the unit for installation.
Equipment Inspection and Handling 5.2.4 Removing Liebert DS from Skid Using Rigging ! WARNING Risk of improper moving. Can cause equipment damage, injury or death. Use the center of gravity indicators (see Figure 36) on the unit to determine the position of the slings. The center of gravity varies depending on the unit size and selected options. The forklift’s tines must be equally spaced on either side of the center of gravity indicator. 1.
Equipment Inspection and Handling Figure 37 Using rigging to lift Liebert DS off skid CENTER OF GRAVITY CENTER OF GRAVITY 186132P1 REV. 0 Equal Distance Equal Distance 181659P1 Rev.
Equipment Inspection and Handling 5.3 Semi-Hermetic Compressor Spring Isolation System Shipping blocks under all semi-hermetic compressors must be removed and the springs must be adjusted before startup. 1. Loosen nuts at each of the four compressor feet and remove the two shipping blocks. 2. Beginning with one compressor foot, retighten nut until the washer under the nut can no longer be rotated by finger. 3. Loosen the nut half a turn. The washer will be slightly loose. 4.
EC Fans—Lowering and Removing 6.0 EC FANS—LOWERING AND REMOVING Liebert DS downflow models DS053, DS070, DS077 and DS105 can be equipped with EC fans that can be operated either in their fully raised position or lowered into the floor stand for increased efficiency from reduced air resistance. The fans are also removable, easing maintenance and replacement. ! WARNING Risk of electric shock and high speed rotating fan blades. Can cause injury or death.
EC Fans—Lowering and Removing Figure 39 Lowering EC fans into floor stand, Steps 1 through 6 1 3 2 TABS 1 A 3 DETAIL A B B Section Not Shown Jack Location Fan Deck 3 "Z" Bracket Location On CW026 - CW060 Section Not Shown 5 5 "Z" Bracket 4 Section B-B "Z" Bracket Location On CW076 - CW114 Wiring Loop TOP VIEW OF FAN DECK DPN002037 Page 1, Rev.
EC Fans—Lowering and Removing 7. Using the jack, lower the fan module slowly until it rests on the frame of the unit. NOTICE Risk of equipment snagging cables and wiring. Can damage the Liebert DS components. Monitor the position of the fan harnesses and other parts while lowering the fan to be sure that they are not caught or pinched. 8. Secure the fan module in the fully lowered position by re-installing the hex head screws directly to the frame. Screw clearance holes are provided in the fan module.
EC Fans—Lowering and Removing 6.2 Removing the EC Fans The EC fans in Liebert DS units can be removed for easier maintenance or for replacement. ! WARNING Risk of electric shock and high speed rotating fan blades. Can cause injury or death. Disconnect all local and remote electric power supplies and verify that fan blades have stopped rotating before working within. ! WARNING Risk of very heavy fan modules dropping downward suddenly. Can cause injury or death.
EC Fans—Lowering and Removing Figure 41 Removing the EC fans, Steps 1 through 5 Remove Middle Panel from Front of Unit Remove Infrared Humidifier Remove Bottom Panel from Front of Unit B B Raise Jack to Support Fan Position Jack to Support Fan A Floor Stand Partially Hidden Position Jack to Support Fan Tabs Detail A Jack Location SECTION B-B Remove and retain any hardware used to secure the lowered fan Remove and retain any hardware used to secure the lowered fan DPN001695 Page 1, Rev. 5 6.
EC Fans—Lowering and Removing Figure 42 Removing the EC fans, Steps 6 through 9 Raise Fan Module With Jack Front Frame Channel Disconnect Hign- and Low-Voltage Wiring Field-Supplied Fan-Removal Devices DPN001695 Page 2, Rev. 5 Front Frame Channel Rear Frame Channel Right Side Panel Not Shown Field-Supplied Fan-Removal Devices, End View Slide the Fan Out the Front of the Unit DPN001695 Page 3, Rev.
Disassembling the Liebert DS for Transport 7.0 DISASSEMBLING THE LIEBERT DS FOR TRANSPORT The Liebert DS has a modular frame construction that allows separating the unit into three sections. Each of these sections is more easily maneuvered through tight spaces or placed in small elevators. A qualified service technician with the required tools and recommended assistance can disassemble an air-cooled unit in about four hours, assuming refrigerant evacuation is not required.
Disassembling the Liebert DS for Transport 7.2 Disassembly—Downflow Units For detailed views of downflow units, see Figures 43 through 51. 1. Remove the unit from its shipping skid before beginning (refer to 5.2 - Unpacking the Unit). 2. Remove all panels except the top front accent. 3. Remove all filters. This allows access to the screws for metal plate blocking off the top coil and removal of the filter plate. 4. All wires are hot-stamped and all circuit board connectors are lettered to ease connection.
Disassembling the Liebert DS for Transport 18. Evacuate and recover all refrigerant from the Liebert DS. Air-cooled units are shipped with a nitrogen holding charge. Water, glycol and GLYCOOL units are factory-charged with refrigerant. Refer to 9.0 - Piping for piping guidelines and to the ASHRAE Refrigeration Handbook for general, good-practice refrigeration piping. NOTICE Risk of compressor oil contamination with moisture. Can cause equipment damage.
Disassembling the Liebert DS for Transport 7.2.2 Remove the Filter and Electric Box Assembly 1. Using a stepladder to reach the top of the Liebert DS, remove the filter support plate; it is attached to the filter and electric box assembly with two screws, one on each end. 2. Remove tags from the Schrader fittings on top of the coil headers. Retain the tags for replacement during reassembly. 3. Remove 16 screws, (8) on each side, from the evaporator top cover plate to coil assembly.
Disassembling the Liebert DS for Transport 7.3.1 Reconnecting Piping, Charging and Replacing Panels 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 7.4 Piping must be reassembled in accordance with local codes. Move insulation and plastic bushings away from the brazing area. Wrap piping with wet cloths. Use copper fittings where required. Refer to 9.0 - Piping for piping guidelines and to the ASHRAE Refrigeration Handbook for general, good-practice refrigeration piping. Open the service valves on the compressor.
Disassembling the Liebert DS for Transport Figure 43 Component dimensions—downflow, air-cooled, 28-42kW (8-12 ton), semi-hermetic compressor models Filter & Electric Box Assembly 39" (991mm) 39" 991mm Compressor Assembly 76" (1930mm) Assembled Height Blower & Coil Assembly 76" (1930mm) 60-3/16" (1529mm) 37" (940mm) 33" (838mm) 26" (660mm) 59" (1499mm) 85" (2159mm) Assembled Length NOTES: Drawing views are simplified with panels removed to show overall dimensions.
Disassembling the Liebert DS for Transport Figure 44 Component dimensions—downflow, air-cooled, 28-42kW (8-12 ton), scroll/digital scroll compressor models Filter & Electric Box Assembly 39" (991mm) 76" (1930mm) Assembled Height Blower & Coil Assembly Compressor Assembly 76" (1930mm) 60-3/16" (1529mm) 37" (940mm) 33" (838mm) 13" (330mm) 59" (1499mm) 72" (1829mm) Assembled Length NOTES: Drawing views are simplified with panels removed to show overall dimensions.
Disassembling the Liebert DS for Transport Figure 45 Component dimensions—downflow, water/glycol/GLYCOOL, 28-42kW (8-12 ton), all compressor models Filter & Electric Box Assembly 39" (991mm) 76" (1930mm) Assembled Height Blower & Coil Assembly Compressor Assembly 76" (1930mm) 60-3/16" (1529mm) 37" (940mm) 33" (838mm) 26" (660mm) 59" (1499mm) 85" (2159mm) Assembled Length NOTES: Drawing views are simplified with panels removed to show overall dimensions.
Disassembling the Liebert DS for Transport Figure 46 Component dimensions—downflow, air-cooled, 53-77kW (15-22 ton), semi-hermetic compressor models; forward-curved and EC fan Filter & Electric Box Assembly 39" (991mm) Compressor Assembly 76" (1930mm) Assembled Height Blower & Coil Assembly 76" (1930mm) 59-7/16" (1509mm) 37" (940mm) 33" (838mm) 26" (660mm) 82" (2083mm) 108" (2743mm) Assembled Length NOTES: Drawing views are simplified with panels removed to show overall dimensions.
Disassembling the Liebert DS for Transport Figure 47 Component dimensions—downflow air-cooled, 53-77kW (15-22 ton), scroll/digital scroll compressor models; forward-curved and EC fan Digital scroll compressor not available on 077 models. Filter & Electric Box Assembly Forward curved blowers shown. DA units only available with EC blowers, optional on DS units.
Disassembling the Liebert DS for Transport Figure 48 Component dimensions—downflow water/glycol, GLYCOOL, 53-77kW (15-22 ton), all compressor models; forward-curved and EC fan Digital scroll compressor not available on 077 models Filter & Electric Box Assembly 39" (991mm) Compressor Assembly 76" (1930mm) Assembled Height Blower & Coil Assembly 76" (1930mm) 59-7/16" (1509mm) 37" (940mm) 33" (838mm) 26" (660mm) 82" (2083mm) 108" Assembled Length (2743mm) NOTES: Drawing views are simplified with
Disassembling the Liebert DS for Transport Figure 49 Component dimensions—downflow, air-cooled, 105kW (30 ton), semi-hermetic compressor models; forward-curved and EC fans Filter and Electric Box Assembly 39" (991mm) 41-11/16" (1059mm) Compressor Assembly 76" (1930mm) Assembled Height Blower and Coil Assembly 76" (1930mm) 59 7/16" (1510mm) 37" (940mm) 33" (838mm) 26" (660mm) 105" (2667mm) DPN001057 Rev.
Disassembling the Liebert DS for Transport Figure 50 Component dimensions—downflow, air-cooled, 105kW (30 ton), scroll compressor models; forward-curved and EC fan Digital scroll compressor not available on 105 models.
Disassembling the Liebert DS for Transport Figure 51 Component dimensions—downflow, water/glycol/GLYCOOL, 105kW (30 ton), forward-curved and EC fan, all compressor models; forward-curved and EC fan Digital scroll compressor not available on 105 models.
Disassembling the Liebert DS for Transport 7.5 Disassembly—Upflow Units For detailed views of upflow units, see Figures 52 through 60. 1. Remove the unit from its skid. 2. Remove all panels except top front accent. 3. Remove all filters on front return units. This allows easier access to items located in the filter and coil assembly. 4. All wires are hot stamped and all circuit board connectors are lettered for easy replacement. Cable ties will need to be cut and replaced as necessary.
Disassembling the Liebert DS for Transport 17. Cut the refrigerant piping with a tubing cutter; if there is no Schrader fitting, let the nitrogen bleed out before cutting all the way through the pipe. NOTE Emerson does not recommend unsweating refrigerant connections. 18. Unsweat or cut all copper water pipes that interconnect unit sections. 19.
Disassembling the Liebert DS for Transport 7.6 Reassembly—Upflow Unit 1. Reattach the top section using thread-cutting bolts; there are four on each side. Torque the bolts to 225 in-lb (25Nm). 2. Reinstall the motor access plate. Do not replace the left end coil access plates until brazing is finished. 3. Reattach the compressor section. Insert all compressor thread-cutting bolts before tightening them all down. 4. Reinstall the pull bar to support the accent panel. 5.
Disassembling the Liebert DS for Transport Figure 52 Component dimensions—upflow, air-cooled, 28-42kW (8-12 ton), semi-hermetic compressor models Blower and Electric Box Assembly 31-1/4" (794mm) Compressor Assembly 76" (1930mm) Assembled\ Height Filter and Coil Assembly 76" (1930mm) 45-13/16" (1163mm) 33" (838mm) 26" (660mm) 85" (2159mm) Assembled Length 59" (1499mm) NOTES: Drawing views are simplified with panels removed to show overall dimensions. See disassembly and handling instructions.
Disassembling the Liebert DS for Transport Figure 53 Component dimensions—upflow, air-cooled, 28-42kW (8-12 ton), scroll/digital scroll compressor models Blower and Electric Box Assembly 31-1/4" (794mm) Compressor Assembly 76" (1930mm) Assembled Height Filter and Coil Assembly 76" (1930mm) 45-13/16" (1163mm) 33" (838mm) 13" (330mm) 59" (1499mm) 72" Assembled Length (1829mm) NOTES: Drawing views are simplified with panels removed to show overall dimensions.
Disassembling the Liebert DS for Transport Figure 54 Component dimensions—upflow, water/glycol/GLYCOOL, 28-42kW (8-12 ton), all compressor models Blower and Electric Box Assembly 31-1/4" (794mm) Compressor Assembly 76" (1930mm) Assembled Height Filter and Coil Assembly 76" (1930mm) 45-13/16" (1163mm) 26" (660mm) 33" (838mm) 59" (1499mm) 85" (2159mm) Assembled Length NOTES: Drawing views are simplified with panels removed to show overall dimensions. See disassembly and handling instructions.
Disassembling the Liebert DS for Transport Figure 55 Component dimensions—upflow, air-cooled, 53-77kw (15-22 ton), semi-hermetic compressor models Blower and Electric Box Assembly 31-1/4" (794mm) Compressor Assembly 76" (1930mm) Assembled Height Filter and Coil Assembly 76" (1930mm) 45-13/16" (1163mm) 33" (838mm) 26" (660mm) 82" (2083mm) 108" (2743mm) Assembled Length NOTES: Drawing views are simplified with panels removed to show overall dimensions. See disassembly and handling instructions.
Disassembling the Liebert DS for Transport Figure 56 Component dimensions—upflow, air-cooled, 53-77kw (15-22 ton), scroll/digital scroll compressor models Blower & Electric Box Assembly 31-1/4" (794mm) Compressor Assembly 76" (1930mm) Assembled Height Filter & Coil Assembly 76" (1930mm) 45-13/16" (1163mm) 33" (838mm) 15" (381mm) 82" (2083mm) 97" (2464mm) Assembled Length NOTES: Drawing views are simplified with panels removed to show overall dimensions.
Disassembling the Liebert DS for Transport Figure 57 Component dimensions—upflow water/glycol/GLYCOOL 53-77kw (15-22 ton), all compressor models Blower and Electric Box Assembly 31-1/4" (794mm) Compressor Assembly 76" (1930mm) Assembled Height Filter and Coil Assembly 76" (1930mm) 45-13/16" (1163mm) 26" (660mm) 33" (838mm) 82" (2083mm) 108" (2743mm) Assembled Length NOTES: Drawing views are simplified with panels removed to show overall dimensions. See disassembly and handling instructions.
Disassembling the Liebert DS for Transport Figure 58 Component dimensions—upflow, air-cooled, 105kW (30 ton), semi-hermetic compressor models Blower & Electric Box Assembly 31-1/4" (794mm) Compressor Assembly Filter & Coil Assembly 76" (1930mm) Assembled Height 76" (1930mm) 45-13/16" (1164mm) 33" (838mm) 26" (660mm) 105" (2667mm) 131" (3327mm Assembled Length NOTES: Drawing views are simplified with panels removed to show overall dimensions.
Disassembling the Liebert DS for Transport Figure 59 Component dimensions—upflow, air-cooled, 105kW (30 ton), scroll/digital scroll compressor models Digital scroll compressor not available on 105 models Blower and Electric Box Assembly 31-1/4" (794mm) Compressor Assembly 76" (1930mm) Assembled Height Filter and Coil Assembly 76" (1930mm) 45-13/16" (1164mm) 33" (838mm) 26" (660mm) 105" (2667mm) 131" (3327mm Assembled Length NOTE: Drawing views are simplified with panels removed to show overall d
Disassembling the Liebert DS for Transport Figure 60 Component dimensions—upflow, water/glycol/GLYCOOL, 105kW (30 ton), all compressor models Digital scroll compressor not available on 105 models Blower & Electric Box Assembly 31-1/4" (794mm) Compressor Assembly 76" (1930mm) Assembled Height Filter & Coil Assembly 76" (1930mm) 45-13/16" (1164mm) 26" (660mm) 33" (838mm) 105" (2667mm) 131" (3327mm Assembled Length NOTES: Drawing views are simplified with panels removed to show overall dimensions.
Electrical Connections 8.0 ELECTRICAL CONNECTIONS Three-phase electrical service is required for all models. Electrical service must conform to national and local electrical codes. Refer to equipment nameplate regarding wire size and circuit protection requirements. Refer to electrical schematic when making connections. Refer to Figure 61 for electrical service entrances into unit. A manual electrical disconnect switch should be installed in accordance with local codes and distribution system.
Electrical Connections Figure 61 Electrical field connections—Upflow and downflow models, single molded case switch disconnect with main fuses See 8.1 - Standard Electrical Connections, 8.2 Optional Electrical Connections and 8.3 - Optional Low-Voltage Terminal Package Connections for keys to numbered components.
Electrical Connections Figure 62 Electrical field connections—Upflow and downflow models, dual fused disconnect switches See 8.1 - Standard Electrical Connections, 8.2 Optional Electrical Connections and 8.3 - Optional Low-Voltage Terminal Package Connections for keys to numbered components.
Electrical Connections 8.1 STANDARD ELECTRICAL CONNECTIONS Source: DPN000807, Rev. 8 1. Primary high voltage entrance—2.5" (64mm); 1.75" (44mm); 1.375" (35mm) diameter concentric knockouts located in bottom of box. 2. Secondary high voltage entrance—2.5" (64mm); 1.75" (44mm); 1.375" (35mm) diameter concentric knockouts located in top of box. 3. Primary low voltage entrance—Quantity (3) 1.375" (35mm) diameter knockouts located in bottom of unit. 4. Secondary low voltage entrance—Quantity (3) 1.
Electrical Connections 17. Remote humidifier—On any call for humidification, normally open dry contact is closed across Terminals 11 & 12 to signal field-supplied remote humidifier. 1A, 24VAC maximum load. Use Class 1 field-supplied wiring. 18. Auxiliary cool contact—On any call for Econ-O-coil operation, normally open dry contact is closed across Terminals 72 & 73 on dual cool units only. 1A, 24VAC maximum load. Use field-supplied Class 1 wiring. 8.
Electrical Connections 8.4 Variable Speed Drive ! WARNING Risk of electric shock from leakage current. Can cause injury or death. Reconnect earth ground if servicing or replacing the variable speed drive (VSD). An optional Variable Speed Drive (VSD) is available on some Liebert DS models. The VSD reduces power consumption by reducing the blower speed to match the unit’s load. This packaged unit is factory-set and should not require field-adjustment.
Electrical Connections 8.4.3 Delta-Connected Power Supply For Delta-connected power, the EMC filter must be removed from the VSD unit during installation. The size of the inverter (C, D, or 2) must be determined by Table 47, based on the unit’s electrical requirements and horsepower. Failure to disconnect or remove EMC filter from VSD with delta connected power may result in failure of VSD and the fan motor to operate.
Electrical Connections Figure 65 Disconnecting EMC filter for operation with Delta-connected power size C & D inverters A Internal EMC filter Tab fully inserted: EMC filter fitted B Internal EMC filter Tab fully extended: EMC filter disconnected DPN001946 Rev. 0 Remove EMC Filter for Delta-Connected Power for Type 2 inverters The EMC filter on the VSD must be disconnected if the Liebert VSD control DS unit will be operated with Delta-connected power. NOTE This procedure requires substantial work.
Piping 9.0 PIPING All fluid and refrigeration connections to the unit, with the exception of the condensate drain, are sweat copper. Factory-installed piping brackets must not be removed. Field-installed piping must be installed in accordance with local codes and must be properly assembled, supported, isolated and insulated. Avoid piping runs through noise-sensitive areas, such as office walls and conference rooms.
Piping Figure 67 Gravity drain for downflow and upflow units DOWNFLOW DS UNIT UPFLOW DS UNIT INTERNAL DRAIN UNIT EXTERNAL DRAIN INTERNAL DRAIN UNIT EXTERNAL DRAIN CONTINUOUS DOWNWARD SLOPE CORRECT CORRECT UNIT CONTINUOUS DOWNWARD SLOPE INTERNAL DRAIN EXTERNAL DRAIN INTERNAL DRAIN UNIT DO NOT EXTERNALLY TRAP THE UNIT EXTERNAL DRAIN INCORRECT DO NOT EXTERNALLY TRAP THE UNIT INCORRECT INTERNAL DRAIN UNIT EXTERNAL DRAIN INTERNAL DRAIN UNIT EXTERNAL DRAIN THESE ARE EXTERNAL TRAPS ALSO, AL
Piping 9.1.2 Humidifier Supply Water—Optional Infrared • 1/4" supply line; maximum water pressure is 150 psi (1034kPa) • Size humidifier supply line for 1 gpm (3.8 l/m), with a minimum water pressure of 20 psi (138kPa) • Do not supply de-ionized water to the humidifier 9.1.3 Humidifier Supply Water—Optional Steam Generating • • • • • 9.1.
Piping Leak Checking of Unit and Field Piping Liebert unit fluid systems are factory-checked for leaks and may be shipped with a nitrogen holding charge. Liebert unit fluid circuits should be checked for leaks at installation as described below. NOTE During leak checking of field-installed piping, Emerson recommends that the unit be isolated using field-installed shutoff valves. When the Liebert units are included in a leak test, use of fluid for pressure testing is recommended.
Piping 9.2.
Piping Table 50 Interconnecting piping refrigerant charge Line Size, O.D., in. R-407C, lb/100 ft. (kg/30m) Liquid Line Hot Gas Line 1/2 6.7 (3.1) — 5/8 10.8 (4.9) 0.8 (0.4) 3/4 16.1 (7.3) 1.2 (0.6) 7/8 22.3 (10.2) 1.7 (0.8) 1-1/8 38.0 (17.4) 2.9 (1.3) 1-3/8 57.9 (26.5) 4.4 (2.0) Table 51 R-407C refrigerant required, approximate Approximate R-407C Refrigerant Needed Dual Circuit lb/circuit (kg/circuit) Standard Condenser Models FSC or VFD Lee-Temp (includes receiver) 165 5 (2.
Piping 9.2.2 Scroll and Digital Scroll—Additional Oil Requirements System charges over 40 lb (18.1kg) per circuit may require additional oil charge to be added. See Table 52 for the amount required for various system charge levels. After the system has been fully charged with refrigerant, use a hand pump to add the additional oil at the suction side of the system while the system is running.
Piping 9.3 Dehydration/Leak Test and Charging Procedures for R-407C 9.3.1 Air-Cooled Condenser with Variable Fan Speed Head Pressure Control Systems The Variable Fan Speed Control systems (FSC & VFD) use pressure activated electronic fan speed control systems and remotely located thermostat(s) to ensure operation at ambient temperatures as low as 0°F (-18°C).
Piping Variable Fan Speed Charging 1. Check unit nameplate for refrigerant type to be used. Unit control configurations differ depending on refrigerant type. 2. Refrigerant charging requires unit operation. Refer to 11.0 - Checklist for Completed Installation. 3. Calculate the amount of charge for the system. Refer to the unit, condenser and refrigerant line charge data in Tables 49, 50 and 51. 4. Weigh in as much of the system charge as possible before starting the unit.
Piping 9.3.2 Air-Cooled Condenser with Liebert Lee-Temp “Flooded Condenser” Head Pressure Control System The Liebert Lee-Temp system consists of a modulating type head pressure control valve and insulated receivers with heater pads to ensure operation at ambient temperatures as low as -30°F (-34.4°C). The Liebert Lee-Temp system can be used with any Liebert DS compressor choice.
Piping 7. After completion of leak testing, release the test pressure (per local code) and pull an initial deep vacuum on the system with a suitable pump. 8. After four hours, check the pressure readings and, if they have not changed, break vacuum with dry nitrogen. Pull a second and third vacuum to 250 microns or less. Recheck the pressure after two hours. After completing this step, proceed to Variable Fan Speed Charging on page 92. 9.
Piping Sight Glass Levels 40°F (4.5°C) and lower—bottom sight glass is 3/4 full 40 to 60°F (4.5 to 15.5°C)—bottom sight glass is full 60°F (15.5°C) and higher—top sight glass is 3/4 full 9.3.3 Water/Glycol Cooled System The water/glycol cooled system is factory-charged and includes and includes a Paradenser condenser and control valves.
Piping Schematics 10.0 PIPING SCHEMATICS Figure 68 Check Valve Piping schematic—air-cooled, semi-hermetic compressor models Relief ValveService Valve Liebert Lee-Temp Receiver Liquid Return Optional Sub-Cooling Coil Head Pressure Control Valve Optional Sub-Cooling Coil Inverted Trap on discharge and liquid lines to extend above base of coil by a minimum of 7-1/2" (190mm).
Piping Schematics Figure 69 Piping schematic—air-cooled, scroll compressor models Inverted Trap on discharge and liquid lines to extend above base of coil by a minimum of 7-1/2" (190mm).
Piping Schematics Figure 70 Piping schematic—water/glycol, semi-hermetic compressor models For systems with drycoolers, refer to 13.14.3 - Drycooler Settings.
Piping Schematics Figure 71 Piping schematic—water/glycol with scroll compressor models For systems with drycoolers, refer to 13.14.3 - Drycooler Settings.
Piping Schematics Figure 72 Piping schematic—GLYCOOL semi-hermetic compressor models LIEBERT HEAT REJECTION For systems with drycoolers, refer to 13.14.3 - Drycooler Settings.
Piping Schematics Figure 73 Piping schematic—GLYCOOL with scroll compressor models For systems with drycoolers, refer to 13.14.3 - Drycooler Settings.
Piping Schematics Figure 74 Piping schematic—water/glycol with digital scroll compressor models LIEBERT HEAT REJECTION CUSTOMER HEAT REJECTION DRYCOOLER (Glycol) COOLING TOWER AND PUMP SYSTEM BY OTHERS Optional Dual Pump System shown EXPANSION TANK** GLYCOL PUMPS Check Valves* (on Dual Pump Systems only) Pressure Port* Gate Valves* Aquastat Sensing Bulbs Hose Bib* Shut-Off Valve* Air Vents (typical)*** Pressure Port* Flow Switch Supplied with Dual Pump Systems LIEBERT DS UNIT (and associated
Piping Schematics Figure 75 GLYCOOL with digital scroll compressor models LIEBERT HEAT REJECTION DRYCOOLER (Glycol) Optional Dual Pump System shown EXPANSION TANK** GLYCOL PUMPS Check Valves* (on Dual Pimp Systems only) Gate Valves* Pressure Port* Aquastat Sensing Bulb Hose Bib* Shut-Off Valve* Air Vents (typical)*** Pressure Port* Flow Switch Supplied with Dual Pump Systems Flow-Regulating Valve* Shut-Off Valve* LIEBERT DS UNIT (and associated piping) ECON-O-COIL LIQUID 28-42kW Digital Sole
Piping Schematics Figure 76 Optional piping schematic for Econ-O-Coil Return Supply Return Supply Thermistor * Thermistor * Actuator Actuator Return Return Supply Supply Econ-O-Coil Econ-O-Coil Optional Econ-O-Coil (3-Way Valve) Optional Econ -O-Coil (2-Way Valve) Factory Piping * Supplied with 10 feet (3m) extra thermistor wire for installation on field supply line. Field Piping Note: 1. Place thermistor in location where flow is always present . DPN000805 2.
Piping Schematics Figure 77 Primary connection locations—downflow, air-cooled, 28-42kW (8-12 ton), semi-hermetic compressor models NOTE: Drawing not to scale. Tolerance on all piping dimensions is ± 1/2" (13mm). A A FRONT VIEW SECTION A-A X BLOWER OUTLET 4" (102mm) L1 L2 G1 G2 ALL DIMENSIONS FROM REAR CORNER OF UNIT INCLUDING PANELS O Y 16-1/16" (408mm) R B 16-7/16" (418mm) 35" (889mm) ECS LV1 LV2 LV3 HUM CD E1 E2 ECR FRONT OF UNIT DPN000803 Rev.
Piping Schematics Figure 78 Primary connection locations—downflow, air-Cooled, 28-42kW (8-12 ton) with scroll compressor models NOTE: Drawing not to scale. Tolerance on all piping dimensions is ± 1/2" (13mm). A A ALL DIMENSIONS FROM REAR CORNER OF UNIT INCLUDING PANELS FRONT VIEW X SECTION A-A O 16-1/16" (408mm) BLOWER OUTLET Y R 4" (102mm) L1 L2 G1 G2 B 11-3/16" (284mm) ECS LV1 LV2 LV3 HUM E1 E2 ECR CD FRONT OF UNIT DPN000804 Rev.
Piping Schematics Figure 79 Primary connection locations—downflow water/glycol/GLYCOOL 28-42kW (8-12 ton), all compressor models NOTE: Drawing not to scale. Tolerance on all piping dimensions is ± 1/2" (13mm). A A FRONT VIEW ALL DIMENSIONS FROM REAR CORNER OF UNIT INCLUDING PANELS X SECTION A-A 8" (203mm) WS WR Y 16-1/16" (408mm) BLOWER OUTLET W O B 3-1/2" (89mm) 35" (889mm) ECS LV1 LV2 LV3 HUM E1 E2 ECR CD FRONT OF UNIT 86" (2184mm) Point Description DPN000900 Rev. 3 X in.
Piping Schematics Figure 80 Primary connection locations—downflow, air-Cooled, 53-77kW (15-22 ton), semi-hermetic compressor models NOTE: Drawing not to scale. All dimensions from rear corner of unit including panels Tolerance on all piping dimensions is ± 1/2" (13mm). A A FRONT VIEW X SECTION A-A 16-1/16" (408mm) BLOWER OUTLET O BLOWER OUTLET Y R 4" (102mm) L1 L2 G1 G2 B2 16-7/16" (418mm) 35" (889mm) B1 ECS LV1 LV2 LV3 HUMECR CD E1 E2 109" (2769mm) DPN000928 Rev.
Piping Schematics Figure 81 Primary connection locations downflow air cooled 53-77kW (15-22 tons) semi-hermetic compressor models, with EC fans All dimensions from rear corner of unit including panels A Note: Drawing not to scale. Tolerance on all piping dimensions is ± 1/2" (13mm). A FRONT VIEW X SECTION A-A O Y R 4" (102mm) BLOWER OUTLET L1 L2 G1 G2 35" (889mm) 16-7/16" (418mm) ECS ECR CD E1 E2 LV1 LV2 B1 LV3 HUM FRONT OF UNIT 109" (2769mm) DPN002179 Rev. 0 Point Description X in.
Piping Schematics Figure 82 Primary connection locations—downflow, air-Cooled, 53-77kW (15-22 ton) with scroll *** compressor models NOTE: Drawing not to scale. Tolerance on all piping dimensions is ± 1/2" (13mm).
Piping Schematics Figure 83 Primary connection locations—downflow, air-Cooled, 53-77kW (15-22 ton) with scroll *** compressor models, with EC fan NOTE: Drawing not to scale. Tolerance on all piping dimensions is ± 1/2" (13mm). A All dimensions from rear corner of unit including panels A FRONT VIEW SECTION A-A X O Y R 4" (102mm) L1 L2 BLOWER OUTLET G1 G2 35" (889mm) 12-3/16" (310mm) ECS ECR CD E1 E2 B1 HUM DS = 98" (2489mm) DA = 100" (2540mm) DPN002182 Rev.
Piping Schematics Figure 84 Primary connection locations—downflow, water/glycol/GLYCOOL, 53-77kW (15-22 ton), all compressor *** models NOTE: Drawing not to scale. A Tolerance on all piping dimensions is ± 1/2" (13mm).
Piping Schematics Figure 85 Primary connection locations—downflow, water/glycol/GLYCOOL, 53-77kW (15-22 ton), all compressor *** models, with EC fans A Note: Drawing not to scale. Tolerance on all piping dimensions is ± 1/2" (13mm). A All dimensions from rear corner of unit including panels FRONT VIEW SECTION A-A X O 3-1/2" (89mm) 8" (203mm) Y W WS WR BLOWER OUTLET 35" (889mm) ECS ECR CD E1 E2 LV1 B1 LV2 LV3 HUM FRONT OF UNIT 109" (2769mm) DPN002183 Rev. 0 Point Description X in.
Piping Schematics Figure 86 Primary connection locations—downflow, air-cooled, 105kW (30 ton), all compressor*** models A A NOTE: Drawing not to scale. Tolerance on all piping dimensions is ± 1/2" (13mm).
Piping Schematics Figure 87 Primary connection locations—downflow, air-cooled, 105kW (30 ton), all compressor *** models, with EC fan A A Note: Drawing not to scale. Tolerance on all piping dimensions is ± 1/2" (13mm). FRONT VIEW All dimensions from rear corner of unit including panels SECTION A-A X O Y BLOWER OUTLET G1G2 R 4" (102mm) 35" (889mm) L1 L2 16-7/16" (418mm) ECS ECR E1 E2 CD HUM B1 LV1 LV2 LV3 FRONT OF UNIT 132" (3353mm) DPN002154 Rev. 0 Point Description X in. (mm) Y in.
Piping Schematics Figure 88 Primary connection locations—downflow, water/glycol/GLYCOOL, 105kW (30 ton), all compressor *** models A A W WS WR 8" (203mm) 15-7/8" (403mm) TYP 3-1/2" (89mm) ECS ECR ALL DIMENSIONS FROM REAR CORNER OF UNIT INCLUDING PANELS FRONT VIEW NOTE: Drawing not to scale. Tolerance on all piping dimensions is ± 1/2" (13mm).
Piping Schematics Figure 89 Primary connection locations downflow water/glycol/GLYCOOL 105kW (30 tons) all compressor *** models, with EC fan A A FRONT VIEW Note: Drawing not to scale. Tolerance on all piping dimensions is ± 1/2" (13mm). All dimensions from rear corner of unit including panels X SECTION A-A 8" (203mm) O W WS WR Y 35" (889mm) BLOWER OUTLET 3-1/2" (89mm) ECS ECR E1 E2 CD LV1 LV2 LV3 B1 HUM FRONT OF UNIT 132" (3353mm) DPN002153 Rev. 0 Point Description X in. (mm) Y in.
Piping Schematics Figure 90 Primary connection locations—upflow, air-cooled, 28-42kw (8-12 ton), semi-hermetic compressor models All dimensions from rear corner of unit including panels 22-1/2" (572mm) NOTES: 1. Drawing not to scale. 2. Tolerance on all piping dimensions is ± 1/2" (13mm). 15-3/16" Field-routed alternatives for refrigerant 35" (386mm) gas and liquid line connection points. (889mm) See submittal page DPN001120 for 4" blower outlet and deck dimensional data.
Piping Schematics Figure 91 Primary connection locations—upflow, air-Cooled, 28-42kW (8-12 ton), semi-hermetic compressor models NOTES: 1. Drawing not to scale. 2. Tolerance on all piping dimensions is ± 1/2" (13mm). 3 Field routed alternatives for refrigerant gas and liquid line connection points. 4 See submittal page DPN001120 for blower outlet and deck dimensional data. All dimensions from rear corner of unit including panels X 10-1/8" (257mm) 4-1/8" (105mm) 3. R1 R2 BLOWER OUTLET 4.
Piping Schematics Figure 92 Primary connection locations—upflow, water/glycol/GLYCOOL, 28-42kW (8-12 ton), all compressor models NOTES: 1. Drawing not to scale. 2. Tolerance on all piping dimensions is ± 1/2" (13mm). All dimensions from rear corner of unit including panels X 3. Field routed alternatives for water/glycol connections. 4. See submittal page DPN001120 for blower outlet and deck dimensional data.
Piping Schematics Figure 93 Primary connection locations—upflow, air-cooled, 53-77kW (15-22 ton), semi-hermetic compressor models All dimensions from rear corner of unit including panels 22-1/2" (572mm) NOTES: 15-3/16" 1. Drawing not to scale. 35" (386mm) 2. Tolerance on all piping dimensions (889mm) is ± 1/2" (13mm). 4" 3. Field routed alternatives for refrigerant (102mm) gas and liquid line connection points. 4. See submittal page DPN001191 for blower outlet and deck dimensional data.
Piping Schematics Figure 94 Primary connection locations—upflow, air-cooled, 53-77kW (15-22 ton), scroll compressor *** models All dimensions from rear corner of unit including panels NOTE 4" 1. Drawing not to scale. (102mm) 2. Tolerance on all piping dimensions 35" is ±1/2" (13mm). 4" (102mm) 3. Field-routed alternatives for refrigerant (889mm) gas and liquid line connection points. 12-13/16" 4. See submittal page DPN001191 for (325mm) blower outlet and deck dimensional data.
Piping Schematics Figure 95 Primary connection locations—upflow, water/glycol/GLYCOOL, 53-77kW (15-22 ton), all compressor *** models All dimensions from rear corner of unit including panels NOTES: 1. Drawing not to scale. 2. Tolerance on all piping dimensions 8" is ± 1/2" (13mm). (203mm) 3. Field routed alternatives for water/glycol 35" connections. (889mm) 2-7/8" (73mm) 4. See submittal page DPN001191 for 3-1/2" blower outlet and deck dimensional data.
Piping Schematics Figure 96 Primary connection locations—upflow, air-cooled, 105kW (30 ton), all compressor ** models All dimensions from rear corner of unit including panels 22-1/2" (572mm) 35" (889mm) 15-3/16" (386mm) 4" (102mm) NOTES: 1. Drawing not to scale. 2. Tolerance on all piping dimensions is ± 1/2" (13mm). 3. Field routed alternatives for refrigerant gas and liquid line connection points. 4. See submittal page DPN001192 for blower outlet and deck dimensional data.
Piping Schematics Figure 97 Primary connection locations—upflow, water/glycol/GLYCOOL, 105kW (30 ton), all compressor ** models All dimensions from rear corner of unit including panels 35" (889mm) Blower Outlet 8" (203mm) Blower Outlet 2-7/8" (73mm) 3-1/2" (89mm) LV1 LV3 NOTES: 1. Drawing not to scale. 2. Tolerance on all piping dimensions is ± 1/2" (13mm). 3. Field routed alternatives for water/glycol connections. 4. See submittal page DPN001192 for blower outlet and deck dimensional data.
Checklist for Completed Installation 11.0 CHECKLIST FOR COMPLETED INSTALLATION 11.1 Moving and Placing Equipment ___ 1. Unpack and check received material. ___ 2. Proper clearance for service access has been maintained around the equipment. ___ 3. Equipment is level and mounting fasteners are tight. ___ 4. If the equipment has been disassembled for installation, unit must be reassembled per instructions. 11.2 Electrical ___ 1. Supply voltage and phase matches equipment nameplate. ___ 2.
Checklist for Completed Installation 11.4 Other ___ 1. Ducting complete (if required), maintain access to filters. ___ 2. Filters installed. ___ 3. Check fasteners that secure compressors, reheats, humidifier and motors—some may have become loose during shipment. ___ 4. Verify water detection is properly installed around all units (recommended). ___ 5. Control panel DIP switches are set based on user requirements. ___ 6. Blower drive system rotates freely and belts are properly aligned and tensioned.
Initial Startup Checks and Commissioning Procedure for Warranty Inspection 12.0 INITIAL STARTUP CHECKS AND COMMISSIONING PROCEDURE FOR WARRANTY INSPECTION ! WARNING Risk of electric shock. Can cause injury or death Disconnect local and remote power supplies before working within. Before proceeding with installation, read all instructions, verify that all the parts are included and check the nameplate to be sure the voltage matches available utility power. Follow all local codes.
Initial Startup Checks and Commissioning Procedure for Warranty Inspection 12.1 Information for Warranty Inspection—Remove Power From Unit Disconnect Complete the following items on the warranty inspection form: • • • • • • • • • • • 12.
Initial Startup Checks and Commissioning Procedure for Warranty Inspection 12.3 Startup 1. Turn On the Main Disconnect. 2. Check voltage at disconnect and record. L1-L2 _________________ L2-L3 _________________ L1-L3 _________________ 3. Check control voltage transformers for proper output. Secondary voltage(s) should not exceed 27VAC under load. Change tap if necessary. T1 __________ Volts. 4. Check fan rotation for proper direction. Change wiring at contactor if necessary. 5.
Initial Startup Checks and Commissioning Procedure for Warranty Inspection 12.4 Commissioning Procedure With Panels On 1. Disconnect all power to the environmental control unit and check. 2. Remove all line voltage fuses except the main fan fuses and the control voltage fuses in the electric panel. (Use Liebert iCOM® to activate loads.) 3. Turn On power to the unit and check line voltage on main unit disconnect switch. Line voltage must be within 10% of nameplate voltage. 4.
Maintenance 13.0 MAINTENANCE ! WARNING Risk of electric shock. Can cause injury or death. Disconnect local and remote power supplies before working within. Before proceeding with installation, read all instructions, verify that all the parts are included and check the nameplate to be sure the voltage matches available utility power. Follow all local codes. ! WARNING Risk of improper wiring, piping, moving, lifting and handling. Can cause equipment damage, injury or death.
Maintenance 13.1 Filters NOTICE Risk of improper filter installation and filter collapse. Can cause equipment damage. Pleat direction is non-standard. Use only short-pleat filters (see Figure 98). Long-pleat filters are subject to collapse at high airflows. To maximize the performance and reliability of Liebert DS equipment, use only Liebert filters. Contact your local Emerson representative to order replacement filters.
Maintenance Figure 98 Proper filter pleat direction Do Not Use 16" (406mm) 25" (635mm) Short Pleat Construction Long Pleat Construction The filter pleat direction should run parallel to the direction of the short side of the filter , as shown above . Do NOT use long pleat filter construction , as shown at right above , because it can result in filter collapse . 13.2 DPN000994 Rev.
Maintenance 13.2.1 Upflow Motor Access 1. Remove the lateral support (sheet metal channel) under electric box by removing two screws at each end. 2. Removed the hinged deadfront panel (30-ton units have open access to the motor). 3. Remove two screws on the right side of the low-voltage electric box that secure the low volt electric box to the sheet metal shoulder. 4. Swing open low-voltage electric box to gain access to the motor.
Maintenance Figure 100 Auto-belt tensioning motor base Spring Housing Motor Base Carriage Minimum 1/2” (13mm) Gap Motor Plate Adjustment Slot Adjustment Nut DPN000995 Rev. 0 Blower Bearing Maintenance • Field lubrication is NOT required for the life of the bearing. • Bearings are permanently sealed and self-lubricating and cannot be greased. Blower Bearing Inspection 1. 2. 3. 4. 5. Disconnect power to unit. Remove drive belts (see 13.2.2 - Belt Removal).
Maintenance 13.2.4 Electronic Variable Speed Drive - Inverter On Liebert DS models with digital scroll, an optional, variable speed drive is available. This packaged unit is factory-set and should not require field adjustment. Removing VSD from Liebert DS 1. Turn off power at the unit disconnect. 2. Remove the front right panel. 3. Remove the VSD subassembly from the unit shoulder (downflow) or from the unit floor (upflow).
Maintenance ! CAUTION Risk of improper moving, lifting and handling. Can cause equipment damage or injury. Only properly trained and qualified personnel should work on this equipment. Fan modules weigh in excess of 100lb. (45kg) each. Take precautions to avoid back injury and dropping during removal. NOTICE Risk of improper installation. Can cause equipment damage. Only a properly trained and qualified technician should install or open this motor. Use 60/75°C copper wire only. Use Class 1 wires only. 13.
Maintenance Figure 101 Correct orientation of float switch Correct Switch Orientation Incorrect Switch Orientation DPN000996 Rev. 0 13.4.2 Changing Humidifier Lamps NOTE Touching quartz lamps with bare hands will severely shorten bulb life. Skin oils create hot spots on lamp surface. Wear clean cotton gloves when handling lamps. 1. Remove humidifier pan (see 13.4.1 - Cleaning Humidifier Pan and Float Switch, Steps 1 through 10). 2. Disconnect power from unit. 3.
Maintenance 13.5 Humidifier—Steam Generating The humidifier drains and refills to maintain a current setpoint and alert the operator when the humidifier canister needs to be replaced. Figure 103 Steam generating humidifier canister 13.5.1 Replacing the Steam Generating Humidifier Canister ! WARNING Risk of electric shock. Can cause injury or death. Disconnect local and remote power supplies before working within.
Maintenance The steam cylinder is disposable and must be replaced at the end of the cylinder’s life. Cylinder life will vary according to water supply conditions and humidifier usage. ! WARNING Risk of humidifier canister meltdown, smoke and fire. Can cause fire suppression system activation, fire and smoke alarm activation, serious equipment and building damage, injury and death. Using a humidifier canister that has reached the end of it’s service life can be extremely hazardous.
Maintenance Mandatory Cleaning of the Drain Valve Always clean the drain valve before installing a new cylinder. Figure 105 shows an exploded view of the drain valve for reference to clean it. 1. Remove old cylinder as previously described. 2. Note that the ring terminal for the drain valve green ground wire is sandwiched between the drain valve and the drain pan. 3. Remove the two screws securing the drain valve body to the drain pan. 4. Remove the hose clip and hose connection from the drain valve body.
Maintenance Installing the New Canister 1. The reverse procedure should be followed to install a new cylinder. The main electrical disconnect is to be left open until the cylinder is completely installed and reconnected. 2. The blue sensor plug on all units is for the high water sensor pin, which always goes on the single pin with collar offset from the others. See Figure 106. 3. Ensure that cylinder plugs are snug on the pins. Replace any loose fitting plugs as these may result in hazardous operation.
Maintenance Table 60 Steam generating humidifier status lamps: causes, corrective action Unit Status Lamp Yellow Green On Corrective Actions Maximum water level inside cylinder. This usually happens on initial startup after replacing the cylinder (normal). Water is concentrated with minerals inside the cylinder. Let unit run, yellow light will disappear when the unit is at full output. This may take a day or two. Off No power to the board. Check for main power supply fault.
Maintenance Figure 107 Circuit board diagram PCB is configured for: MES-L To configure the PCB to the proper voltage, the jumpers should be set as follows: (* = Factory setting; do not adjust) 200V/208V: 230V: 380V/415V: 460V: 575V: J8 J19 J20 J21 J22 J9 Current Transformer P11 1 J1 J2 J3 J4 J5 J6 J7 Capacity adjust (Default at 100%) HW Sensor Jumpers J9: Low Voltage 200-240V J8: High Voltage 380-600V J24 J18 J17 J16 J15 J14 J13 J12 J11 J6, J9, J15*, J17*, J19*, J10*, J23*, P11 pin (2-3)* J5, J9
Maintenance 13.7 Air-Cooled Condenser and Drycoolers • • • • • • • 13.8 Clear coil surface of all debris that will inhibit airflow. Check for bent or damaged coil fins and correct. Do not permit snow to accumulate around or under outdoor unit. Periodically consider commercial cleaning of coil surface Inspect fans, motors and controls for proper operation. Check all piping and capillaries for proper support. Inspect for leaks.
Maintenance 13.10 Compressor 13.10.1Compressor Oil NOTICE Risk of improper compressor lubrication. Can cause compressor and refrigerant system damage. Failure to use oil types, viscosities and quantities recommended by the compressor manufacturer may reduce compressor life and void the compressor warranty. See oil types specified in Table 62. • Do NOT mix polyolester (POE) and mineral-based oils. • Do NOT mix oils of different viscosities.
Maintenance 13.11.2Digital Compressor Unloading Solenoid(s) Models 028, 035 and 042 When replacing a digital scroll compressor, digital solenoid valve and coil must be replaced. Compressor and valve kit are shipped separately. Valve kit must be field-brazed to top of compressor in proper orientation and supported with original factory bracket. Models 053, 070 and 077 When replacing a digital scroll compressor, digital solenoid coil must be replaced. Compressor and coil kit are shipped separately. 13.11.
Maintenance 13.13.1 Cleaning Instructions Refer to Figure 1 - Downflow model component locations. 1. Disconnect power to unit. 2. Close field-installed isolation valves to isolate this unit’s condenser system from facility water or glycol circuit. 3. Remove access panel from front of compressor section. 4. Locate the 1/2" NPT drain plugs located at lower front of compressor section and provide means to collect fluid drained from system 5.
Maintenance Testing Function of Valve First, turn off the refrigeration system. When the refrigeration system has been off for approximately 10 to 15 minutes, the water flow should stop. If the water continues to flow, the valve is either improperly adjusted (with head pressure too low) or the pressure-sensing capillary is not connected properly to the condenser. Location The water regulating valves are located in the condenser fluid supply line. 13.14.
Maintenance 13.14.3Drycooler Settings Applications with the Optional Stat Setting require field piping to be insulated to prevent condensation. Table 64 shows acceptable applications where stats must be adjusted to Optional Setting. Aquastats must be field-adjusted to Optional Setting for: • GLYCOOL/Dual Cool applications • Single Drycooler loops with motor ball valve flow controls (motor ball valves are used on all Liebert DS units with digital compressors).
HVAC Maintenance Checklist 14.0 HVAC MAINTENANCE CHECKLIST Inspection Date Job Name Indoor Unit Model # Indoor Unit Serial Number # Condenser/Drycooler Model # Condenser/Drycooler Serial # Room Temperature/Humidity ° % Ambient Temperature Filters ___ 1. Check/replace filters ___ 2. Grille area unrestricted ___ 3. Wipe section clean ___ 4. Coil clean Blower Section ___ 1. Blower wheels free of debris ___ 2. Check belt tension and condition on centrifugal fans (replace if needed) ___ 3.
HVAC Maintenance Checklist Condensate Pump ___ 1. Check for debris in sump ___ 2. Check operation of float(s) (free movement) Refrigeration Piping ___ 1. Check refrigerant lines (clamps secure/no rubbing/no leaks) ___ 2. Check for moisture (sight glass) Water-Cooled Condensers ___ 1. Check water regulating valve operation ___ 2. Cap tubes (not rubbing) ___ 3. Check for water/glycol leaks ___ 4. Entering water temperature ______________ ° ___ 5. Leaving water Drain Piping ___ 1.
HVAC Maintenance Checklist Controls ___ 1. Check/Verify Control Operation (Sequence) ___ 2. Check humidifier high water alarm operation ___ 3. Check operation of the air safety switch ___ 4. Check setting/operation of the filter clog switch ___ 5. Check/test changeover device(s) ___ 6. Check/test water detection device(s) Air-Cooled Condenser / Drycooler ___ 1. Coil surfaces and fans free of debris (clean, wash and straighten fins as needed) ___ 2. Fan motors securely mounted ___ 3.
HVAC Maintenance Checklist Maintenance Notes___________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ___________________
HVAC Maintenance Checklist NOTES Liebert® DS™ 156
COMPLIANCE WITH EUROPEAN UNION DIRECTIVES Liebert Corporation 1050 Dearborn Drive P.O.
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