Precision Cooling For Business-Critical Continuity™ Liebert® Air Cooled, Direct Drive Condensers Installation, Operation and Maintenance Manual - 50/60Hz
Figure i Product model nomenclature Example: DCDF165-Y D C Condenser D = Disconnect Switch (optional on Fan Speed Control, Chiller & Standard Lee-Temp Condensers; standard on Quiet-Line and VFD Control condensers T = TVSS & Disconnect Switch; available only on the VFD Control condensers D F 165 F = Fan Speed Control L = Main Control / Lee-Temp C = No Control / Chiller Lee-Temp T = Ambient Fan Cycle/ Lee-Temp V = Variable Frequency Drive (VFD) Control (available only for dual refrigerant circuit co
TABLE OF CONTENTS 1.0 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 1.1 Product Description and Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.2 Head Pressure Control Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.2.1 1.2.2 1.2.3 1.3 Fan Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.4 Other . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 5.0 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 5.1 Startup Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 5.2 Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction 1.0 INTRODUCTION 1.1 Product Description and Features The Liebert condenser is low-profile direct-drive propeller fan-type air cooled unit suitable for mounting outdoors. It provides for the heat rejection of either one or two separate refrigeration circuits, matching heat rejection capacity varying with the outdoor ambient temperatures with each corresponding compressors heat rejection requirements.
Introduction 1.2.3 Liebert Lee-Temp™ Refrigerant Control The Liebert Lee-Temp head pressure control system is designed to maintain proper operating head pressures in outdoor temperatures down to -30°F (-34.4°C). The condensers utilize head pressure control valves, extra refrigerant and insulated refrigerant receivers with heater pads.
Introduction Figure 2 Typical system configuration—indoor unit and outdoor condenser and field piping Check Valve Inverted trap on discharge & liquid lines to extend above base of coil by a minimum of 7-1/2” (190mm).
Site Preparation 2.0 SITE PREPARATION 2.1 Site Considerations The condensers should be installed in a location offering maximum security and access for maintenance. Avoid ground-level sites with public access and areas that contribute to heavy snow or ice accumulations. Utilize Piggyback condensers whenever interior building locations must be used.
Site Preparation Figure 3 Condenser planning dimensional data—One-fan and two-fan units 51-1/2" (1308mm) 43-9/16" (1106mm) 43-9/16" (1106mm) 91-1/2" (2324mm) 37-7/8" (962mm) 37-7/8" (962mm) 18" (457mm) 43-3/16" (1097mm) 44" (1118mm) 18" (457mm) 84" (2134mm) Note: Overall height to the top of fan guard 43-1/8" (1095mm) 42" (1067 mm) 43-3/16" (1097mm) ANCHOR PLAN Liebert recommends a clearance of 36" (915mm) on each side for proper operation and component access.
Site Preparation Figure 4 Condenser planning dimensional data—Three-fan and four-fan units 43-9/16" (1106mm) 131-1/2" (3340mm) 43-9/16" (1106mm) 37-7/8" (962mm) 171-1/2" (4356mm) 70" (1778mm) 18" (457mm) 124" (3150mm) 37-7/8" (962mm) Eyebolts for Lifting 18" (457mm) 43-3/16" (1097mm) 164" (4166mm) Note: Overall height to the top of fan guard 43-1/8" (1095mm) 43-3/16" (1097mm) ANCHOR PLAN 42" (1067mm) Electric Box End Legs supplied with Lee-Temp option only Liebert recommends a clearance of 36"
Site Preparation Figure 5 Condenser planning dimensional data—Six- and eight-fan units 87-1/8" (2213mm) 131-1/2" (3340mm) 87-1/8" (2213mm) 37-7/8" (962mm) 171-1/2" (4356mm) 37-7/8" (962mm) 59" (1499mm) 18" (457mm) 18" (457mm) 124" (3150mm) 86-3/4" (2203mm) 70" (1778mm) 1-1/2" (38mm) diameter hole for rigging (typ.4) Overalll height to the top of the fan guard is 43-1/8” (1095mm).
Site Preparation Figure 6 Typical condenser footprint—dimensions 1” (25.4mm) 1-3/4” (44.5mm) 4-1/4” (108mm) 2” (50.8mm) 1-3/4” (44.5mm) 9/16" (14mm) Typical Diameter 4-1/4” (108mm) 2” (50.
Site Preparation Figure 8 Piping connections for 1-, 2-, 3- and 4-fan Lee-Temp and Quiet-Line Condensers Inverted Traps (field-supplied) to extend 8" (203mm) above coil base Entering Hot Gas Line Hot Gas Line Liquid Line Fasten liquid and hot gas lines to leg using flat surface clamps with isolators (field-provided). Support field piping separately to avoid coil damage and loss of charge.
Site Preparation Figure 10 Piping connections for 6- and 8-fan Lee-Temp and Quiet-Line Condensers Access Valve (Hot Gas) on Condensers (Typ. 2) Inverted traps (field-supplied) to extend above base of coil by a minimum of 7-1/2" (190mm). Inlet Connection Upper Headers (Typ.) Condenser Connections, Typical Liquid Line Entering Hot Gas Line Hot Gas Line Leaving Liquid Line Fasten liquid and hot gas lines to leg using flat surface clamps with isolators (field-supplied).
Site Preparation Table 2 Condenser physical data Model # Number of Fans Number of Circuits Connection Size, OD, In.
Site Preparation 2.3 Refrigerant Planning Values Planning for the refrigerant requirements of the completed system is the addition of the charges from Indoor Unit, Condenser (including Lee-Temp receiver, if used) and the interconnecting piping. Tables 3 and 4 provide the approximate charge required for the condensers and the interconnecting piping. Consult indoor unit manuals for indoor unit charge requirements.
Inspection and Installation 3.0 INSPECTION AND INSTALLATION 3.1 Equipment Inspection Before unpacking the condenser, verify that the labeled equipment matches the bill of lading. Carefully inspect all items for damage, either visible or concealed. Report any damage immediately to the carrier and your local Liebert representative. File a damage claim with the carrier and send a copy to your local Liebert representative. 3.1.1 Packing Material All material used to package this unit is recyclable.
Inspection and Installation 3.2 Handling Unit on the Skid Transport the unit using a fork lift or a crane with sling and spreader bars. • If using a fork lift, make sure the forks (if adjustable) are spread to the widest allowable distance to still fit under the skid. • Ensure the fork length is suitable for the unit length. • When moving the packaged unit, do not lift the unit any higher than 6" (152mm) off the ground. Exercise great care if the unit must be lifted higher than 6" (152mm).
Inspection and Installation 3.4 Preparing a 1-, 2-, 3- or 4-Fan Condenser for Moving and Installation 3.4.1 Removing the Skid and Attaching Slings 1. Install the legs, provided by Liebert, on the condenser with the mounting bolts, also provided by Liebert. Liebert recommends using a 5/8" socket and ratchet. 2. Place slings or equivalent items through holes in the legs on 1, 2- and 3-fan condensers (see Step 2 and Step 3 in Figure 13).
Inspection and Installation 3.5 Preparing a 6-Fan or 8-Fan Condenser for Moving and Installation 3.5.1 Removing the Skid and Attaching Slings The following procedure is one recommended process for removing a Liebert condenser from its shipping skid. Other methods may be used, provided that the methods are safe for personnel, the condenser and equipment. 1. Place a sling through to rigging attachment points as shown in Step 1 in Figure 14. 2.
Inspection and Installation Figure 15 Attaching sling to a 6-fan or 8-fan unit for moving Step 4 Step 5 Six-fan unit shown for illustration. Method for 8-fan condenser is the same. 3.5.2 Mounting the Condenser The condenser must be installed so that it is level within 1/2" (13mm) to ensure proper refrigerant flow. For roof installation, mount the condenser on suitable curbs or other supports; follow all local and national codes.
Inspection and Installation 3.6 Electrical Supply Preparation Line voltage electrical service is required for all models. Refer to equipment nameplate regarding wire size and circuit protection requirements. Electrical service must conform to national and local electrical codes. Refer to Figures 19, 20 and 21 for electrical service entrances into unit. Refer to electrical schematic when making connections. Each unit is shipped from the factory with all internal unit wiring completed.
Inspection and Installation Table 5 60Hz condenser data Model # 83, 104 165, 205 251, 308 415, 510 616 830, 1010 # of Fans 1 2 3 4 6 8 Input Voltage ph FLA WSA OPD FLA WSA OPD FLA WSA OPD FLA WSA OPD FLA WSA OPD FLA WSA OPD Fan Speed Controlled 208/230 460 1 575 4.8 6.0 15 — — — — — — — — — — — — — — — 2.5 3.1 15 — — — — — — — — — — — — — — — 1.9 2.4 15 — — — — — — — — — — — — — — — — — — 8.3 9.5 15 11.8 13.0 15 15.3 16.
Inspection and Installation Table 8 Lee-Temp receiver electrical data, 50Hz and 60Hz Rated Voltage - Single Phase Watts/Receiver 3.6.2 120 150 300 200/208/230 450 150 300 450 Full Load Amps 1.4 2.8 4.2 0.7 1.4 2.1 Wire Size Amps 1.8 3.5 5.3 0.9 1.8 2.7 Maximum Overcurrent Protection Device, Amps 15 15 15 15 15 15 Low Voltage Control Wiring NOTICE Risk of control malfunction. Can cause improper unit operation.
Inspection and Installation 3.7.1 VFD Control Condensers (TCDV) only The installer/startup technician must determine the type of 3-phase supply power being used for the VFD Control Condenser: Wye-connected power or Delta- connected power. Wye-connected power has two different voltages that can be measured: Phase-to-Phase voltage (this is equal to the nominal input voltage) and Phase-to-Neutral voltage (typically used for small single phase loads (120 VAC or 277 VAC). See Figure 16.
Inspection and Installation Disconnect EMC Filter for Delta-Connected Power Installer/startup technician needs to disconnect the EMC filter on the VFD to ensure proper operation if the Liebert VFD Control Condenser will be operated with Delta-connected power. 1. Disconnect the power supply before working on the unit. 2. Open the electrical panel cover and locate the VFD (Refer to Figure 20). 3.
Inspection and Installation 3.8 Electrical Field Connection Descriptions Figure 19 Electrical field connections for Fan Speed Control Condensers Electric service connection terminals when factory disconnect is NOT supplied. Electric service connection and fuse block. Factory wired to 24V Class 2 control circuit. Electric service connection terminals when factory disconnect is supplied.
Inspection and Installation Figure 20 Electrical field connections for VFD control condensers Factory-installed fuse block on 60Hz units. Circuit breaker supplied in lieu of fuse block on 50Hz units. Factory-wired to 24V control circuit. Control interlock (70, 71) Field-supplied Class 1 wiring to interlock condenser 24V controls to Liebert room unit; 7/8 in. (22.2mm) diameter hole provided in bottom of electric box. Electric service connection terminals with factorysupplied disconnect.
Inspection and Installation Figure 21 Electrical field connections for Liebert Lee-Temp control condensers Lee-Temp receiver tank (1 per circuit). NOTE: Standard heater pads are 150 watts each. (Optional 300 watt heater pads are available.) Standard heater pad voltage is 230V. (120V heater pad voltage is optional.) Electrical connection box with cover. Electrical service connection.
Inspection and Installation 3.9 Refrigeration Piping Connections ! WARNING Risk of explosive discharge from high-pressure refrigerant. Can cause equipment damage, injury or death. Relieve pressure before working with piping. ! WARNING Risk of refrigerant system rupture or explosion from overpressurization. Can cause equipment damage, injury or death.
Inspection and Installation 3.9.2 Field Piping Installation One discharge line and one liquid line must be field-installed for each circuit of the indoor unit and the outdoor condenser(s). Dual circuit condensers are available for most dual circuit indoor unit applications. Refer to Figures 22, 23 and 24 below for additional field-installed piping needed at the condenser.
Inspection and Installation Figure 23 Lee-Temp head pressure control condenser piping Inverted Traps (field-supplied) to extend 8" (203mm) above coil base Entering Hot Gas Line Hot Gas Line Liquid Line Fasten liquid and hot gas lines to leg using flat surface clamps with isolators (field-supplied). Support field piping separately to avoid coil damage and loss of charge. Leaving Liquid Line See Detail A-A Position elbow to direct relief valve downward DPN000669 Rev.
Inspection and Installation Figure 24 General arrangement—Air cooled models with Lee-Temp control Condenser Coil Inverted Trap * on discharge line to extend 7-1/2" (190mm) above coil base Piping Assembly ** Check Head Pressure Valve Rotalock Valve ** 1/4" (6.4mm) Pressure Relief Valve** Control with Integral Check Valve temp Lee- iver e Rec * Traps every 25 ft (7.
Inspection and Installation 3.10 System Dehydration/Leak Test and Charging Procedures Procedures for leak check and evacuation of the entire refrigeration system are contained in the installation manual of the indoor unit. Use the proper manual section corresponding to the winter control system used on the condenser (VFD/Fan Speed Control or Lee-Temp Control) and the refrigerant to be charged into the system.
Checklist for Completed Installation 4.0 CHECKLIST FOR COMPLETED INSTALLATION 4.1 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 4.2 Electrical ___ 1. Line voltage connected and matches equipment nameplate ___ 2. Power line circuit breakers or fuses have proper ratings for equipment installed ___ 3.
Operation 5.0 OPERATION ! WARNING Risk of electric shock. Can cause injury or death. Disconnect all local and remote electric power supplies before working within. Unit contains potentially lethal electrical voltage. Only properly trained and qualified personnel may perform repair, maintenance and cleaning operations. The fans may start unexpectedly. Disconnect power supply before working on unit. Line side of factory disconnect remains energized when disconnect is off.
System Maintenance 6.0 SYSTEM MAINTENANCE ! WARNING Risk of electric shock. Can cause injury or death. Disconnect all local and remote electric power supplies before working in the unit. Use voltmeter to make sure power is turned Off before making any electrical connections. Unit contains lethal voltage in some circuits. Only properly trained and qualified personnel may perform repair, maintenance and cleaning operations. The fans may start unexpectedly. Disconnect power supply before working on unit.
System Maintenance 6.2 Special Procedures 6.2.1 Condenser Cleaning Keeping the outdoor condenser coils clean is an important factor in maintaining peak efficiency, reliability and long life of the equipment. It is much easier to keep up on frequent cleanings rather than wait until heavy build up has occurred which may create head pressure problems with the evaporator units. When to Clean Normal conditions typically dictate cleaning twice a year, spring and fall.
System Maintenance 6.2.2 Maintenance Inspection Checklist Date:____________________________________ Prepared By:____________________________________ Model #:_________________________________ Serial Number:__________________________________ NOTE Regular inspections are necessary to ensure that the cooling fins are clean. Should inspection reveal dirt or corrosion, appropriate cleaning should be performed. Monthly Condenser Semiannually Condenser ___ 1. Coil surfaces free of debris ___ 1.
System Maintenance Table 9 Troubleshooting Symptom Condenser will not start Possible Cause Check or Remedy No power to condenser Check voltage at input terminal block Circuit breaker for low voltage transformer in condenser is tripped Locate problem in condenser electrical panel and repair No low voltage signal to/from indoor unit Locate open circuit and repair Low indoor unit suction pressure Low discharge pressure Insufficient refrigerant in system Check for leaks, repair, and add refrigerant
System Maintenance NOTES 37
System Maintenance 38
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