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Liebert DS Network Card User Manual

1. maa T LA g O 5 l SS Y Y L T _ Spring Housing V L LI Motor Base Carriage C g gt o 0 Minimum 1 2 y ma Zeper l zy S 13mm Gap NL Zo A n an Motor Plate 22 g DPN000995 Adjustment Slot Adjustment Nut 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 Disconnect power to unit Remove drive belts see 12 2 2 Belt Removal Inspect bearing for tightness of set screws and mounting bolts Rotate fan wheel by hand SEAS NES Listen for unusual noise and look for signs of unusual play Blower Bearing Replacement E To maximize performance and reliability of Liebert DS equipment use only SealMaster Reduced Maintenance pillow block bearing with tapered lands race and double lock set screws Contact local Emerson representative to order replacement bearings 2 Properly mount and align bearings on shaft Tighten set screws in proper sequence and to proper torque using a torque wrench in accordance with the manufacturer s instructions Blower Motor Inspect motor at regular intervals Keep motor clean and ventilation openings clear of dust dirt and other debris Blower Motor Lubrication M
2. NOTES including panels X O 1 Drawing not to scale 2 Tolerance on all piping dimensions OECR is 1 2 13mm OECS Field routed alternatives for refrigerant e HUM BLOWER gas and liquid line connection points CPD OUTLET See submittal page DPN001120 for R2 blower outlet and deck dimensional data E TET gt Sad T 11 1316 300mm 73 1854mm TOP VIEW 6 152mm 17 3 16 437mm 17 1 16 434mm 3 7 8 14 114 98mm 362mm FACTORY LOCATION elise DPN001119 403mm FRONT SECTION VIEW Peny LEFT SIDE SECTION VIEW LEFT FRONT PANEL NOT SHOWN X Y Connection Size Opening Point Description inches mm inches mm inches mm R1A Refrigerant Access Top 60 5 8 1539 2 13 16 71 10 1 8 x 4 1 8 257 x 105 R2A Refrigerant Access Bottom 63 1600 13 13 16 351 16 7 16 x 4 418 x 102 L1 Liquid Line System 1 79 3 16 2011 16 3 4 425 1 2 Cu Sweat L2 Liquid Line System 2 76 1 2 1943 16 3 4 425 1 2 Cu Sweat G1 Hot Gas Discharge 1 73 7 8 1876 16 5 8 422 5 8 Cu Sweat G2 Hot Gas Discharge 2 70 1 8 1780 16 5 8 422 5 8 Cu Sweat R3A Refrigerant Access Side 6 x 17 3 16 152 x 437 CGD Condensate Gravity Drain 3 4 FPT CPD Condensate Pump Discharge Opt 56 1 4 1429 11 1 8 283 1 2 Cu Sweat HUM Humidifier Supply Line 56 1 4 1429 9 1 8 233 1 4 Cu Sweat ECS Econ O Co
3. Expansion Solenoid Sight Filter Dryer Valve Valve Glass Sensor Relief valve s supplied TO SECOND with 50Hz EU CE units rated REFRIGERATION maximum 480 PSIG 33 Bar CIRCUIT Factory Piping Components are not supplied by Liebert but are recommended for proper circuit operation and Optional Factory Piping maintenance Field installed at highest point in system on return line to pumps y Service Schrader Access Connections With Valve Core Locate at tops of all risers and any intermediate system high points Note Schematic representation shown This schematic does not imply or define elevations and DPN000896 component location unless specifically noted REV 3 Two refrigeration circuits provided Single refrigeration circuit shown for clarity Field Piping Y Service Schrader Access Connection No Valve Core 85 Piping Schematics Figure 61 Piping schematic GLYCOOL semi hermetic compressor models For systems with drycoolers refer to 12 11 3 Drycooler Settings LIEBERT HEAT REJECTION EXPANSION TANK DRYCOOLER Glycol Aquastat Sensing Bulbs Shutoff Valve LIEBERT DS UNIT ECON O COIL and associated piping 3 Way Chilled Glycol Valve LIQUID EVAPORATOR COIL Thermistor Cylinder Unloader s Service Valve COMPRESSOR Muffler Service Valve DISCHARGE External Equalizer
4. See disassembly and handling instructions in installation manual DPN001256 REV 0 Table 44 Component weights upflow water glycol GLYCOOL 105kW 30 ton all compressor models Dry Weight Approximate Including Panels Ib kg Semi Hermetic Compressor Scroll or Digital Scroll Compressor Component Water Glycol GLYCOOL Dual Cool Water Glycol GLYCOOL Dual Cool Compressor Assembly 1320 599 1320 599 1200 544 1200 544 Blower amp Electric Box Assembly 1080 490 1080 490 1080 490 1080 490 Filter amp Coil Assembly 970 440 1300 590 970 440 1300 590 67 Electrical Connections 7 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 55 for electri cal service entrances into unit A manual electrical disconnect switch should be installed in accordance with local codes and distribu tion system Consult local codes for external disconnect requirements A A gt WARNING Risk of electric shock Can cause injury or death Disconnect local and remote power supplies before working within Use voltmeter to make sure power is turned off before making any electrical connections Before proceeding with installation read all instru
5. 0c ccc cee ee eee eee eens Cabinet and floor planning dimensions downflow air cooled 53 77kW 15 22 ton scroll compressor models Cabinet and floor planning dimensions downflow water glycol GLYCOOL 53 77kW 15 22 ton all compressor models 0 00 ccc cence eee eens Cabinet and floor planning dimensions downflow air cooled 105kW 30 ton all Compressor models tibia BE ae Eh Bay GS ste BE Bn Le alr Oe BEADS LG icy EBM Ig She Se Cabinet and floor planning dimensions downflow water glycol GLYCOOL 105kW 80 ton all compressor models lt a aS ie ee Hap kB A ee AIEEE hcg RR TEA Coal S X Cabinet and floor planning dimensions upflow air cooled 28 42kW 8 12 ton semi hermetic compressor Models 0c ccc eee eee eee eee nee Cabinet and floor planning dimensions upflow air cooled 28 42kW 8 12 ton scroll or digital scroll compressor models 0c ccc cece cece eee eens Cabinet and floor planning dimensions upflow water glycol GLYCOOL 28 42kW 8 12 ton all compressor models 0 ect e nee eeees Cabinet and floor planning dimensions upflow air cooled 53 77kW 15 22 ton semi hermetic compressor Models 0c ccc eee eee eee e tenn nne Cabinet and floor planning dimensions upflow air cooled 53 77kW 15 22 ton scroll or digital scroll compressor Models Cabinet and floor planning dimensions upflow water glycol GLYCOOL 53 77kW 15 22 ton all compressor mo
6. 49 Disassembling the Liebert DS for Transport Figure 40 Component dimensions downflow air cooled 53 77kW 15 22 ton semi hermetic compressor models Y EEE YR KP DAN A W Filter amp Electric Box Assembly 39 991mm G c 76 Blower amp Coil A 1930mm oe Assembled Height 59 7 16 1509mm 37 940mm 26 108 2743mm Assembled Length NOTES Drawing views are simplified with panels removed to show overall dimensions See disassembly and handling instructions in installation manual DPNO00926 Rev 2 Table 30 Component weights downflow air cooled 53 77kW 15 22 ton semi hermetic Dry Weight Approximate Including Panels Ib kg Component Air Cooled Dual Cool Compressor Assembly 970 441 970 441 Filter amp Electric Box Assembly 250 114 250 114 Blower amp Coil Assembly 1230 560 1410 641 Disassembling the Liebert DS for Transport Figure 41 Component dimensions downflow air cooled 53 77kW 15 22 ton scroll digital scroll compressor models Filter amp Electric Box Assembly UNA E N7 IS 39 Compressor Assembly 76 Blower 8 Coil 1930mm Assembly Assembled Height 76 1930mm 59 7 16 1509mm 37 940mm 15 L P 33 L_ 82 2083mm Ho eem LT 97 2464mm Assembled Length NOTES Drawing views are simplified with panels removed to show overall
7. Liebert DS Components and Nomenclature 1 0 LIEBERT DS COMPONENTS AND NOMENCLATURE Figure 1 Downflow model component locations OONDOaABRWDN iCOM Control Display Electric Box Filters Evaporator Coil Motor Blower Fan Pulley Motor Sheave and Belts Compressor Section 10 Infrared Humidifier optional 11 Disconnect optional 12 Condensate Pump optional 13 Smoke Sensor optional 14 Condenser Cleanout Plugs fluid cooled units only 15 Condenser Drain Plugs fluid cooled units only 16 Econ O Coil Valve GLYCOOL Dual Cooling DPNO000958 Rev 1 Liebert DS Components and Nomenclature Figure 2 Upflow model component locations GJW E MM gt Com Control Display Electric Box Filters Evaporator Coil Motor Blower Fan Pulley Motor Sheave and Belts 10 DPN001222 9 Compressor Section Rev 0 10 Infrared Humidifier optional 11 Disconnect optional 12 Condensate Pump optional 13 Smoke Sensor optional 14 Condenser Cleanout Plugs fluid cooled units only 15 Condenser Drain Plugs fluid cooled units only 16 Econ O Coil Valve GLYCOOL Dual Cooling Liebert DS Components and Nomenclature Figure 3 Liebert DS model number nomenclature 1 2 3 4 5 6 7 8 D S 0 3 5 A U A 0 3 I Air Distribution Factory Configuration DS Downflow Standard Number VS Upflow Standard Nominal k
8. 28 Liebert DS Dimensions and Weights Figure 24 Floor stand dimensions downflow 105kW 30 ton models 132 1 2 3366mm with feet 131 3327mm al EZA with feet 33 838mm Supply air discharge opening 4 25mm TYP Gussets supplied on floor stands 12 305 mm tall and greater Optional turning vane shown as front air discharge 7 IA a A E l j Aa Turning vane air outlet Optional turning vane can be field installed in supply air discharge opening for front or rear air discharge NOTE Right side of paneled unit is flush with right side of floorstand All other paneled sides overhang floor stand 1 25mm Leveling feet are provided with 1 1 2 38mm adjustment from nominal height C DPN001059 REV 1 Table 21 Floor stand and floor planning dimensions downflow 105kW 30 ton models Height in mm c D turning vane 9 229 4 111 12 305 7 187 15 381 10 264 18 457 13 340 21 533 16 416 24 610 19 492 29 Liebert DS Dimensions and Weights Figure 25 Blower outlet and deck dimensions upflow 28 42kW 8 12 ton E 72 1829mm or 85 2159mm Ref Blower Outlet gt Blower Outlet Location Top View E Front of Unit Top of Unit Blower Deck a D T 38mm L 76 Ref 1930 mm Front or Rear Throw Air Supply Du
9. Insulated storage receiver one per circuit Head pressure control valve with integral check valve one per circuit Service valve one per circuit Pressure relief valve one per circuit Liquid level sight glass two per circuit Check valve one per circuit NOTE Lee Temp heater pads require a separate continuous electrical source See nameplate on unit for proper voltage Lee Temp Leak Check and Evacuation Procedure Proper leak check and evacuation can be accomplished only with all system solenoid valves open and check valves accounted for NOTE Systems with scroll or digital scroll compressors include a factory installed check valve and an additional downstream Schrader valve with core in the compressor discharge line Proper evacuation of the condenser side of the compressor can be accomplished only using the downstream Schrader valve See piping schematic Figure 59 If unit power is available open the unit liquid line solenoid valves using the evacuation function for System 1 and System 2 in the diagnostic section of the iCOM control If unit power is not available a field supplied 24VAC 75VA power source must be directly connected to each of the unit solenoid valves Attach a jumper hose from the service valve fitting on the outlet of the receiver and the Schrader fitting on the discharge header of the condenser Front seat the service valve approximately two 2 turns For semi hermetic compressors con
10. 15m 7 8 1 2 7 8 1 2 7 8 1 2 7 8 5 8 1 1 8 7 8 1 1 8 7 8 1 3 8 7 8 Hot Hot Hot Hot Hot Hot Hot 100 ft 30m 7 8 5 8 7 8 5 8 7 8 5 8 1 1 8 7 8 1 1 8 7 8 1 1 8 7 8 1 3 8 7 8 150 ft 45m 7 8 5 8 7 8 5 8 718 5 8 1 1 8 7 8 1 1 8 7 8 1 1 8 7 8 1 3 8 1 1 8 4 Step Semi Hermetic and Digital Scroll Models Model 028 035 042 053 070 077 105 Equivalent Gas Liquid Gas Liquid Gas Liquid Gas Liquid Gas Liquid Gas Liquid Gas Liquid Length Line Line Line Line Line Line Line Line Line Line Line Line Line Line 50 ft 15m 3 4 1 2 3 4 1 2 7 8 5 8 7 8 7118 1 1 8 7 8 1 1 8 7 8 1 3 8 7 8 100 ft 30m 3 4 5 8 7 8 5 8 7 8 5 8 1 1 8 7 8 1 1 8 7 8 1 1 8 7 8 1 3 8 7 8 Hot Hot Hot Hot Hot Hot Hot 150 ft 45m 7 8 5 8 7 8 5 8 1 1 8 5 8 1 1 8 7 8 1 1 8 7 8 1 1 8 7 8 1 3 8 1 1 8 Downsize vertical riser one trade size 1 1 8 to 7 8 Table 46 Indoor unit approximate refrigerant charge for R 22 or R 407C System Type Model R 22 Charge R 407C Charge per Circuit lb kg per Circuit Ib kg 028 035 042 6 5 3 0 5 5 2 5 Air Cooled 053 070 077 9 5 5 0 8 0 3 6 105 11 0 5 0 9 5 4 3 028 035 042 13 0 5 9 12 2 5 6 Water Glycol GLYCOOL 053 070 077 18 5 8 4 17 0 7 8 105 24 0 10 9 22 5
11. 24 and 55 Pull conduit and wires into filter and coil assembly section of unit Glycool Dual Cool optional component On units with actuator unplug valve actuator harness at actuator and pull wire harness into electric box Disconnect glycol sensor from control board and pull into filter and coil assembly section of unit Smoke detector optional component For units with smoke detector remove cover on smoke detector Remove plug connector from smoke detector and pull into electric box Remove wires from terminal strip 91 92 93 and route the wires to the smoke detector box Remove the sensing tube from the bottom of the plastic elbow Filter Clog Switch Disconnect both tubes from the filter clog switch Pull both of the tubes into the electric box Close the electric box cover and the accent panel Remove the pull bar that supports the accent panel from left end of unit otherwise it will fall out when the compressor section is removed Evacuate and recover all refrigerant from the unit Air cooled units contain a nitrogen holding charge Water glycol and GLYCOOL units are factory charged with refrigerant Refer to 8 0 Piping for piping guidelines and to the ASHRAE Refrig eration Handbook for general good practice refrigeration piping NOTICE Risk of compressor oil contamination with moisture Emerson recommends front seating the compressor service valves Front seating the valves keeps the nitrogen or refrigerant charge in th
12. 33 Bar REFRIGERATION CIRCUIT NOTE TWO REFRIGERATION CIRCUITS PROVIDED SINGLE REFRIGERATION CIRCUIT SHOWN FOR CLARITY FACTORY PIPING Components are not supplied by FIELD PIPING Liebert but are recommended for A S proper circuit operation and OPTIONAL FACTORY PIPING IE y SERVICE SCHRADER ACCESS CONNECTION NO VALVE CORE Field installed at highest point in system on return line to pumps SERVICE SCHRADER ACCESS CONNECTION WITH VALVE CORE Locate at tops of all risers and any intermediate system high points NOTE SCHEMATIC REPRESENTATION SHOWN THIS SCHEMATIC DOES NOT IMPLY OR DEFINE ELEVATIONS AND DPN001430 COMPONENT LOCATION UNLESS SPECIFICALLY NOTED Rev 0 88 Piping Schematics Figure 64 GLYCOOL with digital scroll compressor models Optional Dual Pump System shown LIEBERT EXPANSION TANK HEAT REJECTION GLYCOL PUMPS Check Valves DRYCOOLER Cee 7 Systems only Glycol Aquastat Gate Valves Sensing i Bulb Ld Hose Air Vents Pressure Port Bib Shut Off Valve typical gt M Flow Switch Supplied with Dual Pump Systems tye Flow Regulating Shut Off Valve Valve RETURN a es LIEBERT DS UNIT ECON O COIL RETURN SUPPLY and associated piping Shut Off Valve X L Shut Off Valve LIQUID 3 Way Chilled Glycol T EVAPORATOR Valve thermistor BOs COIL Big Externa 3 Way Motoriz
13. 790 2 1 2 LV1 Electrical Connection Low Volt 1 7 8 48 28 1 2 724 718 LV2 Electrical Connection Low Volt 1 7 8 48 30 1 4 768 718 LV3 Electrical Connection Low Volt 1 7 8 48 32 813 7 8 Bi Blower Outlet 15 x 15 23 1 8 587 18 1 16 459 18 3 4 x 16 1 16 476 x 408 Blower Outlet 15 x 11 27 3 4 705 18 1 16 459 14 3 4 x 16 1 16 375 x 408 a Blower Outlet 15 x 15 50 3 8 1280 18 1 16 459 18 3 4 x 16 1 16 476 x 408 14 3 4 375 x 16 1 16 408 Field pitch condensate drain line a minimum of 1 8 3 2 mm per foot 305 mm All units contain a factory installed condensate trap Do not trap external to the unit Drain line may contain boiling water Select appropriate drain system materials The drain line must comply with all local codes k Supplied on Dual Cool systems only 4 pipe system 95 Piping Schematics Figure 71 Primary connection locations downflow water glycol GLYCOO L 53 77kW 15 22 ton all compressor models Note Drawing not to scale ig Sl 8 203mm Tolerance on all piping dimensions is 1 2 13mm Front View Section AA Blower Outlet Blower Outlet All dimensions from rear corner of unit including panels E1 E2 Front of Unit 109 ala DPNO000933 Rev 2 X Y Connection Size Opening Point Description inches mm inches mm inches mm W Water Glycol GLYCOO
14. G1 Hot Gas Discharge 1 65 1 2 1664 16 13 16 411 5 8 Cu Sweat G2 Hot Gas Discharge 2 62 7 16 1586 16 13 16 411 5 8 Cu Sweat an Condensate Drain 46 1168 29 1 2 749 3 4 FPT W Optional Pump 46 1168 29 1 2 749 1 2 Cu Sweat HUM Humidifier Supply Line 53 1 2 1359 29 737 1 4 Cu Sweat ECS Econ O Coil Supply 54 7 8 1394 22 9 16 573 1 5 8 Cu Sweat ECR Econ O Coil Return 49 3 8 1254 30 3 4 781 1 5 8 Cu Sweat HS Hot Water Reheat Supply Consult factory HR Hot Water Reheat Return Consult factory E1 Electrical Connection High Volt 55 1 2 1410 31 1 4 794 2 1 2 E2 Electrical Connection High Volt 52 7 16 1332 31 1 4 794 2 1 2 LV1 Electrical Connection Low Volt 2 1 4 57 27 686 718 LV2 Electrical Connection Low Volt 2 1 4 57 29 737 718 LV3 Electrical Connection Low Volt 2 1 4 57 31 787 718 B Blower Outlet 21 15 16 557 18 1 16 459 18 3 4 x 16 1 16 476 x 408 Field pitch condensate drain line a minimum of 1 8 3 2mm per foot 305mm All units contain a factory installed condensate trap Do not trap external to the unit Drain line may contain boiling water Select appropriate drain system materials The drain line must comply with all local codes 92 Piping Schematics Figure 68 Primary connection locations downflow water glycol GLYCOOL 28 42kW 8 12 ton all compressor models Note Drawing not to scale 8 203mm Tolerance on all piping dime
15. Stat Open Temp Set for Mid Differential 8 F 4 4 C Rise to Close Stat Location Factory Setting Optional Setting Aquastat Fans Cabinet Glycol see Notes 1 and 2 GLYCOOL see Note 3 FAOT FA Man rO 35 F 17C AQ2 F2 Main 70 F 21 1 C 40 F 4 4 C AQ3 F3 amp F4 Auxiliary 73 F 22 8 C 43 F 6 1 C AQ4 F5 amp F6 Auxiliary 75 F 23 9 C 45 F 7 2 C Table 60 Aquastat settings eight fan drycoolers Dial Setting Stat Open Temp Set for Mid Differential 8 F 4 4 C Rise to Close Stat Location Factory Setting Optional Setting Aquastat Fans Cabinet Glycol see Notes 1 and 2 GLYCOOL see Note 3 AQ1 F1 Main 65 F 18 3 C 35 F 1 7 C AQ2 F2 Main 70 F 21 1 C 40 F 4 4 C AQ3 F3 amp F4 Auxiliary 73 F 22 8 C 43 F 6 1 C AQ4 F5 amp F6 Auxiliary 75 F 23 9 C 45 F 7 2 C AQ5 F7 8 F8 Main 78 F 25 6 C 48 F 8 9 C NOTE Q 2 All drycoolers are shipped at Factory Setting 2 Factory Setting is used for all glycol applications except single drycooler loops with motor ball valve controls 3 Stats must be field adjusted to Optional Setting for GLYCOOL Dual Cool applications and all single drycooler loops using motor ball valve flow controls 121 HVAC Maintenance Checklist 13 0 HVAC MAINTENANCE CHECKLIST Inspection Date Job Name Indoor Unit Model Indoor Unit Serial Number Condenser Drycooler Model Condenser Drycooler Seri
16. Thermistor must be located out of the supply air stream DPNO000805 Rev 1 90 Piping Schematics Figure 66 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 A is 1 2 13mm Li l2 G1 G2 OOOO 16 7 16 418mm A Front View Section A A Blower Outlet B All dimensions from rear corner of unit including panels 16 1 16 408mm 35 889 mm FRONT QF UNIT 2184mm DPN000803 Rev 2 X Y Connection Size Opening Point Description inches mm inches mm inches mm R Refrigerant Access 63 1600 13 13 16 351 16 7 16 x 4 418 x 102 L1 Liquid Line System 1 79 3 16 2011 16 3 4 425 1 2 Cu Sweat L2 Liquid Line System 2 76 1 2 1943 16 3 4 425 1 2 Cu Sweat G1 Hot Gas Discharge 1 73 7 8 1876 16 3 4 425 5 8 Cu Sweat G2 Hot Gas Discharge 2 70 1 8 1780 16 3 4 425 5 8 Cu Sweat cp Condensate Drain 46 1168 29 1 2 749 3 4 FPT W Optional Pump 46 1168 29 1 2 749 1 2 Cu Sweat HUM Humidifier Supply Line 53 1 2 1359 29 737 1 4 Cu Sweat ECS Econ O Coil Supply 54 7 8 1394 22 9 16 573 1 5 8 Cu Sweat ECR Econ O Coil Return 49 3 8 1254 30 3 4 781 1 5 8 Cu Sweat HS Hot Water Reheat Supply Consult factory HR Hot Water Reheat Return Consult factory E1 Electrical Connection High Volt 55 1 2 1410 31 1 4 79
17. in addition to front service area shown also include 25 635mm on one side of unit for access to rear return filter box See DPNO01196 Table 17 Weights upflow air cooled 105kW 30 ton all 24 610mm DPN001168 REVO Dry Weight Approximate Ib kg Model 105 Semi Hermetic Air Cooled 3000 1361 Semi Hermetic Dual Cool 3330 1510 Scroll or Digital Scroll Air Cooled 2880 1306 Scroll or Digital Scroll Dual Cool 3210 1456 25 Liebert DS Dimensions and Weights Figure 21 Cabinet and floor planning dimensions upflow water glycol GLYCOOL 105kW 30 ton all compressors Alternate Refrigerant Piping Entrance Required for 3 4 condenser cleanout 19mm Alternate Condenser Bezels Fluid Piping Entrance TOP VIEW Minimum required i for blower replacement High Volt Connection s Low Volt Connection s p 132 1 1 2 38mm 3353mm E 24 ae 1 qe Shaded area indicates a 864mm f recommended minimum gt 2 131 clearance for com t ponen 51mm 3327mm access FRONT VIEW Note Front air return unit shown For rear return unit in addition to front service area shown also include 25 635mm on one side of unit for access to rear DPN001169 return filter box See DPN001196 REV 0 Table 18 Weights upflow water glycol GLYCOOL 105kW 30 ton all com
18. maintenance Field installed at highest point in system on return line to pumps Locate at tops of all risers and any intermediate system high points DPNO000898 REV 3 87 Piping Schematics Figure 63 Piping schematic water glycol with digital scroll compressor models CUSTOMER LIEBERT Optional Dual Pump System shown TANK HEAT REJECTION HEAT REJECTION GLYCOL Check Valves on Dual Pump DRYCOOLER T systems only a Pressure COOLING TOWER Glycol Port H AND PUMP Aquastat Gate Valves SYSTEM l Sensing H H BY OTHERS 7 Bulbs Hose Air Vents m Bib Shut Off Valve typical Ll i RI S Flow Switch y 1 AY Pressure Port Supplied with Dual Pump Systems Flow Regulating RETURN SUPPLY Ras Valve Loo RETURN SUPPLY LIEBERT DS UNIT HOT GAS REHEAT reun OY en and associated piping l Optional 3 Way LIQUID Motorized Ball Shut Off Valve z Shut Off Valve Valve 28 42kW Digital Solenoid Valve Sensing Bulb PARAR T T EVAPORATOR See l Hose Bib y Bib C A t Y 2 Way N XN y Valy o COMPRESSOR External Motorized S Equalizer Ball Valve From iCOM DISCHARGE Control PARADENSER CONDENSER To Expansion Solenoid Sight Filter Drier iCOM Valve Valve Glass Pressure Control Relief valve s supplied Transducer with 50 Hz EU CE units rated TO SECOND maximum 480 PSIG
19. reassembled and ready for installation NOTE Emerson recommends using piano jacks when moving this section Remove Blower and Electric Box Assembly 1 Remove the motor access plate from right end of unit This will provide a place to grasp the blower and electric box assembly and move it Remove the coil access plates on the left side of the unit for clearance when brazing the suction and discharge lines 2 Remove the thread cutting bolts holding the unit sections together there are four on the left and four on the right 3 Separate the unit sections with caution NOTICE Risk of improper handling May cause damage to the Liebert DS The blower and electric box assembly should be moved forward and set on the floor Emerson recommends using four people to remove this section The motor end will be significantly heavier than the other end The filter and coil assembly must remain upright The coil is not secured to the filter and coil assembly Secure the coil to the bottom section with straps or a similar means before moving the section 4 Move each section of the Liebert DS to the installation location 57 Disassembling the Liebert DS for Transport 6 6 6 7 Reassembly Upflow Unit 1 13 14 15 16 17 18 Reattach the top section using thread cutting bolts there are four on each side Torque the bolts to 225 in lb 25Nm Reinstall the motor access plate Do not replace the left
20. suppression system Prepare and take appropriate steps to manage this possibility Activating reheat during initial startup may burn off particulate from electric reheat elements Before beginning initial startup checks make certain that unit was installed according to the instructions in this manual All exterior panels must be in place Confirm that all items on 10 0 Checklist for Completed Installation have been done Locate Liebert DS Warranty Inspection Check Sheet in unit electric panel Document number SAFM 8542 29 Complete Liebert DS Warranty Inspection Check Sheet during startup Document number SAFM 8542 29 This information must be completed and forwarded to Emerson to vali date warranty Forward the completed Liebert DS Warranty Inspection Check Sheet to your local Emerson sales office Contact your local Emerson sales representative or Liebert Air Product Support if you have any questions or problems during unit startup and commissioning Local Emerson Sales offices and Liebert Air Product Support contacts can be found at www liebert com or by calling 1 800 LIEBERT Liebert DS Warranty startup procedure includes the following steps These steps must be completed to validate warranty 108 Initial Startup Checks and Commissioning Procedure for Warranty Inspection 11 1 Information for Warranty Inspection Remove Power From Unit Disconnect Complete the following items on the warranty inspe
21. 0 0c eee 39 5 3 Semi Hermetic Compressor Spring Isolation System 0 000 eee eee eee 41 5 4 Placing the Unit on a Floor Stand cc eet ennes 41 6 0 DISASSEMBLING THE LIEBERT DS FOR TRANSPORT lt lt lt lt lt lt 00 eee eee ene eeeeaes 42 6 1 Required EQUIPMENT AS A OE A OG a E 42 6 2 Disassembly Downflow Units 42 6 2 1 Remove the Compressor Assembly 44 6 2 2 Remove the Filter and Electric Box Assembly 44 6 3 Reassembly Downflow Units oo 45 6 3 1 Reconnecting Piping Charging and Replacing Panels o o o ooooooooooooo o 45 6 4 Reassembly Checklist a WS ea ee Bee PARES TEE TARA SERIE ORAS 46 6 5 Disassembly Upflow Units eee ees 56 6 5 1 Remove Compressor Assembly 57 6 5 2 Remove Blower and Electric Box Assembly 57 6 6 Reassembly Upflow Unit 58 6 7 Reassembly Checklist ccc eee nen beeen eens 58 7 0 7 1 8 0 8 1 8 2 8 3 9 0 10 0 10 1 10 2 10 3 10 4 11 0 11 1 11 2 11 3 12 0 12 1 12 2 12 3 12 4 ELECTRICAL CONNECTIONS lt atea oh oie ae be eet a eee ade 68 Electrical Field Connection Descriptions 0 c ccc cece cece ees 70 PIPING 5 1 7 S A Ae GE SS ERAS ea RE 72 Fluid Connect fe aerate a Gar Len ah Bias lee Oa in aoe 72 8 1 1 Condensate Piping Field Installed 0 0 ccc tenets 72 8 1 2 Humidifier Supply Water Optional Infrared 0 0 0 0 eens 74 8 1 3
22. 10 3 76 Piping Table 47 Line charges refrigerant per 100 ft 30m of Type L copper tube O D Liquid Line Ib kg 4 2 7 3 3 3 5 8 11 7 5 3 7 8 24 4 11 1 1 1 8 41 6 18 9 Table 48 Outdoor condenser approximate refrigerant charge Ib kg per circuit Fan Lee Temp Model Speed includes receiver 165 523 27 123 205 7 3 2 38 17 2 251 10 4 6 38 17 20 308 11 5 0 58 26 3 415 15 6 8 75 34 0 510 30 13 6 149 67 6 143 17 8 64 29 214 23 10 81 37 286 29 13 98 44 409 36 16 129 59 477 24 11 80 36 572 57 26 196 89 77 Piping 8 3 8 3 1 Dehydration Leak Test and Charging Procedures for R 407C and R 22 Air Cooled Condenser with Fan Speed Head Pressure Control System The Fan Speed Control system uses a pressure activated electronic fan speed control system and remotely located thermostat s to ensure operation at ambient temperatures as low as 0 F 18 C Fan Speed Control Piping Two discharge lines and two liquid lines must be field installed between the indoor unit and the out door condenser See Figures 57 and 59 for details Fan Speed Control Materials Supplied e Built in pre wired condenser control box Air Cooled condenser Piping access cover to be reinstalled when piping is complete Bolts four per leg 3 8 x 5 8 Terminal block for two wi
23. 2 Unpacking the Unit Remove outer packaging when ready to install the unit Remove the exterior stretch wrap packaging material from around the unit exposing the protec tive corner and side packaging planks Remove the corner and side packaging planks from the unit exposing the bag over the unit Remove the bag from the unit when ready to remove the skid and install the unit Figure 31 Removing packaging 181659P1 Rev 5 36 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 A 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 34 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 2 Insert the tines of the forklift completely under the base of the Liebert DS A WARNING Risk of improper moving Can cause equipment damage injury or death Ensure that the tines are level not angled up or down The tines must be at a height that will allow proper clearance under the unit Ensure the tines extend beyond the opposite side of the unit 3 Remove the lag bolts from each bracket holding the Liebert DS to the skid 4 Lift the unit off the skid no more than
24. 2 gt Belt Removal a A SE Eg hw a iw Sa ee EA 113 12 2 3 Belt Installation and TensionmMg suuna sasssa aranan eee eee eee enn 113 Hundido tn a Di latte 115 12 31 Infrared H umiditier i ur td dd oaks 115 12 3 2 Cleaning Humidifier Pan and Float Switch 115 12 3 3 Changing Humidifier Lamps 000000 eee teen eens 116 Condensate Drain and Condensate Pump Systems 0 cc ccc cece eens 116 12 431 Condensate Dra esses dois aah ii Roe hee RIA RAS ey hla Tea BR Bios E ia 116 12 4 2 Condensate PUMP zie oes TA Pie TTT 116 12 5 12 6 12 7 12 8 12 9 12 10 12 11 13 0 Air Cooled Condenser and Drycoolers ccc ccc cece cee eee eee eee ees 117 Reheat Electric Reheat Three Stage and SCRI 117 COmipressOr ce i ches he ti O ed dy in AE a Be oN 2 L CoN A AO 117 T2371 Compressor Outs a A A A A Si 117 12 7 2 Semi Hermetic Compressor 117 12 7 3 Scroll and Digital Scroll Compressors 0c eee een nas 117 Compressor Replacement 0 ete eee nent tenn ees 118 12 8 1 Compressor Motor Burnout 118 12 8 2 Digital Compressor Unloading Solenold S 00 cee eens 118 12 8 3 Compressor Replacement Procedure 118 Facility Fluid and Piping Maintenance 0 0 cc eee eens 118 Paradenser Water Cooled Condenser 0 0 cece eee eee nes 119 12 10 1 Cleaning Instructions 119 Water Glycol Control Valves 00 ccc ee ee een nes 119 12 11 1 Regulating Valves Semi He
25. 28 42kW 8 12 ton all Component weights downflow air cooled 53 77kW 15 22 ton semi hermetic Component weights downflow air cooled 53 77kW 15 22 ton scroll digital scroll Component weights downflow water glycol GLYCOOL 53 77kW 15 22 ton all Component weights downflow air cooled 105kW 30 ton semi hermetic compressors Component weights downflow air cooled 105kW 80 ton scroll compressor models Component weights downflow water glycol GLYCOOL 105kW 30 ton all compressor Model tin tye A este eck viata Bowe Walp A aoe eth op cab Rowe ade Red Boies Component weights upflow air cooled 28 42kW 8 12 ton semi hermetic compressor Models eet eae aa A ai r R ae ee E me A ds Component weights upflow air cooled 28 42kW 8 12 ton scroll digital scroll compressor TDS e a A eh ae Sead let at N SE SA cea tes Alen d N ORA Component weights upflow water glycol GLYCOOL 28 42kW 8 12 ton all compressor models eho Ki oie ieee fies e o he Sera Component weights upflow air cooled 53 77kw 15 22 ton semi hermetic compressor MOC CLS Ac cutee aaa heave Minn E on Ato aoe atte in Soest tensed etn here alsin Ace lola R cad Component weights upflow air cooled 53 77kw 15 22 ton scroll digital scroll Compressor models vitara bb Es eats OS HERS Co Rh eee wie th ea ate eS Component weights upflow water glycol GLYCOOL 53 77kW 15 22 ton all compres
26. 3 DOWNFLOW LOW VOLT SECTION Note Typical orientation of components shown Component location varies by option and unit size 07 21 5 O CAUTION m AA O Q AI DIO l O DIOIO DIO DIO AI UPFLOW Risk of broken or shorted low volt 88189 75 76 94 95 96 97 91 92 93 80 81 11 12 77 78 wag aane low oe DAO OTOIOTOTOTOTOIOTIOT OIIO must be routed with loop as shown to allow electric box to swing A B Boa 00 000 e ES SS SSS SSS Ss DUDO ANNO SL 371 38 241 801 51155158 70 74 72 C CIOIOIOICICIOIOIOIOIOIC Refer to 7 1 Electrical Field Connection Descriptions for keys to numbered items Note Refer to DPN000807 for descriptions of numbered callouts POINT OF HINGED LOW VOLT ELECTRIC BOX DPNO00806 Rev 3 UPFLOW LOW VOLT SECTION 69 Electrical Connections 7 1 Electrical Field Connection Descriptions Standard Electrical Connections 1 2 bs 10 11 Primary high voltage entrance 2 1 2 64mm 1 3 4 44mm 1 3 8 85mm diameter concentric knockouts located in bottom of box Secondary high voltage entrance 2 1 2 64mm 1 3 4 44mm 1 3 8 835mm diameter concentric knockouts located in top of box Primary low voltage entrance Three 1 1 8 28mm diameter knockouts in bottom of unit Secondary low voltage entrance Three 1 1 8 28mm diameter knockouts in top of box Three phase electrical service Terminals are on high voltage terminal
27. 373mm 1484mm x Rear Throw 15 7 8 14 11 16 11 5 8 31 3 8 14 11 16 58 7 16 404mm 373mm 295mm 797mm 373mm 1484mm 31 Liebert DS Dimensions and Weights Figure 27 Blower outlet and deck dimensions upflow 105kW 30ton 132 3353mm Blower Outlets K B gt Bo kB carers of Unit Blower Outlet Location TOP VIEW Duct Flanges Not Provided Top of Unit Blower Deck D _ gt 1 1 2 38mm 76 1930mm Ref y DPNO01192 Front or Rear Throw Air Supply Rev 0 Table 24 Blower outlet and deck dimensions upflow 105kW 30ton Dimensions in mm Models Blower SUPPLY A B C D E F G Front 15 7 8 14 11 16 2 1 8 25 5 8 30 3 4 54 1 2 78 1 8 105kW aau Throw 404 373 54 651 781 1384 1984 x 30 ton Rear 15 7 8 14 11 16 11 5 8 25 5 8 30 3 4 54 1 2 78 1 8 Throw 404 373 295 651 781 1384 1984 32 Liebert DS Dimensions and Weights Figure 28 Rear return filter box dimensions Filter Access Door 7 15 16 202mm 971mm Duct Size Filter Access 89mm D Duct Size A B C NOTES 1 Filters can be accessed from either side 2 25 635mm minimum clearance provided on one side for filter access DPN001196 3 Filter boxes are shipped flat and must be field assembled Rev 0 Table 25 Rear return filter box dimensions Dimens
28. 6 152mm and remove the skid Figure 32 Remove the unit from the skid 181659P1 Rev 5 Equipment Inspection and Handling 5 2 2 Moving the Unit to the Installation Location with Piano Jacks 1 2 3 4 With the Liebert DS elevated place two piano jacks into position one at either end of the unit Lower the unit to a height suitable for the piano jacks and place protective material between the Liebert DS and the piano jacks Secure the unit to the piano jacks and remove the forklift Use the piano jacks to move the unit for installation Figure 33 Moving the unit to its installation location 181659P1 Rev 5 5 2 3 Removing Piano Jacks 1 2 3 Lower the unit as much as the piano jacks will allow Undo all strapping holding the piano jacks to the unit Use a pry bar or similar device to lift one end of the unit just enough to allow removal of the piano jack from that end Repeat Step 3 to remove the piano jack on the opposite end Remove all material that might have been used to protect the unit from the piano jacks and strapping Equipment Inspection and Handling 5 2 4 Removing Liebert DS from Skid Using Rigging A WARNING Risk of improper moving Can cause equipment damage injury or death Use the center of gravity indicators see Figure 34 on the unit to determine the position of the slings The center of gravity varies depending on the unit size and selected options The f
29. DRYCOOLER Glycol Glycol Aquastat Sensing Bulbs Hose Bib Shutoff Valve LIEBERT DS UNIT and associated piping LIQUID ECON O COIL 3 Way Chilled Glycol Valve EVAPORATOR COIL 3 Way Chilled Glycol Valve Valve COMPRESSOR Ye External DISCHARGE Paradenser Condenser Expansion Solenoid Sight Filter Dryer EXPANSION TANK Shutoff Valve Thermistor Optional Dual Pump System shown GLYCOL PUMPS Check Valves T i on Dual Pump Systems only i Pressure Port N Air Vents typical Cer Port KE Switch G with Dual H iro Systems 2 Flow Regulatng be RETURN m n RETURN SUPPLY 2 Shuto Valve L E Kl Shutoff veel L Hose a l Bib 3 Way Regulating Valve Valve Valve Glass Relief valve s supplied with 50 Hz EU CE units rated maximum 480 PSIG 33 Bar To Second Refrigeration Circuit NOTE Two refrigeration circuits provided Single refrigeration circuit shown for clarity FIELD PIPING FACTORY PIPING V SERVICE SCHRADER ACCESS CONNECTION WITH VALVE CORE y SERVICE SCHRADER ACCESS CONNECTION NO VALVE CORE NOTE Schematic representation shown This schematic does not imply or define elevations and component location unless specifically noted Components are not supplied by Liebert but are recommended for proper circuit operation and
30. Dimensions and Weights Figure 10 Cabinet and floor planning dimensions downflow air cooled 53 77kW 15 22 ton scroll compressor models Secondary Refrigerant Piping Entrance Notes Filters are accessible 80 Opening only through top of unit 2032mm Downflow electrical connections can be made from top or bottom of unit 24 5 8 625mm Opening me er 19mm Bezels Minimum required Secondary Entrance Top View Secondary Entrance for filter replacement High Volt Connection s Low Volt Connections 98 2489mm 76 1930mm H 2 97 Shaded area indicates a 51mm 2464mm recommended minimum clearance for component Front View access DPN000925 Rev 1 Table 7 Weights for downflow air cooled 53 77kW 15 22 ton scroll compressor models Dry Weight Ib kg Approximate Model No 053 070 077 Air Cooled 1920 873 1970 896 2020 919 Dual Cool 2100 955 2150 978 2200 1000 15 Liebert DS Dimensions and Weights Figure 11 Cabinet and floor planning dimensions downflow water glycol GLYCOOL 53 77kW 15 22 ton all compressor models Condenser Cleanout Access 80 2032mm Opening ISSO gt gt 555 Air Inlet Opening e 3 4 20mm Bezels Notes Filters are accessible 24 5 8 625mm through top of unit only Opening Downflow electrical connections can be made from top or bottom of unit Secondary Condens
31. Electrical Connection High Volt 98 1 8 2492 31 1 4 794 2 1 2 E2 Electrical Connection High Volt 91 2311 31 1 4 794 2 1 2 LV1 Electrical Connection Low Volt 2 51 28 1 4 718 718 LV2 Electrical Connection Low Volt 2 51 30 1 4 768 7 8 LV3 Electrical Connection Low Volt 2 51 32 813 718 B1 Blower Outlet 27 7 8 708 18 457 14 1 2 x 15 11 16 368 x 398 B2 Blower Outlet 52 1 16 1322 18 457 14 1 2 x 15 11 16 368 x 398 B3 Blower Outlet 76 1 4 1937 18 457 14 1 2 x 15 11 16 368 x 398 Field pitch condensate drain line a minimum of 1 8 3 2 mm per foot 305 mm All units contain a factory installed condensate trap Do not trap external to the unit Drain line may contain boiling water Select appropriate drain system materials The drain line must comply with all local codes Supplied on Dual Cool systems only 4 pipe system 97 Piping Schematics Figure 73 Primary connection locations downflow air cooled 105kW 30 ton all compressor models A A Front View All dimensions from rear corner of unit including panels Note Drawing not to scale Tolerance on all piping dimensions is 1 2 13mm 8 203mm 15 7 8 Blower ca 403mm Outlet PEN 1 2 ba an 368mm ECS ECR Typ OoOo CD Section AA Blower Outlet HUM 1 E2 Front of Unit 131 AOO 3327mm DPN001015 Rev 2 X Y Connection
32. PARADENSER CONDENSER 3 Way Regulating Valve Expansion Solenoid Sight Filter Optional Dual Pump System shown GLYCOL Check Valves Pressure on Dual Pump Port Systems only Gate Valves 1 at Air Vents typical Pressure Port Flow Switch Supplied with Dual Pump Systems Flow Regulating N Valve 1 T O E T R Shutoff Valve X E a 1 Shutoff Valve se ib H B Valve Valve Glass Dryer Sensor Relief valve s supplied with 50Hz EU CE units rated maximum 480 PSIG 33 Bar TO SECOND REFRIGERATION CIRCUIT Factory Piping Field Piping Service Schrader Access Connection No Valve Core Service Schrader Access Connections With Valve Core Notes Schematic representation shown This schematic does not imply or define elevations and component location unless specifically noted Two refrigeration circuits provided Single refrigeration circuit shown for clarity Components are not supplied by Liebert but are recommended for proper circuit operation and maintenance Field installed at highest point in system on return line to pumps Locate at tops of all risers and any intermediate system high points DPN000897 Rev 02 86 Piping Schematics Figure 62 Piping schematic GLYCOOL with scroll compressor models For systems with drycoolers refer to 12 11 3 Drycooler Settings LIEBERT HEAT REJECTION
33. Requirements of Systems Using Water or Glycol 0 0 0 00 ccc eens 74 Refrigeration Pipine ii A IA AA Gears Pea EE PR REA 75 8 2 1 Piping Guidelines Air Cooled Units 76 Dehydration Leak Test and Charging Procedures for R 407C and R 22 78 8 3 1 Air Cooled Condenser with Fan Speed Head Pressure Control System 78 8 3 2 Air Cooled Condenser with Lee Temp Flooded Condenser Head Pressure Control System 80 PIPING SCHEMATICS ere e a he Guia N SR AG one tae AA 82 CHECKLIST FOR COMPLETED INSTALLATION 00 0 cece cece ence eee eens 107 Moving and Placing Equipment 107 Electric A l ae eae eee AAA 107 PAPI 998 A WSR OEE Sa Red ERG MR EAs R R Oa Be es on AT S 107 UE ce o A os Bae Bi on A Fa AS Le cee A A rer IN UD 107 INITIAL STARTUP CHECKS AND COMMISSIONING PROCEDURE FOR WARRANTY INSPECTION 108 Information for Warranty Inspection Remove Power From Unit Disconnect 109 Startup Checks Inspection With Panels Removed and Disconnect Off 109 Commissioning Procedure With Panels On 0 0 0 ec eee een 110 MAN NAN CE Arat ATR sce es iio 111 TGR ahs A BOR Ges BAI ae BR BGA ET US NRT oN NR SENS 111 12 1 1 Filter Replacement Procedure Downflow Units 000 0 ccc cece eee 112 12 1 2 Filter Replacement Procedure Upflow Units 00 0 eens 112 Blower Drive System lt Rr TER R R RR eee eee nent nent tens 112 12 21 UW pflow Motor Access 5 A haunts le oiled oa Wesco Sina 113 12 2
34. Size Opening Point Description inches mm inches mm inches mm W Water Glycol GLYCOOL Access 125 15 16 3199 9 229 3 1 2 x 8 89 x 203 WS Water Glycol GLYCOOL Supply 127 7 8 3248 10 1 16 256 2 1 8 Cu Sweat WR _ Water Glycol GLYCOOL Return 127 7 8 3248 13 1 4 337 2 1 8 Cu Sweat CD Condensate Drain 83 13 16 2129 30 762 3 4 FPT W Optional Pump 83 13 16 2129 30 762 1 2 Cu Sweat HUM Humidifier Supply Line 102 3 4 2610 31 3 4 806 1 4 Cu Sweat ECS Econ O Coil Supply 101 7 8 2588 29 737 2 5 8 Cu Sweat ECR Econ O Coil Return 94 9 16 2402 29 737 2 5 8 Cu Sweat HS Hot Water Reheat Supply Consult Factory HR Hot Water Reheat Return Consult Factory E1 Electrical Connection High Volt 98 1 4 2496 30 762 2 1 2 E2 Electrical Connection High Volt 88 7 16 2246 30 762 2 1 2 LV1 Electrical Connection Low Volt 2 51 27 1 2 796 718 LV2 Electrical Connection Low Volt 2 51 30 1 4 768 718 LV3 Electrical Connection Low Volt 2 51 32 813 718 B1 Blower Outlet 28 1 4 718 18 457 14 1 2 x 15 7 8 368 x 403 B2 Blower Outlet 52 1321 18 457 14 1 2 x 15 7 8 368 x 403 B3 Blower Outlet 75 11 16 1922 18 457 14 1 2 x 15 7 8 368 x 403 Field pitch condensate drain line a minimum of 1 8 3 2 mm per foot 305 mm All units contain a factory installed condensate trap Do not trap external to the unit Drain line may contain boiling water Select appropriate drain system mater
35. The raised floor must provide 7 1 2 191mm of clearance Ensure that there is adequate clearance above the unit for service such as replacing filters Optional plenums are available for downflow unit ducting Figure 4 Downflow unit ducting and plenum ducting Provided Condenser Access water glycol and GLYCOOL units only Field Fabricated Ductwork Field Service Access for filter replacement minimum height of 12 305mm minimum distance from unit 2 51mm Field Fabricated Ductwork Provided Service Access Door for filter replacement At Optional DIRECT UNIT DUCTING Liebert Plenum Provided Condenser Access water glycol and GLYCOOL units only Liebert Plenum Refer to plenum installation sheet 186582P 1 included in the plenum package PLENUM DUCTING Pre Installation Guidelines 3 3 Air Distribution Upflow Units Various configurations are available Front return Rear return Top front supply gt 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 Refer to the rear return instal lation sheet 187230P1 inside the rear return
36. VSWR DS VSWG 2286x1067x2083 114x42x82 3454x 1067x2083 DS VSHS DS VSHD DS VSHR DS VSHG 2896 x 1067 x2083 DS VSWU DS VSWM DS VSHU DS VSHM Table 2 Shipping weights approximate kg Cooling Compressor Downflow Unit Weight Ib Upflow Unit Weight Ib Size Type Type Domestic Export Domestic Export o ome 71 1918 2088 1968 2138 Scroll 1608 1778 1658 1828 L Semi 2068 2238 2118 2288 8 12 Ton ADS Scroll 1758 1928 1808 1978 WIG Semi 2068 2238 2118 2288 Scroll 1918 2088 1968 2138 GIC Semi 2218 2388 2268 2438 Scroll 2068 2238 2118 2288 Air Semi 2512 2712 2512 2712 Scroll 2070 2260 2220 2410 Air DIC Semi 2692 2892 2692 2892 45 Ton Scroll 2250 2440 2400 2590 WIG Semi 2812 3012 2812 3012 Scroll 2382 2582 2532 2732 air Semi 2992 3192 2992 3192 Scroll 2562 2762 2712 2912 Air Semi 2562 2762 2662 2862 Scroll 2120 2310 2220 2410 Semi 2742 942 2842 3042 20 Ton AIER Scroll 2300 2490 2400 2590 WIG Semi 2862 3062 2962 3162 Scroll 2432 2632 2532 2732 GIC Semi 3042 3242 3142 3342 Scroll 2612 2812 2712 2912 Air Semi 2612 2812 2662 2862 Scroll 2170 2360 2220 2410 Air DIC Semi 2792 2992 2842 3042 22 Ton Scroll 2350 2540 2400 2590 WIG Semi 2912 3112 2962 3162 Scroll 2470 2660 2532 2732 air Semi 3092 3292 3142 3342 Scroll 2650 2840 2712 2912 Air Semi 3223 3443 3183 3403 Scroll 3103 3323 3063 3283 l Semi 3583 3803 3513 3733 30 Ton ADG Scroll 3463 3683 3393 3613 W G Semi 3593 3813 3553 3773 Scroll 3473 3693 3433 3653 GIC Semi 3953 4173 3883 4103 S
37. amp Coil Assembly 1230 560 1410 641 1230 560 1410 641 Disassembling the Liebert DS for Transport Figure 43 Component dimensions downflow air cooled 105kW 30 ton semi hermetic compressor models Filter and Electric Box Assembly 41 11 16 1059mm 76 1930mm Assembled Height 59 7 16 1510mm A Eo al 26 IL 105 660mm 2667mm eae 131 3327mm DPN001057 Assembled Length Rev 0 Table 33 Component weights downflow air cooled 105kW 30 ton semi hermetic compressors Dry Weight Ib kg Approximate Includes Panels Component Air Cooled Dual Cool Compressor Assembly 950 432 950 432 Filter amp Electric Box Assembly 270 123 270 123 Blower amp Coil Assembly 1820 827 2180 991 53 Disassembling the Liebert DS for Transport Figure 44 Component dimensions downflow air cooled 105kW 30 ton scroll compressor models Filter amp Electric Box Assembly K 41 11 16 zg 1059mm 76 991mm 1930mm Assembled Height 59 7 16 1510mm 26 J J 105 660mm 2667mm l 131 3327mm Sae elas Assembled Length NOTES Drawing views are simplified with panels removed to show overall dimensions See disassembly and handling instructions in installation manual Table 34 Component weights downflow air cooled 105kW 30 ton scroll compressor
38. and coil must be replaced Compres sor 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 Compressor Replacement Procedure 1 Disconnect power and follow all warnings at front of this manual Attach suction and discharge gauges to access fittings Front seat service valves to isolate the compressor Reclaim charge from compressor Ap wN Remove marked pressure transducer and discharge pressure switch Disconnect all electrical connections Detach service valves from compressor Remove failed compressor If required follow compressor manufacturer s suggested clean out procedures Install replacement compressor and make all connections Replace gaskets or seals on service valves Replace unloading solenoid 9 Evacuate charge and operate per 8 3 Dehydration Leak Test and Charging Procedures for R 407C and R 22 10 Semi hermetic only see 5 3 Semi Hermetic Compressor Spring Isolation System for compressor spring adjustment A CAUTION Risk of improper component reinstallation Can cause equipment damage 90 O Identify and mark location of suction pressure transducer and discharge pressure switch These devices look similar and they must be reinstalled in thei
39. block disregard if unit has optional disconnect switch Three phase service not by Emerson Earth ground Terminal for field supplied earth grounding wire Remote unit shutdown Replace existing jumper between terminals 37 and 38 with field supplied normally closed switch having a minimum 75VA 24VAC rating Use field supplied Class 1 wiring Customer alarm inputs Terminals for field supplied normally open contacts having a minimum 75VA 24VAC rating between terminals 24 and 50 51 55 56 Use field supplied Class 1 wiring Terminal availability varies by unit options Liebert SiteScan Terminals 77 and 78 for a two wire twisted pair communication cable available from Emerson to optional Liebert SiteScan Common alarm On any alarm normally open dry contact is closed across terminals 75 and 76 for remote indication 1A 24VAC max load Use Class 1 field supplied wiring Heat rejection interlock On any call for compressor operation normally open dry contact is closed across terminals 70 and 71 to heat rejection equipment 1A 24VAC max load Use Class 1 field supplied wiring Optional Electrical Connections 12 13 14 15 16 17 18 19 Factory installed disconnect switch Secondary disconnect switch and earth ground Three phase electrical service Terminals are on top of disconnect switch Three phase service not by Emerson Smoke sensor alarm Factory wired dry contacts from smoke sensor
40. discharge amp liquid lines to extend above base of coil by a minimum of 7 1 2 190mm Liquid Return ee N Head Pressure P Lee Temp Receiver K Control Valve Fusible i E A INE i Condenser Coil Condenser Coil 1 Fan Speed Lee Temp W gt nee ie oe Hot Gas Lee Temp Discharge Required with Digital Scrol r l s Te every l l 25ft 7 6m 28 42kW Digital Solenoid Valva lata Evaporator Coil S 53 70kW Digital C S orn Solenoid Valve l l hd ree Field installed relief valve s required ield jef valv ul Valve External i Valve Equali for 50 Hz EU CE units rated Compressor alee maximum 480 PSIG 33 Bar l Check Isolation LH g valve S Hot Gas Discharge Expansion Solenoid Sight Glass Filter Dryer Liquid Return Isolation Valve Valve valve Refrigerant Piping Components are not supplied by Liebert but are recommended for proper circuit operation and maintenance Field Piping Y Service Schrader Access Connection No Valve Core Service Schrader Access Connection With Valve Core Note Schematic representation shown Do not use for specific connection locations DPNO0O00798 Two refrigeration circuits provided Single refrigeration circuit shown for clarity Rev 2 83 Piping Schematics Figure 59 Piping schematic water glycol semi hermetic compressor models For systems with drycooler
41. installed relief valve One or more additional pressure relief valves are required downstream of any and all field installed isolation valves as shown in Figures 57 and 58 Do not isolate any refrigerant circuits from overpressurization protection For systems requiring EU CE compliance 50Hz the pressure relief valve must be CE certified to the EU Pressure Equipment Directive by an EU Notified Body CAUTION Risk of oil contamination with water Can cause equipment damage Some Liebert DS Systems require the use of POE polyolester oil See 12 7 1 Compressor Oil for requirements POE oil absorbs water at a much faster rate when exposed to air than previously used oils Because water is the enemy of a reliable refrigeration system extreme care must be used when opening systems during installation or service If water is absorbed into the POE oil it will not be easily removed and will not be removed through the normal evacuation process If the oil is too wet it may require an oil change POE oils also have a property that makes them act as a solvent in a refrigeration system Maintaining system cleanliness is extremely important because the oil will tend to bring any foreign matter back to the compressor NOTE A pressure relief valve is provided with Liebert Lee Temp condensers A fusible plug is provided on Liebert Fan Speed Control condensers The Liebert indoor cooling unit has a factory installed high pressure safety switch
42. models Dry Weight Approximate Including Panels Ib kg Component Air Cooled Dual Cool Compressor Assembly 830 377 830 377 Filter amp Electric Box Assembly 270 123 270 123 Blower amp Coil Assembly 1820 827 2180 991 Disassembling the Liebert DS for Transport Figure 45 Component dimensions downflow water glycol GLYCOOL 105kW 30 ton all compressor models Filter amp Electric Box Assembly 41 11 16 1059mm 76 1930mm Assembled Height 76 1930mm 59 7 16 1510mm 33 26 fe 105 2667mm e38mm 660mm gt DPN001060 131 3327mm Rev 0 Assembled Length NOTES Drawing views are simplified with panels removed to show overall dimensions See disassembly and handling instructions in installation manual Table 35 Component weights downflow water glycol GLYCOOL 105kW 30 ton all compressor models Dry Weight Approximate Including Panels Ib kg Semi Hermetic Compressor Scroll Compressor Component Water Glycol GLYCOOL Dual Cool Water Glycol GLYCOOL Dual Cool Compressor Assembly 1320 600 1320 600 1200 545 1200 545 Filter amp Electric Box Assembly 270 123 270 123 270 123 270 123 Blower amp Coil Assembly 1820 827 2180 991 1820 827 2180 991 55 Disassembling the Liebert DS for Transport 6 5 Disassembly Upflow Units Fo
43. or underside damage NOTICE Risk of damage from forklift Keep tines of the forklift level and at a height suitable to fit below the skid and or unit to prevent exterior and or underside damage NOTICE Risk of improper storage Keep the Liebert DS upright indoors and protected from dampness freezing temperatures and contact damage 35 Equipment Inspection and Handling Figure 30 Equipment recommended for handling Liebert DS T V Spreader Bars and Slings Pallet f Jack Piano Jacks 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 Forklift 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 When moving the packaged Liebert DS with a forklift lift the unit from the designated heavy side of the unit no higher than 6 152mm off the ground Ensure that the opposite end still touches the ground The unit is to be pulled by the forklift If the unit must be lifted higher than 6 152mm great care must be exercised Personnel who are not directly involved in moving the unit must be kept 20 5m or farther from the lift point of the unit Always refer to the location of the center of gravity indicators when lifting the Liebert DS see Figure 34 5
44. similar to the pressure adjustment on a water regulating valve Changing the setpoint offset will adjust the pressure thresh olds for both circuits Units are factory set at a 30 PSI 207 kPa setpoint offset 30 PSI 207 kPa above minimum This results in a 220 PSIA 1517 kPa lower threshold and a 255 PSIA 1758 kPa upper threshold pressure Startup The setpoint offset is adjusted to the minimum value during startup then transitions to the set value once the compressor reaches normal operating pressures Due to the control dead band it is possible for each circuit to stabilize at different pressures within the dead band Additionally changes in fluid temperature could cause pressure changes that do not result in valve movement within the dead band Fan cycling stats should be set to prevent continuous fluid temperature swings greater than 10 F 5 6 C see 12 11 3 Drycooler Settings Location The motorized ball valves are located in the condenser fluid return line Three way valves are piped in a mixing arrangement with the common port at the valve outlet Manual Control The valve can be manually set by disconnecting AC power depressing the manual override button on the valve actuator and adjusting the valve position with the handle You also have the option to control the MBV s through the Service menu using manual mode to override the normal control 120 Maintenance 12 11 3Drycooler Settings Applications with
45. the liquid line sight glass becomes clear Then add one additional pound 2 2kg of refrigerant NOTE A digital scroll compressor will have a clear sight glass only when operating at 100 capacity T When operating below 100 the sight glass may show bubbles with each 15 second unloading cycle As head pressure builds the fan speed controlled condenser fan begins rotating The fan will run at full speed when sufficient head pressure is developed fan starts to rotate at 190 psig 1310 KPA and is full speed at 250 psig 1724 KPA 79 Piping 8 3 2 Air Cooled Condenser with Lee Temp Flooded Condenser Head Pressure Control System The Lee Temp system consists of a modulating type head pressure control valve and insulated receiv ers with heater pads to ensure operation at ambient temperatures as low as 30 F 34 4 C Lee Temp Piping Two discharge lines and two liquid lines must be field installed between the indoor unit and the out door condenser See Figures 57 and 59 for details Lee Temp Controlled Materials Supplied Built in pre wired condenser control box Air Cooled condenser Piping access cover to be reinstalled when piping is complete Bolts four per leg 3 8 x 5 8 Terminal block for two wire 24V interlock connection between unit and condenser Condensate legs four with 1 fan six on two and three fan models and eight on four fan models Bolts six per receiver 3 8 x 1 Lee Temp system
46. ton all All dimensions from rear corner of unit including panels NOTES 1 Drawing not to scale 2 Tolerance on all piping dimensions aa is 1 2 13mm L 132 Arad routed alternatives for water glycol 3353mm connections A See submittal page DPN001192 for blower outlet and deck dimensional data LV3 09 o LV2_Lv4 Front Of Unit TOP VIEW OF UNIT 17 3 16 437mm WILL LLL bbdd AAA 3 7 8 98mm FRONT SECTION VIEW OF UNIT Left Front Panel Not Shown 403mm DPN001258 LEFT SIDE SECTION VIEW OF UNIT SE Table 52 Piping data upflow upflow water glycol GLYCOOL 105kW 30 ton all X Y Connection Size Point Description inches mm inches mm Opening inches mm W1A Water Glycol GLYCOOL Access Bottom 126 1 8 3204 9 229 3 1 2 x 8 89 x 203 W2A Water Glycol GLYCOOL Access Top 126 1 8 3204 9 229 3 1 2 x 8 89 x 203 W3 A Water Glycol GLYCOOL Access Side 6 x 17 3 16 152 x 437 WSA Water Glycol GLYCOOL Supply 2 1 8 Cu Sweat WRA Water Glycol GLYCOOL Return 2 1 8 Cu Sweat CGD Condensate Gravity Drain 3 4 FPT CPD Condensate Pump Discharge Opt 102 3 8 2600 13 5 8 346 1 2 Cu Sweat HUM _ Humidifier Supply Line 101 1 8 2569 13 1 8 333 1 4 Cu Sweat ECS Econ O Coil Supply 101 1 8 2569 10 1 4 260 2 5 8 Cu Sweat ECR Econ O Coil Return 101 1 8 2569 5 1 4 133 2 5 8 Cu Sweat El Electrical C
47. 10 19 492 27 Liebert DS Dimensions and Weights Figure 23 Floor stand dimensions downflow 53 77kW 15 22 ton models A 1 1 2 38mm with feet A 69 3 4 4 1 2 1772mm 114mm x jp CCC s L 7 7 34 1 2 S 16 3 4 k 876mm i YY 425mm 7 with feet A A l discharge 838mm opening 1 1 4 Supply air discharge opening m 25mm TYP Gussets supplied on floor stands 12 305 mm tall and greater Optional turning vane E 7 VECA E shown as front _ l l 3 et D l 76mm Turning vane air outlet Optional turning vane can be field installed in supply air discharge opening for front or rear air discharge NOTE Right side of paneled unit is flush with right side of floor stand All other paneled sides overhang floor stand 1 25mm Leveling feet are provided with 1 1 2 38mm adjustment from nominal height C DPN000930 REV 1 Table 20 Floor stand and floor planning dimensions downflow 53 77kW 15 22 ton models Dimensions in mm Height in mm Model A B C D Turning Vane 9 229 4 111 Air Cooled Semi Hermetic Models and 108 26 All Water Glycol GLYCOOL Models 2743 660 12 305 7 187 15 381 10 264 18 457 13 340 Air Cooled Scroll Models and 97 15 Air Cooled Digital Scroll Models 2464 381 21 533 161416 24 610 19 492
48. 2 L1 Liquid Line System 1 121 3 4 3092 16 3 4 425 5 8 Cu Sweat L2 Liquid Line System 2 118 1 8 3000 16 3 4 425 5 8 Cu Sweat G1 Hot Gas Discharge 1 118 1 4 3004 14 1 4 362 1 1 8 Cu Sweat G2 Hot Gas Discharge 2 115 5 8 2937 14 1 4 362 1 1 8 Cu Sweat R3A Refrigerant Access Side 6 x 17 3 16 152 x 437 CGD Condensate Gravity Drain 3 4 FPT CPD _ Condensate Pump Discharge Opt 102 3 8 2600 13 5 8 346 1 2 Cu Sweat HUM Humidifier Supply Line 101 1 8 2569 13 1 8 333 1 4 Cu Sweat ECS Econ O Coil Supply 101 1 8 2569 10 1 4 260 2 5 8 Cu Sweat ECR Econ O Coil Return 101 1 8 2569 5 1 4 133 2 5 8 Cu Sweat E1 Electrical Conn High Volt 98 1 2 2502 30 762 2 1 2 E2 Electrical Conn High Volt 93 2362 30 762 2 1 2 LV1 Electrical Conn Low Volt 41 1 8 1045 30 3 8 772 7 8 LV2 Electrical Conn Low Volt 38 7 8 987 30 3 8 772 7 8 LV3 Electrical Conn Low Volt 35 1 8 892 30 3 8 772 7 8 LV4 Electrical Conn Low Volt 31 5 8 803 30 3 8 772 7 8 Field pitch condensate drain line a minimum of 1 8 3 2 mm per foot 305 mm All units contain a factory installed condensate trap Do not trap external to the unit Drain line may contain boiling water Select appropriate drain system materials The drain line must comply with all local codes 105 Piping Schematics Figure 81 Primary connection locations upflow water glycol GLYCOOL 105kW 30
49. 2 85 9 16 2173 16 3 8 416 7 8 1 1 8 Cu Sweat R3A Refrigerant Access Side 6 x 17 3 16 152 x 437 CGD Condensate Gravity Drain 3 4 FPT CPD Condensate Pump Discharge Opt 79 5 16 2015 11 7 8 302 1 2 Cu Sweat HUM Humidifier Supply Line 79 5 16 2015 9 7 8 251 1 4 Cu Sweat ECS Econ O Coil Supply 78 5 8 1998 7 7 8 200 2 1 8 Cu Sweat ECR Econ O Coil Return 78 5 8 1998 4 5 8 117 2 1 8 Cu Sweat E1 Electrical Connection High Voltage 75 3 8 1915 30 762 2 1 2 E2 Electrical Connection High Voltage 69 7 8 1775 30 762 2 1 2 LV1 Electrical Connection Low Voltage 19 1 2 495 29 1 16 738 718 LV2 Electrical Connection Low Voltage 19 1 2 495 30 1 2 775 718 LV3 Electrical Connection Low Voltage 19 1 2 495 31 15 16 811 718 Field pitch condensate drain line a minimum of 1 8 3 2 mm per foot 305 mm All units contain a factory installed condensate trap Do not trap external to the unit Drain line may contain boiling water Select appropriate drain system materials The drain line must comply with all local codes Supplied on Dual Cool systems only 4 pipe system 103 Piping Schematics Figure 79 Primary connection locations upflow water glycol GLYCOOL 53 77kW 15 22 ton all NOTE compressor models 1 Drawing not to scale 2 Tolerance on all piping dimensions is 1 2 13mm Field routed alternatives for water glycol connections See submitt
50. 4 2 1 2 E2 Electrical Connection High Volt 52 7 16 1332 31 1 4 794 2 1 2 LV1 Electrical Connection Low Volt 2 1 4 57 27 686 7 8 LV2 Electrical Connection Low Volt 2 1 4 57 29 737 7 8 LV3 Electrical Connection Low Volt 2 1 4 57 31 787 7 8 B Blower Outlet 21 15 16 558 18 1 16 459 18 3 4 x 16 1 16 476 x 408 Field pitch condensate drain line a minimum of 1 8 3 2mm per foot 305mm All units contain a factory installed condensate trap Do not trap external to the unit Drain line may contain boiling water Select appropriate drain system materials The drain line must comply with all local codes 91 Piping Schematics Figure 67 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 t 1 11 3116 284mm Front View Section A A Blower Outlet E1E2 ECR B Front of Unit All dimensions from rear corner of unitincluding panels 16 1 16 408mm 73 1854mm DPNO00804 Rev 2 X Y Connection Size Opening Point Description inches mm inches mm inches mm R Refrigerant Access 59 5 16 1507 14 3 4 375 11 3 16 x 4 284 x 102 L1 Liquid Line System 1 69 15 16 1776 16 13 16 411 1 2 Cu Sweat L2 Liquid Line System 2 67 5 8 1718 16 13 16 411 1 2 Cu Sweat
51. 403mm Left Front Panel Not Shown DPN001179 Left Side Section View Rev 2 Xx Y Connection Size Opening Point Description in mm in mm in mm WMA Water Glycol GLYCOOL Access Bottom 79 15 16 2030 9 229 3 1 2 x 8 89 x 203 WA Water Glycol GLYCOOL Access Top 79 15 16 2030 9 229 3 1 2 x 8 89 x 203 WA Water Glycol GLYCOOL Access Side 6 x 17 3 16 152 x 437 WSA Water Glycol GLYCOOL Supply 1 5 8 Cu Sweat WRA Water Glycol GLYCOOL Return 1 5 8 Cu Sweat CGD Condensate Gravity Drain 3 4 FPT CPD Condensate Pump Discharge Opt 56 1 4 1429 11 1 8 282 1 2 Cu Sweat HUM Humidifier Supply Line 56 1 4 1429 9 1 8 232 1 4 Cu Sweat ECS Econ O Coil Supply 56 1423 7 5 16 186 1 5 8 Cu Sweat ECR Econ O Coil Return 56 1423 4 1 2 114 1 5 8 Cu Sweat E1 Electrical Connection High Voltage 52 3 8 1330 30 762 2 1 2 E2 Electrical Connection High Voltage 46 7 8 1191 30 762 2 1 2 LV1 Electrical Connection Low Voltage 19 1 2 495 29 1 16 738 7 8 LV2 Electrical Connection Low Voltage 19 1 2 495 30 1 2 775 7 8 LV3 Electrical Connection Low Voltage 19 1 2 495 31 15 16 811 718 Field pitch condensate drain line a minimum of 1 8 3 2 mm per foot 305 mm All units contain a factory installed condensate trap Do not trap external to the unit Drain line may contain boiling water Select appropriate drain system materials The drain line must comply with all loc
52. 5 31 15 16 811 7 8 Field pitch condensate drain line a minimum of 1 8 3 2 mm per foot 305 mm All units contain a factory installed condensate trap Do not trap external to the unit Drain line may contain boiling water Select appropriate drain system materials The drain line must comply with all local codes Supplied on Dual Cool systems only 4 pipe system 104 Piping Schematics Figure 80 Primary connection locations upflow air cooled 105kW 30 ton all All dimensions from rear corner of unit including panels O 15 3 16 35 386mm 889mm NOTES 1 Drawing not to scale 2 Tolerance on all piping dimensions is 1 2 13mm Field routed alternatives for refrigerant gas and liquid line connection points See submittal page DPN001192 for blower outlet and deck dimensional data LEFT SIDE SECTION VIEW OF UNIT 10 L 132 3353mm FRONT SECTION VIEW OF UNIT Left Front Panel Not Shown LV1 LV3 e LV2_ LV4 Front Of Unit TOP VIEW OF UNIT Factory Location DPN001257 Rev 0 Table 51 Piping data upflow air cooled 105kW 30 ton all Point Description Xx Y Connection Size Opening R1A Refrigerant Access Top 106 7 8 2715 1 7 8 48 22 1 2 x 15 3 16 572 x 386 R2A Refrigerant Access Bottom 109 1 8 2772 13 7 8 352 16 7 16 x 4 418 x 10
53. Charging and Replacing Panels 1 al opa 1 0 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 8 0 Piping for piping guidelines and to the ASHRAE Refrigeration Handbook for general good practice refrigeration piping Open the service valves on the compressor Reinsert the plastic bushings Charge the Liebert DS with refrigerant see the unit s nameplate for the proper charge Reinstall the galvanized panels on the left side of the coil Replace the filters Replace the panels 45 Disassembling the Liebert DS for Transport 6 4 Reassembly Checklist Thread cutting bolts reconnected and torqued to 225 in lb 25Nm 1 2 3 4 gt N o 10 _ 1 Top cover plate attached to coil Filter plate attached High voltage wires connected to proper contactors __ a Compressor b Fan motor c Reheat if applicable d Humidifier if applicable e Condensate pump if applicable Low voltage wires connected __ a Actuator b Terminal strip __ c Plug connections d Smoke detector if applicable Coil access plates on right and left replaced Water lines brazed Suction and liquid refrigerant lines brazed Unit recharged Filters replaced Panels replaced 46 Disassembling the Liebert DS for Transport Figur
54. Entrance Minimum required for blower replacement Top View Low Volt High Volt Connection s Connection s 1 1 2 109 38mm 2769mm 7 76 1930mm Shaded area indicates a recommended minimum clearance for component 2 access 51 2743mm l l 51mm Note Front air return unit shown For rear return unit Front View in addition to front service area shown also include 25 635mm on one side of unit for access to rear return filter box See DPN001196 Figure 28 DPN001167 Rev 1 Table 16 Weights for upflow water glycol GLYCOOL 53 77kW 15 22 ton all compressor models Dry Weight Ib kg approximate Compressor Type Model 053 070 077 l l Water Glycol 2650 1205 2800 1270 Semi Hermetic Compressor GLYCOOL Dual Cool 2830 1287 2980 1352 i Water Glycol 2370 1075 Scroll or Digital Scroll Compressor GLY COOL Dual Cool 2550 1157 24 Liebert DS Dimensions and Weights Figure 20 Cabinet and floor planning dimensions upflow air cooled 105kW 30 ton all Alternate Refrigerant Piping Entrance Minimum required for blower replacement Bezels TOP VIEW Low Volt Connection s Connection s 132 Gor 3353mm T 76 190mm 1 2 _f 131 51mm 3327mm Shaded area indicates a FRONT VIEW recommended minimum p clearance for component Note Front air return unit shown For rear return unit access
55. Glycol GLYCOOL Dual Cool Water Glycol GLYCOOL Dual Cool Compressor Assembly 950 432 950 432 800 364 800 364 Blower amp Electric Box Assembly 510 231 510 231 510 231 510 231 Filter 8 Coil Assembly 520 236 670 304 520 236 670 304 61 Disassembling the Liebert DS for Transport Figure 49 Component dimensions upflow air cooled 53 77kw 15 22 ton semi hermetic compressor models y Ur DOS Blower amp Electric VY Box Assembly 31 1 4 794mm 76 1930mm Filter amp Coil Assembly Assembled Height 82 660mm 2083mm 108 2743mm Assembled Length NOTES Drawing views are simplified with panels removed to show overall dimensions See disassembly and handling instructions in installation manual DPN001209 Rev 0 Table 39 Component weights upflow air cooled 53 77kw 15 22 ton semi hermetic compressor models Dry Weight Approximate Including Panels Ib kg Component Air Cooled Dual Cool Compressor Assembly 970 441 970 441 Blower amp Electric Box Assembly 770 349 770 349 Filter amp Coil Assembly 760 345 940 426 62 Disassembling the Liebert DS for Transport Figure 50 Component dimensions upflow air cooled 53 77kw 15 22 ton scroll digital scroll compressor models Blower amp Electric Box Assembly 31 1 4 794mm Compressor Assembly 76 1930
56. H Precision Cooling For Business Critical Continuity Liebert Ds User Manual 28 105kW 8 30 Tons Upflow and Downflow 50 60Hz EMERSON Network Power TABLE OF CONTENTS IMPORTANT SAFETY INSTRUCTIONS 0000 cee eee eee eee eee ee eee ees 1 SAVE THESE INSTRUCTIONS 2225 252 brink eee hoe Se 2 owe eee wie se eek es See ieee eS 1 1 0 LIEBERT DS COMPONENTS AND NOMENCLATURE lt e cece cece eee eeeneee 3 2 0 COOLING CONFIGURATIONS lt lt eee eee eee eens 6 3 0 PRE INSTALLATION GUIDELINES lt cece eee eee eee ees 7 3 1 Room Preparations r a 97 A Se oI NE ES td 7 3 2 Ar Distribution Downflow Unite wisi E A EA es ob eae aha ee ed 7 3 3 Air Distribution Upflow Units 8 3 4 Connections and System Setup ee ee ene ee ne nee errre 9 3 5 Operating Conditions 9 4 0 LIEBERT DS DIMENSIONS AND WEIGHTS 0000 eee eee eee eee eens 10 5 0 EQUIPMENT INSPECTION AND HANDLING x x x K e x eee eee eee eee eee ees 35 5 1 Packaging Material yori init dr eee wala Lad wae iS ete ds 35 SAFETY INFORMATION lt lt lt e 35 5 2 Unp cking the Unitn ce Vee eh A E OE ae Cae AR SOE AS 36 5 2 1 Removing the Unit from the Skid With a Fork 37 5 2 2 Moving the Unit to the Installation Location with Piano Jacks asaue 38 DS Removing Plano Jacks ni ee eh EE ee EO re hae ee Mee Bon ea ea ae Ee ef 38 5 2 4 Removing Liebert DS from Skid Using Rigging 0 0 0
57. L Access 103 2616 9 229 3 1 2 x 8 89 x 203 WS Water Glycol GLYCOOL Supply 104 3 4 2661 11 279 2 1 8 Cu Sweat WR Water Glycol GLYCOOL Return 104 3 4 2661 15 381 2 1 8 Cu Sweat cD Condensate Drain 69 1 4 1759 30 762 3 4 FPT W Optional Pump 69 1 4 1759 30 762 1 2 Cu Sweat HUM Humidifier Supply Line 76 1 2 1943 29 736 1 4 Cu Sweat ECS Econ O Coil Supply 78 5 8 1997 22 1 4 565 2 1 8 Cu Sweat ECR Econ O Coil Return 72 1829 29 737 2 1 8 Cu Sweat HS Hot Water Reheat Supply Consult Factory HR Hot Water Reheat Return Consult Factory E1 Electrical Connection High Volt 78 1 2 1994 31 1 8 790 2 1 2 E2 Electrical Connection High Volt 75 3 8 1915 31 1 8 790 2 1 2 LV1 Electrical Connection Low Volt 1 7 8 48 28 1 2 724 7 8 LV2 Electrical Connection Low Volt 1 7 8 48 30 1 4 768 718 LV3 Electrical Connection Low Volt 1 7 8 48 32 813 718 pi Blower Outlet 15 x 15 23 1 8 587 18 1 16 459 18 3 4 x 16 1 16 476 x 408 Blower Outlet 15 x 11 27 3 4 705 18 1 16 459 14 3 4 x16 1 16 375 x 408 B2 Blower Outlet 15 x 15 50 3 8 1280 18 1 16 459 18 3 4 x 16 1 16 476 x 408 Blower Outlet 15 x 11 54 3 8 1381 18 1 16 459 14 3 4 x16 1 16 375 x 408 Field pitch condensate drain line a minimum of 1 8 3 2mm per foot 305mm All units contain a factory installed condensate trap Do not trap external to the unit Drain line may contain boiling water Select app
58. Using Water or Glycol These guidelines apply to the field leak checking and fluid requirements for field piping systems includ ing Liebert chilled water hot water condenser water or glycol GLYCOOL and drycooler circuits General Guidelines Equipment damage and personal injury can result from improper piping installation leak check ing fluid chemistry and fluid maintenance Follow local piping codes safety codes Qualified personnel must install and inspect system piping Contact a local water consultant regarding water quality corrosion protection and freeze protec tion requirements Install manual shutoff valves at the supply and return line to each indoor unit and drycooler to permit routine service and emergency isolation of the unit A A CAUTION Risk of frozen fluids Can cause equipment damage and building damage Freezing system fluids can rupture piping Complete system drain down cannot be ensured When the field piping or unit may be exposed to freezing temperatures charge the system with the proper percentage of glycol and water for the coldest design ambient Automotive antifreeze is unacceptable and must NOT be used in any glycol fluid system CAUTION Risk of corrosion Can cause equipment damage Read and follow individual unit installation instructions for precautions regarding fluid system design material selection and use of field provided devices Liebert systems contain iron and c
59. W 028 035 042 053 Humidification 070 077 105 0 None l Infrared Cooling Type S Steam Generating Canister A Air Cooled D Dual Cooling Air Cooled W Water Glycol K GLYCOOL Reheat Type H Dual Cooling Water Glycol 0 None E Three stage electric Compressor S SCR U Semi hermetic with four step R 407C W Hot water S Scroll R 407C D Digital Scroll R 407C Voltage M Semi hermetic A 460 3 60 with four step R 22 G Rev Level R Scroll R 22 Rev 0 s C 208 3 60 G Digital Scroll R 22 D 230 3 60 2 380 3 60 J 200 3 50 M 380 415 3 50 Cooling Configurations 2 0 COOLING CONFIGURATIONS NOTE All field installed piping must comply with applicable local state and federal codes Air Cooled Glycol Cooled Air cooled unit piping is spun closed from Glycol cooled units are factory charged and the factory and contain a nitrogen holding tested Field installed piping is required from the charge Each installation requires refrigerant unit to the drycooler and pump package piping to a condenser GLYCOOL i i Water Cooled GLYCOOL units are factory charged and tested Field installed Water cooled units are factory charged and piping is required from the unit to the drycooler and pump tested Field installed water piping is package An additional coil is included for use when fluid required from the unit to the cooling tower temperatures are sufficien
60. W 30 ton all compressor Models di AS ce OE Component dimensions upflow air cooled 28 42kW 8 12 ton semi hermetic compressor TOC ES Sat Says shar RE Component dimensions upflow air cooled 28 42kW 8 12 ton scroll digital scroll Compressor MODES re cesta sho AAA Goel A AI seedy lating Bile gra we Gi Asa Rossi nutes dT td Feller is Component dimensions upflow water glycol GLYCOOL 28 42kW 8 12 ton all compressor Models ada a 85 ssn Pid ne AE BTR a a a ea T las de Component dimensions upflow air cooled 53 77kw 15 22 ton semi hermetic compressor Models cinto lt TLE NTR Ra a so hte aT RTA 9 TRER EA sd Component dimensions upflow air cooled 53 77kw 15 22 ton scroll digital scroll compressor models fre fcc it Ge Binds R A Han aL Sie aoe Cady Gag R R deb ng Wl Kobe grainy RE Taa eens Component dimensions upflow water glycol GLY COOL 53 77kw 15 22 ton all compressor Models a Ge ay Sle DANAE AR ita Component dimensions upflow air cooled 105kW 80 ton semi hermetic compressor TOC EG oi nego Di a A a Ad AA a8 Component dimensions upflow air cooled 105kW 30 ton scroll digital scroll compressor models Component dimensions upflow water glycol GLYCOOL 105kW 30 ton all compressor models tii dl tise ee A A a dd DOU de Electrical field connections oesie ada 0 ce KR REN RRR KRE R Gravity drain for downflow and upflow units eee eee nes Piping schematic air cooled semi hermetic compressor
61. al Room Temperature Humidity Ambient Temperature S Filters 1 Check replace filters Grille area unrestricted 2 3 Wipe section clean 4 Coil clean Blower Section 1 Blower wheels free of debris 2 Check belt tension and condition replace if needed 3 Check lube bearings 4 Check sheave pulley replace if worn 5 Check motor mount 6 Motor amp draw L1 L2 L3 Compare to nameplate amps Reheat 1 Inspect elements ___ 2 Check wire connections inside reheat box 3 Reheat amp draw _ a 1 _ a 2 __ a 8 Steam Generating Humidifier ___ 1 Check drain valve drain lines trap for clogs _ 2 Check water make up valve and all hoses for leaks 3 Clean strainer ___ 4 Replace humidifier bottle if necessary ___ 5 Check operation of humidifier 6 Humidifier amp draw L1 L2 L3 Infrared Humidifier 1 Check drain lines and trap for clogs Check clean pan for mineral deposits Clean reflector Check water make up valve for leaks Check wire connections inside humidifier box 2 3 4 5 Check humidifier lamps replace if burnt out 6 7 Humidifier amp draw L1 L2 L3 122 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 leaks __ 2 Check for moisture sight glass Water Cooled Condensers 1 Check water regula
62. al codes Supplied on Dual Cool systems only 4 pipe system 101 Piping Schematics compressor models NOTES 1 Drawing not to scale 2 Tolerance on all piping dimensions 35 386mm is 1 2 13mm n a Field routed alternatives for refrigerant 102mm gas and liquid line connection points See submittal page DPN001191 for blower outlet and deck dimensional data 17 3 16 437mm Lo 14 1 4 3 7 8 98mm 362mm 15 7 8 403mm 20 1 16 509mm LEFT SIDE SECTION VIEW OF UNIT Field pitch Condensate Drain line a minimum of 1 8 3 2 mm per foot 305 mm All units contain a factory installed condensate trap Do not trap external to the unit Drain line may contain boiling water Select appropriate drain system materials The drain line must comply with all local codes Supplied on Dual Cooling Systems only 572mm L1 FILL LL ZZZ ZAAPA 22 1 2 ho 109 2769mm CGD Figure 77 Primary connection locations upflow air cooled 53 77kW 15 22 ton semi hermetic All dimensions from rear corner of unit x O including panels Blower Outlet Y LV1 SLV2 e LV3 Front of Unit TOP VIEW OF UNIT Ss S AAA Ld Ld G1 G2 Oe f mmm L2 Factory Location FRONT SECTION VIEW OF UNIT Left Front Panel Not Shown DPN001212 Rev 2 X Y Connection Size Opening Point Description
63. al page DPN00 1191 for blower outlet and deck dimensional data WILZLLLL LL ZE 5 09 2769mm Blower Outlet All dimensions from rear corner of unit including panels 109 Top View Blower Outlet 15 7 8 CGD 403mm Front Section View DPN001214 Left Side Section View Left Front Panel Not Shown Rev 1 Xx Y Connection Size Opening Point Description inches mm inches mm inches mm WA Water Glycol GLYCOOL Access Bottom 102 15 16 2615 9 229 3 1 2 x 8 89 x 203 W2A Water Glycol GLYCOOL Access Top 102 15 16 2615 9 229 3 1 2 x 8 89 x 203 WA Water Glycol GLYCOOL Access Side S 6 x 17 3 16 152 x 437 WSA Water Glycol GLYCOOL Supply S 2 1 8 Cu Sweat WRA Water Glycol GLYCOOL Return 2 1 8 Cu Sweat CGD Condensate Gravity Drain 3 4 FPT CPD Condensate Pump Discharge Option 79 5 16 2015 11 7 8 302 1 2 Cu Sweat HUM Humidifier Supply Line 79 5 16 2015 9 7 8 251 1 4 Cu Sweat ECS Econ O Coil Supply 78 5 8 1998 7 7 8 200 2 1 8 Cu Sweat ECR Econ O Coil Return 78 5 8 1998 4 5 8 117 2 1 8 Cu Sweat El Electrical Connection High Voltage 75 3 8 1915 30 762 2 1 2 E2 Electrical Connection High Voltage 69 7 8 1775 30 762 2 1 2 LV1 Electrical Connection Low Voltage 19 1 2 495 29 1 16 738 7 8 LV2 Electrical Connection Low Voltage 19 1 2 495 30 1 2 775 7 8 LV3 Electrical Connection Low Voltage 19 1 2 49
64. amaged 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 Reheat Electric Reheat Three Stage and SCR Inspect and clean reheat elements Inspect and tighten support hardware Compressor Compressor Oil A CAUTION 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 55 Do NOT mix polyolester POE and mineral based oils Do NOT mix oils of different viscosities Consult Emerson or the compressor manufacturer if you have questions Table 55 Compressor oil types Refrigerant Type Compressor Type R 22 R 407c 41 POE Oil ISO Carlyle Semi Hermetic Mineral Oil 68 Viscosity 2 Copeland Scroll lt n and Digital Scroll POE Oil ISO 22 Viscosity 1 Use Carlyle Mineral Oil Totaline P903 2001 Witco Suniso 3GS or other Carlyle approved oils 2 Use Carlyle POE Oil Totaline P903 1001 Castrol SW68 or other Carlyle approved oils 3 Use Copeland POE Oil ULTRA 22CC Mobil EAL Arctic 22CC or other Copeland approved oils Semi Hermetic Compressor
65. ance spring valve seat valve disc holders capillary tube to discharge pressure and adjusting screw Adjustment Johnson Controls Penn Johnson Valves The valves may be adjusted with a standard refrigeration service valve wrench or screwdriver Table 56 Recommended refrigerant pressures System Design PSIG kPa Wate Coled 65 to 75 F water 18 to 24 C 210 1450 85 F water 29 C 225 1550 Glycol Cooled 295 2035 Maximum 330 2275 High Pressure Cut out 400 2859 119 Maintenance To lower the head pressure setting turn the square adjusting screw clockwise until the high pressure gauge indicates the desired setting To raise the head pressure setting turn the adjusting screw coun terclockwise until the desired setting is obtained Consult the factory if your unit is equipped with valves from other manufacturers 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 12 11 2Motor Ball Valve Digital Scroll Compressors On digital scroll units discharge pressure is controlled by a motorized bal
66. are 91 common 92 NO and 93 NC Supervised contacts 80 and 81 open on sensor trouble indication This smoke sensor is not intended to function as or replace any room smoke detection system that may be required by local or national codes 1A 24VAC max load Use Class 1 field supplied wiring Reheat and humidifier lockout Remote 24VAC required at terminals 82 and 83 for lockout of reheat and humidifier Condensate alarm with condensate pump option On pump high water indication normally open dry contact is closed across terminals 88 and 89 for remote indication 1A 24VAC max load Use Class 1 field supplied wiring Remote humidifier On any call for humidification normally open dry contact is closed across terminals 11 and 12 to signal field supplied remote humidifier 1A 24VAC max load Use Class 1 field supplied wiring Auxiliary cool contact On any call for Econ O Coil operation normally open dry contact is closed across terminals 72 and 73 on dual cool units only 1A 24VAC max load Use Class 1 field supplied wiring 70 Electrical Connections Optional Low Voltage Terminal Package Connections 20 21 22 23 Remote unit shutdown Two additional contact pairs available for unit shutdown labeled as 37B and 38B 37C and 38C Replace jumpers with field supplied normally closed switch having a minimum 75VA 24VAC rating Use Class 1 field supplied wiring Common alarm On any alarm two additional normal
67. ater may back up in the drain pan 72 Piping Figure 56 Gravity drain for downflow and upflow units DOWNFLOW DS UNIT UPFLOW DS UNIT INTERNAL DRAIN EXTERNAL DRAIN EXTERNAL DRAIN CONTINUOUS DOWNWARD SLOPE CONTINUOUS DOWNWARD SLOPE CORRECT CORRECT INTERNAL INTERNAL Ur DRAIN EXTERNAL EXTERNAL DRAIN DO NOT EXTERNALLY DO NOT EXTERNALLY TRAP THE UNIT TRAP THE UNII INCORRECT INCORRECT INTERNAL EXTERNAL NTERNAL EXTERNAL DRAIN THESE ARE EXTERNAL TRAPS ALSO ALTHOUGH THESE ARE EXTERNAL TRAPS ALSO ALTHOUGH UNINTENTIONAL LINES MUST BE RIGID ENOUGH UNINTENTIONAL LINES MUST BE RIGID ENOUGH NOT TO BOW OVER TOP OF OTHER OBJECTS NOT TO BOW OVER TOP OF OTHER OBJECTS INCORRECT INCORRECT Lava Rev 0 Condensate Pump 1 2 copper sweat connection is provided on units with optional factory installed condensate pump Condensate Pump 60Hz Condensate pump is rated for approximately 400 gph at 10 feet total head Condensate Pump 50Hz Condensate pump is rated for approximately 315 gph at 10 feet total head Size piping based on available condensate head 73 Piping 8 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 1 m with a minimum water pressure of 20 psi 138kPa Do not supply de ionized water to the humidifier 8 1 3 Requirements of Systems
68. binets HI Connectivity ZZ Embedded Power ZZ Power Switching amp Controls E Services MI Dc Power HI Monitoring I Precision Cooling I Surge Protection Business Critical Continuity Emerson Network Power and the Emerson Network Power logo are trademarks and service marks of Emerson Electric Co 2008 Emerson Electric Co
69. boiling water Select appropriate drain system materials The drain line must comply with all local codes Supplied on Dual Cool systems only 4 pipe system 102 Piping Schematics Figure 78 Primary connection locations upflow air cooled 53 77kW 15 22 ton scroll compressor models NOTE 1 Drawing not to scale 2 Tolerance on all piping dimensions is 1 2 13mm Blower Outlet Field routed alternatives for refrigerant 889mm gas and liquid line connection points See submittal page DPN001191 for blower outlet and deck dimensional data 17 3 16 437mm 12 13 16 325mm 17 1 16 433mm All dimensions from rear corner of unit including panels O Blower Outlet lt Lv1 2 v2 98 2489mm Top View Front 1 3 7 8 Factory Location ST Gap Left Side Section View Left Pont Panel Not Shon Rout Point Description inches mm inches mm inches mm R1 A Refrigerant Access Top 83 5 8 2124 2 51 12 x 4 305 x 102 R2A Refrigerant Access Bottom 82 3 4 2102 14 3 4 374 12 3 16 x 4 310 x 102 53kW 15 tons 70 amp 77kW 20 amp 22 ton L1 Liquid Line System 1 94 11 16 2405 16 3 4 425 1 2 5 8 Cu Sweat L2 Liquid Line System 2 91 7 8 2334 16 3 4 425 1 2 5 8 Cu Sweat G1 Hot Gas Discharge 1 88 3 4 2254 16 3 8 416 7 8 1 1 8 Cu Sweat G2 Hot Gas Discharge
70. ce Check Valve Vave rios lines to extend above base of coil by Liquid Return a minimum of 7 1 2 190mm Head Pressure Lee Temp Receiver Control Valve Fusible Condenser Coil 1 I FNI j Fan Speed Condenser Coil Lee Temp L 4 7 N Hot Gas Discharge l Traps every Sensing Evaporator Coil 25ft 7 6m Bulb of rise Cylinder Unloader s Field installed relief valve s required for 50Hz EU CE units rated Compressor External maximum 480 PSIG 33 Bar Muffler ervice Equalizer Valve i l Isolation l e eee Hot Gas Discharge ee a e e e Muffler Expansion Valve DXI t Solenoid Sight Glass Filter Dryer Liquid Return Isolation V valve ae Components are not supplied by Refrigerant Piping Liebert but are recommended for Field Piping proper circuit operation and Y Service Schrader Access Connection No Valve Core maintenance Components supplied by Liebert and must be field installed 70kW 77kW and 105kW models only Note Schematic representation shown Do not use for specific connection locations Two refrigeration circuits provided Single refrigeration circuit shown for clarity y Service Schrader Access Connection With Valve Core DPNO000797 Rev 3 82 Piping Schematics Figure 58 Piping schematic air cooled scroll compressor models Relief Check valve Service Valve Valve Inverted trap on
71. cess 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 Packaging Material DY All material used to package this unit is recyclable Please save for future use or dispose of the material appropriately R SAFETY INFORMATION KT A WARNING Risk of top heavy unit falling over Can cause equipment damage injury or death Read all of the following instructions before attempting to move the unit lift it remove packaging or prepare the unit for installation A CAUTION Risk of sharp edges splinters and exposed fasteners Can cause personal injury Only properly trained personnel wearing appropriate safety headgear gloves shoes and glasses should attempt to move the unit lift it remove packaging or prepare the unit for installation NOTICE Risk of overhead interference The unit may be too tall to fit through a doorway while on the skid Measure the unit and doorway heights and refer to the installation plans to verify clearances prior to moving the unit If the Liebert DS is too large to fit through doors halls or other tight spaces the unit can be partly dismantled as detailed in 6 0 Disassembling the Liebert DS for Transport NOTICE Risk of damage from forklift Keep tines of the forklift level and at a height suitable to fit below the skid and or unit to prevent exterior and
72. croll 3833 4053 3763 3983 10 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 56 7 8 Opening 1445mm Notes Filters are accessible 33 through top of unit only 838mm aji l Ea 8 Opening Downflow electrical 35 619mm connections can be made 889mm from top or bottom of unit 3 4 Top View 19mm Bezels Secondary Entrance Secondary Entrance Minimum clearance High Volt Connection s Low Volt Connections required for filter 86 replacement 2184mm 76 1930mm Shaded areas indicate a 864mm recommended minimum E IE clearance for component access Pront View DPN000795 Sn 85 Rev 3 2159mm Table 3 Weights for downflow air cooled 28 42kW 8 12 ton semi hermetic compressor models Dry Weight Ib kg Approximate Model No 028 035 042 Air Cooled 1780 809 Dual Cool 1930 877 11 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 Notes Filters are accessible through top of unit only Downflow electrical connections can be made from top or bottom of unit 56 7 8 Opening 24 3 8 619mm Open
73. ct flange not provided DPNO001120 Rev 1 Table 22 Dimensions for upflow 28 42kW 8 12 ton Models Blower Supply A B C D E 15 7 8 18 5 8 2 1 8 25 5 8 25 rane Front Throw 404mm 472mm 54mm 651mm 635mm x Rear Throw 15 7 8 18 5 8 11 5 8 25 5 8 25 28 42kW 404mm 472mm 295mm 651mm 635mm 8 12 ton Front Throw 15 7 8 14 1 2 2 1 8 25 5 8 25 404mm 368mm 54mm 651mm 635mm 15x11 x Rear Throw 15 7 8 14 1 2 11 5 8 25 5 8 25 404mm 368mm 295mm 651mm 635mm 30 Liebert DS Dimensions and Weights Figure 26 Blower outlet and deck dimensions upflow 53 77kW 15 22 ton 98 2489mm or 109 2769mm Blower Outlets Front of Blower Outlet Location TOP VIEW Unit Duct Flanges Not Provided TOP OF UNIT 1 1 2 Blower Deck 38mm NA 76 1930mm Ref DPN001191 Front or Rear Air Throw Supply Rev 3 Table 23 Blower outlet and deck dimensions for upflow 53 77kW 15 22 ton Dimensions in mm Models Blower Supply A B C D E F Front 15 7 8 18 5 8 2 1 8 27 3 4 18 5 8 55 ESE Throw 404mm 472mm 54mm 705mm 472mm 1410mm x 15 7 8 18 5 8 11 5 8 27 3 4 18 5 8 55 Rear Throw 53 77kW 404mm 472mm 295mm 705mm 472mm 1410mm 15 22 ton Front Throw 1077 8 14 11 16 2 1 8 31 3 8 14 11 16 58 7 16 eee 404mm 373mm 54mm 797mm
74. ction form Installer and address Owner and address Site Contact name and phone Installation date Indoor unit model and serial number Outdoor unit condenser or drycooler model and serial number Condition of unit when received Is there a freight damage claim in process Have manuals been kept with unit Is the air product connected to site monitoring or switchover controls Provide model and serial of connected controls for switchover controls Startup Checks Inspection With Panels Removed and Disconnect Off 1 2 3 4 10 11 12 13 14 Check all internal piping clamps and tighten or secure if needed Check field piping for proper support Check unit belts for correct tension and alignment Check unit electrical connections and tighten or secure if needed Check control plugs and Mate N Loc connections to the control boards and components Check all major components such as compressors reheats humidifiers and motors that may have loosened during shipping Remove shipping blocks from compressor s adjust spring tension Remove all debris tools and documents from unit area Record main fan horsepower and voltage from nameplate record belt size motor sheave and fan pulley Record filter size and quantity Record piping size for discharge and liquid lines Check piping for proper traps including inverted traps on condensers Record total equivalent length for discharge and liquid piping Record comp
75. ctions verify that all the parts are included and check the nameplate to be sure the voltage matches available utility power 50Hz Models Only Re install all terminal covers before connecting power to the unit Failure to install these covers exposes high voltage terminals Follow all local codes WARNING Risk of improper wiring piping moving lifting and handling Can cause equipment damage injury or death Installation and service of this equipment should be done only by qualified personnel who have been specially trained in the installation of air conditioning equipment CAUTION Risk of backward compressor rotation Can cause equipment damage Three phase power must be connected to the unit line voltage terminals in the proper sequence so that scroll compressors rotate in the proper direction CAUTION Risk of improper electrical supply connection Can cause equipment damage See transformer label for primary tap connections Installer will need to change transformer primary taps if applied unit voltage is other than pre wired tap voltage CAUTION Risk of overheated terminals Can cause wiring and component damage Use copper wiring only Make sure that all connections are tight 68 Electrical Connections Figure 55 Electrical field connections 2 IntelliSlot Housing SERI BERI 7 OVERLOAD PROTECTORS 10009 E iage CONTACTORS NNI cos ee CONTACTORS amp RELAYS O 6 50 Hz DOWNFLOW
76. d Piping Ent Iping Entrance for blower replacement l l Low Volt Connection s High Volt Connection s 86 1 2 ll 2184mm 7 76 1930mm gt x Np 64mm Shaded area indicates a recommended minimum clearance for component access F RONT VIEW 2 85 DPN001164 51mm Rev 1 S 2159mm S Table 143 Weights for upflow water glycol GLYCOOL 28 42kW 8 12 ton all compressor models Dry Weight Ib kg approximate Compressor Type Model 028 042 l l Water Glycol 1980 898 Semi Hermetic GLYCOOL Dual Cool 2130 966 a Water Glycol 1830 830 Scroll or Digital Scroll GLYCOOL Dual Cool 1980 898 21 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 3 4 19mm Minimum required Bezels for blower replacement Top View High Volt Connection s Low Volt Connection s 1 1 2 109 38mm 2769mm 76 1930mm Shaded area indicates a recommended minimum clearance for component 51mm 2743mm access Note Front air return unit shown For rear return unit Front View Be in addition to front service area shown also include 25 635mm on one side of unit for access to rear return filter box See DPN001196 Figure 28 DPNO01165 Rev 1 Table 14 Weights for upflow air coo
77. d 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 S 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 When pressurized gas is used for leak testing the Liebert unit the maximum recommended pressure is 30 psig 2 bars and tightness of the unit should be verified by pressure decay over time lt 2 psig hour 0 3 bars hour or sensing a tracer gas with suitable instrumentation Dry seals in fluid valves and pumps may not hold a high gas pressure Refrigeration Piping A A WARNING Risk of explosive discharge from high pressure refrigerant Can cause injury or death This unit contains fluids and or gases under high pressure Relieve pressure before working with piping WARNING Risk of refrigerant system rupture or explosion from over pressurization Can cause equipment damage injury or death If a pressure relief device is not provided with the condenser unit the system installer must provide and install a discharge pressure relief valve rated for a maximum of 500 psig 34bar in the high side refrigerant circuit Do not install a shutoff valve between the compressor and the field
78. d capacity Enterprises benefit Outside the US 614 841 6755 from greater IT system availability operational flexibility and Single Phase UPS reduced capital equipment and operating costs 800 222 5877 upstech emersonnetworkpower com Outside the US 614 841 6755 Three Phase UPS 800 543 2378 powertech emersonnetworkpower com Environmental Systems 800 543 2778 Outside the United States 614 888 0246 Locations United States 1050 Dearborn Drive P O Box 29186 Columbus OH 43229 Europe Via Leonardo Da Vinci 8 Zona Industriale Tognana 35028 Piove Di Sacco PD Italy 39 049 9719111 While every precaution has been taken to ensure the accuracy d and completeness of this literature Liebert Corporation assumes no Fax 39 049 5841 257 responsibility and disclaims all liability for damages resulting from use of Asia this information or for any errors or omissions 7 F Dah Sing Financial Centre 2008 Liebert Corporation 108 Gloucester Road Wanchai All rights reserved throughout the world Specifications subject to change without notice Hong Kong Liebert is a registered trademark of Liebert Corporation 852 2572220 All names referred to are trademarks Fax 852 28029250 or registered trademarks of their respective owners SL 18825_REVO7_05 08 Emerson Network Power The global leader in enabling Business Critical Continuity EmersonNetworkPower com I AC Power ZZ Embedded Computing I Outside Plant I Racks amp Integrated Ca
79. d on site specific conditions See the Com user manual SL 18835 for instructions on how to utilize the unit controller to pre dict some service maintenance intervals gt Emerson recommends the use of trained and authorized service personnel extended service con tracts and factory specified replacement parts Contact your local Emerson representative Filters A CAUTION Risk of improper filter installation and filter collapse Can cause equipment damage Pleat direction is non standard Use only short pleat filters see Figure 82 Long pleat filters are subject to collapse at high airflows To maximize the performance and reliability of Liebert DS equipment use only Liebert filters Con tact your local Emerson representative to order replacement filters Table 53 Filter quantities downflow units Filter Quantities Filter Size 4 Filter Option 2 Primary 2 Pre Filter Option Unit Size Width x Length Merv 8 or Merv 11 Merv 11 Primary Filter Merv 7 Pre Filter DS 028 035 042 5 5 5 DS 053 070 077 16x25 7 717 DS 105 9 9 9 Table 54 Filter quantities upflow units Filter Quantities Filter Size 2 Primary 2 Pre Filter Option Upflow Models Width x Length 4 Filter Option Merv 8 or Merv 11 Merv 11 Primary Merv 7 Pre Filter vso25 035 042 4 44 44 VS053 070 077 25 x 20 6 6 6 VS105 8 8 8 111 Maintenance 12 1 1 Filter Replacement Procedure Do
80. dels 0 00 ccc ene ee ee eens Cabinet and floor planning dimensions upflow air cooled 105kW 30 ton all Cabinet and floor planning dimensions upflow water glycol GLYCOOL 105kW 80 ton all oeae lt a sic bs oh a E a as GOR Bice ee tte Se We tis ated Seite Ye gt Floor stand dimensions downflow 28 42kW 8 12 ton models ooooooo o o Floor stand dimensions downflow 53 77kW 15 22 ton models 002 eee Floor stand dimensions downflow 105kW 30 ton models o ooooooooooo o Blower outlet and deck dimensions upflow 28 42kW 8 12 t0M oooooooo o o Blower outlet and deck dimensions upflow 53 77kW 15 22 Lon Blower outlet and deck dimensions upflow 105kW 30t0D o Rear return filter box dimensions xe waa e e e N K R R ken R RR RRR R T NR eens Upflow unit plenum dimensions 0 0 cence eee nee ees Equipment recommended for handling Liebert DS 0 cen Removins paGka cine sta td ERT Kae R ATR ET we Be ere ala Me gia odes otal WA Rara as Remove the unit from the skid S sy R R a KARR ee tenn eee teen nena Moving the unit to its installation location 0 ccc eee een ns Locate center of gravity marker and place slings 0 cece eee eee oo Using rigging to lift Liebert DS off skid 0 0 teen ene eens Setting the unit on a floor stand eee ence teen nes Figure 37 Figure 38 Figure 39 Figure 40 Fig
81. dimensions See disassembly and handling instructions in installation manual DPN000927 Rev 2 Table 31 Component weights downflow air cooled 53 77kW 15 22 ton scroll digital scroll Dry Weight Approximate Including Panels Ib kg Component Air Cooled Dual Cool Compressor Assembly 540 246 540 246 Filter amp Electric Box Assembly 250 114 250 114 Blower amp Coil Assembly 1230 560 1410 641 Disassembling the Liebert DS for Transport Compressor Assembly MEN OJ 76 1930mm j Oo WEN O 838mm Filter amp Electric Box Assembly 82 Blower amp Coil Assembly 2083mm 108 2743mm Assembled Length NOTES Drawing views are simplified with panels removed to show overall dimensions See disassembly and handling instructions in installation manual Figure 42 Component dimensions downflow water glycol GLYCOOL 53 77kW 15 22 ton all compressor models 39 991mm _ 76 1930mm Assembled Height DPN000932 Rev 1 Table 32 Component weights downflow water glycol GLYCOOL 53 77kW 15 22 ton all Semi Hermetic Compressor Scroll Compressor GLYCOOL GLYCOOL Water Glycol Dual Cool Water Glycol Dual Cool Liebert DS Section Ib kg Ib kg Ib kg Ib kg Compressor Assembly 1270 578 1270 578 840 382 840 382 Filter and Electric Box Assembly 250 114 250 114 250 114 250 114 Blower
82. e 10 Weights for downflow water glycol GLYCOOL 105kW 30 ton all compressor models Dry Weight Ib kg approximate Scroll Compressor Compressor Type Model 105 l Water Glycol 3410 1550 Semi Hermetic Compressor GLYCOOL Dual Cool 3770 1714 Water Glycol 3290 1495 GLYCOOL Dual Cool 3650 1659 18 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 t s 33 838mm 35 889mm 3 4 19mm 1 Y Bezels Top View High Volt Connection s Low Volt Connection s Minimum required for blower replacement 86 gammy F 2184mm 76 1930mm Np 864mm Shaded area indicates a recommended minimum clearance for component access Note Front air return unit shown For rear return unit in addition to front service area LELLE Front View 2 51mm 85 shown also include 25 635mm on one side 2159mm of unit for access to rear return filter box See DPN001196 Figure 28 DPN001162 Rev 1 Table 11 Weight for upflow air cooled 28 42kW 8 12 ton semi hermetic compressor models Dry Weight Ib kg approximate Model No 028 042 Air Cooled 1830 830 Dual Cool 1980 898 19 Liebert DS Dimensions and Weights Figure 15 Cabinet and floor planning dimensions
83. e 37 Component dimensions downflow air cooled 28 42kW 8 12 ton semi hermetic compressor models i G 2 gt Filter amp Electric Box Assembly YA 39 991mm 76 Blower amp Coil 1930mm Assembly Assembled Height 60 3 16 1529mm S 26 59 1499mm 660mm 85 2159mm Assembled Length NOTES Drawing views are simplified with panels removed to show overall dimensions DPNO00801 See disassembly and handling instructions in installation manual Rev 1 Table 27 Component weights downflow air cooled 28 42kW 8 12 ton semi hermetic Dry Weight Approximate Including Panels Ib kg Component Air Cooled Dual Cool Compressor Assembly 800 364 800 364 Filter amp Electric Box Assembly 210 96 210 96 Blower amp Coil Assembly 770 350 920 418 47 Disassembling the Liebert DS for Transport Figure 38 Component dimensions downflow air cooled 28 42kW 8 12 ton scroll digital scroll compressor models Filter amp Electric Box Assembly 76 Compressor Assembly oe eat Height 76 1930mm 33 __ 13 L 59 1499mm 838mm 330mm 72 1829mm Assembled Length NOTES Drawing views are simplified with panels removed to show overall dimensions See disassembly and handling instructions in installation manual DPN000802 Rev 1 Table 28 Component weights downflow air cooled 28 42kW 8 12 ton scroll dig
84. e 5 Weights for downflow water glycol GLYCOOL 28 42kW 8 12 ton all compressor models Dry Weight Ib kg Approximate Compressor Type Model 028 035 042 l l Water Glycol 1930 877 Semi Hermetic Compressor GLYCOOL Dual Cool 2080 945 E Water Glycol 1780 809 Scroll or Digital Scroll Compressor GLYCOOL Dual Cool 1930 877 13 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 80 Opening 2032mm Notes Filters are accessible through top of unit only Downflow electrical connections can be made from top or bottom of unit 24 3 8 Air Inlet Opening 619 mm Opening 3 4 Bezels 19mm Secondary Entrance High Volt Connection s Secondary Entrance Low Volt Connections Minimum required for filter replacement Top View 109 F 2769mm oa 1930mm oun Shaded area indicates a recommended minimum clearance for component access a ront View 51mm pe 2743mm DPN000924 Rev 2 Table 6 Weights for downflow air cooled 53 77kW 15 22 ton semi hermetic compressor models Dry Weight Ib kg Approximate Model 053 070 077 Air Cooled Dual Cool 2350 1069 2530 1150 2400 1091 2580 1173 2450 1114 2630 1196 14 Liebert DS
85. e compressor and prevents moisture from contaminating the compressor oil This is particularly important with units using R 407C refrigerant Cut and pull back insulation from piping 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 56 Disassembling the Liebert DS for Transport 6 5 1 6 5 2 19 Immediately cap off and seal all piping that has been cut including the suction and liquid lines the humidifier supply line and the condensate discharge line if applicable as well as fluid piping on GLYCOOL and dual cool units Remove Compressor Assembly 1 Secure the compressor wire harness to the compressor assembly 2 Remove the 10 thread cutting bolts holding compressor section together a b 3 Begin removing bolts at the bottom of the Liebert DS and progress toward the top Use this method for the front and back bolts Stabilize the compressor section before removing the top middle bolt NOTICE The compressor section is top heavy and has a small base It must remain upright Do not lay the compressor section on its side during or after removing it from the Liebert DS Do not remove the shipping blocks from the semi hermetic compressors until the Liebert DS is fully
86. e conduit and wires into the unit s blower and coil assembly section GLYCOOL Dual Cool Optional Component a On units with an actuator unplug the valve actuator harness at the actuator and pull the wire harness into the electric box b Disconnect the glycol sensor from the control board and pull it into the unit s blower and coil assembly section Disconnect the air sail switch wires and pull them into the electric box Smoke Detector Optional Component a Remove the smoke detector cover b Remove the plug connector from the smoke detector and pull it into electric box c Remove the wires from terminal strips 91 92 93 and route them into the smoke detector box d Remove the sensing tube from top of the smoke detector The wand and tube will remain attached to filter and electric box assembly Close the electric box cover and the accent panel Remove the pull bar that supports the accent panel from the left end of unit otherwise it will fall out when the compressor section is removed 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 8 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 Emerson recommends front seating the compressor service val
87. ected _ a actuator ___b terminal strip __ Cc plug connections d smoke detector if applicable 4 Coil access plates on left side replaced 5 Motor access plate on right side replaced 6 Water lines brazed 7 Suction and liquid refrigerant lines brazed 8 Unit recharged Filters replaced 10 Panels replaced 58 Disassembling the Liebert DS for Transport Figure 46 Component dimensions upflow air cooled 28 42kW 8 12 ton semi hermetic compressor models Blower amp Electric Box Assembly 76 1930mm Assembled Filter amp Coil Height Assembly 76 1930mm 45 13 16 1163mm 59 33 al 26 838mm 660mm 1499mm 85 Assembled Length 2159mm NOTES Drawing views are simplified with panels removed to show overall dimensions See disassembly and handling instructions in installation manual DPN001171 Rev 0 Table 36 Component weights upflow air cooled 28 42kW 8 12 ton semi hermetic compressor models Dry Weight Approximate Including Panels Ib kg Component Air Cooled Dual Cool Compressor Assembly 800 364 800 364 Blower amp Electric Box Assembly 510 231 510 231 Filter amp Coil Assembly 520 236 670 304 59 Disassembling the Liebert DS for Transport Figure 47 Component dimensions upflow air cooled 28 42kW 8 12 ton scroll digital scroll compressor models Blower amp Electric Box Assembly Compre
88. ection locations downflow water glycol GLYCOO L 53 77kW 15 22 ton all compr ssot Models jo esc se ew ie wos eb A a Elle T whe 96 Primary connection locations downflow air cooled 105kW 80 ton all compressor models 97 Primary connection locations downflow air cooled 105kW 80 ton all compressor models 98 Primary connection locations upflow air cooled 28 42kw 8 12 ton semi hermetic compressor model sis a RR A eo a eae E di ORS 99 Primary connection locations upflow air Cooled 28 42kW 8 12 ton semi hermetic compressor MODELS n d Ake ek e 5 a a bik ahs A BA 100 Primary connection locations upflow water glycol GLYCOOL 28 42kW 8 12 ton all compressor models 101 Primary connection locations upflow air cooled 53 77kW 15 22 ton semi hermetic compressor Models nce cst ede sea a cada 2 102 Primary connection locations upflow air cooled 53 77kW 15 22 ton scroll compressor models tn A a tt Qin leuko es ea 103 Primary connection locations upflow water glycol GLYCOOL 53 77kW 15 22 ton all compressor model yuri ts Seabee TE Stone Aw Alera te dy ads Save R Ha aa ets 104 Primary connection locations upflow air cooled 105kW 30 ton all 105 Primary connection locations upflow water glycol GLYCOOL 105kW 30 ton all 106 Proper filter pleat direction 112 Upflow motor ACCESS Guti a E dak wags a te ane head Ge Lk sad Moa eed 113 Auto belt tensi
89. ed F Equal rom ques Ball Valve COM Vas COMPRESSOR DISCHARGE Control PARADENSER CONDENSER Expansion Solenoid Sight Filter Drier CON Valve Valve Glass Pressure l Control Relief valve s supplied Transducer with 50 Hz EU CE units rated TO SECOND maximum 480 PSIG 33 Bar REFRIGERATION CIRCUIT NOTE TWO REFRIGERATION CIRCUITS PROVIDED SINGLE REFRIGERATION CIRCUIT SHOWN FOR CLARITY FACTORY PIPING Components are not supplied by a FIELD PIPING Liebert but are recommended for proper circuit operation and V SERVICE SCHRADER ACCESS CONNECTION NO VALVE CORE maintenance Field installed at highest point in y SERVICE SCHRADER ACCESS CONNECTION WITH VALVE CORE system on return line to pumps Locate at tops of all risers and any intermediate system high points NOTE SCHEMATIC REPRESENTATION SHOWN THIS SCHEMATIC DOES NOT IMPLY OR DEFINE ELEVATIONS AND COMPONENT LOCATION UNLESS SPECIFICALLY NOTED DPN001432 Rev 0 89 Piping Schematics Figure 65 Optional piping schematic for Econ O Coil Return Supply Return Supply Thermistor o Thermistor Actuator a Actuator Econ O Coil i i Econ O Coil Optional Econ O Coil 2 Way Valve Optional Econ O Coil 3 Way Valve Factory Piping Supplied with 10 feet 3m extra thermistor wire for installation eree Field Piping on field supply line Note 1 Place thermistor in location where flow is always present 2
90. em 2 76 1 2 1943 16 3 4 425 1 2 Cu Sweat G1 Hot Gas Discharge 1 73 7 8 1876 16 3 4 425 5 8 Cu Sweat G2 Hot Gas Discharge 2 70 1 8 1780 16 3 4 425 5 8 Cu Sweat RA Refrigerant Access Side 6 x 17 3 16 152 x 437 CGD Condensate Gravity Drain 3 4 FPT CPD Condensate Pump Discharge Opt 56 1 4 1429 11 1 8 283 1 2 Cu Sweat HUM Humidifier Supply Line 56 1 4 1429 9 1 8 233 1 4 Cu Sweat ECS Econ O Coil Supply 56 1423 7 5 16 186 1 5 8 Cu Sweat ECR Econ O Coil Return 56 1423 4 1 2 114 1 5 8 Cu Sweat E1 Electrical Connection High Voltage 52 3 8 1330 30 762 2 1 2 E2 Electrical Connection High Voltage 46 7 8 1191 30 762 2 1 2 LV1 Electrical Connection Low Voltage 19 1 2 495 29 1 16 738 7 8 LV2 Electrical Connection Low Voltage 19 1 2 495 30 1 2 775 7 8 LV3 Electrical Connection Low Voltage 19 1 2 495 31 15 16 811 7 8 Field pitch condensate drain line a minimum of 1 8 3 2 mm per foot 305 mm All units contain a factory installed condensate trap Do not trap external to the unit Drain line may contain boiling water Select appropriate drain system materials The drain line must comply with all local codes Supplied on Dual Cool systems only 4 pipe system 99 Piping Schematics Figure 75 Primary connection locations upflow air Cooled 28 42kW 8 12 ton semi hermetic compressor models All dimensions from rear corner of unit 10 1 8
91. end coil access plates until brazing is finished Reattach the compressor section Insert all compressor thread cutting bolts before tightening them all down Reinstall the pull bar to support the accent panel Reinstall the low voltage plugs in the compressor section Rewire the compressor reheat humidifier condensate pump and smoke detector if applicable Reattach the sensing tube to the blower inlet Reattach the plug connection at the actuator and reroute the sensor back through electric box and onto control board on GLYCOOL and dual cool units Piping must be reassembled in accordance with local codes Move the insulation and plastic bushings away from the brazing area Wrap the piping with wet cloths Use copper fittings where required Refer to 8 0 Piping for piping guidelines and to the ASHRAE Refrigeration Handbook for general good practice refrigeration piping Open service valves on compressor Reinsert plastic bushings Charge the Liebert DS with refrigerant see the unit s nameplate for the proper charge Replace the galvanized panels on the left side of the coil Replace the filters Replace the panels Reassembly Checklist 1 Thread cutting bolts reconnected at a torque specification of 225 in lb 25Nm 2 High voltage wires connected to proper contactors __ a compressor ___b reheat if applicable c humidifier if applicable d condensate pump if applicable 3 Low voltage wires conn
92. er Fluid Piping Entrance Required for condenser cleanout Secondary Entrance Secondary Entrance High Volt Connection s Low VOIE COnNECNONS zj 610mm Y Minimum required for filter replacement 76 1930mm FRONT VIEW Shaded area indicates a om 2 108 recommended minimum 51mm 2743mm clearance for component access DPN000931 Rev 3 Table 8 Weights for downflow water glycol GLYCOOL 53 77kW 15 22 ton all compressor models Compressor Dry Weight Ib kg Approximate Type Model 053 070 077 Semi Hermetic Water Glycol 2650 1205 2700 1228 2750 1250 Compressor GLYCOOL Dual Cool 2830 1287 2880 1310 2930 1332 Scroll or Water Glycol 2220 1010 2270 1032 2320 1055 Digital Scroll Compressor GLYCOOL Dual Cool 2400 1091 2450 1114 2500 1137 16 Liebert DS Dimensions and Weights Figure 12 Cabinet and floor planning dimensions downflow air cooled 105kW 30 ton all compressor models Second Refrigerant Piping Entrance 102 13 16 Opening 2611mm 33 838mm Air Inlet Opening 35 889mm A AS Top View Secondary Entrance High Volt Connection s Secondary Entrance Low Volt Connections 132 R 3353mm 76 1930mm Front View 131 3327mm Notes Filters are accessible only through top of unit Downflow electrical connections can be made from top o
93. etic Compressor Spring Isolation System a Remove rubber band from float in optional infrared humidifier 9 Installation materials and tools have been removed from equipment literature shipping materials construction materials tools etc 10 Locate blank startup sheet ready for completion by installer or startup technician 107 Initial Startup Checks and Commissioning Procedure for Warranty Inspection 11 0 INITIAL STARTUP CHECKS AND COMMISSIONING PROCEDURE FOR WARRANTY INSPECTION A 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 A WARNING Risk of improper wiring piping moving lifting and or handling Can cause equipment damage injury or death Only qualified service personnel should move install or service this equipment Read all installation operating and safety instructions before proceeding Read and follow all warnings on page 1 and elsewhere in this manual A WARNING Risk of fire suppression and alarm system activation Can cause injury during building evacuation and mobilization of emergency fire and rescue services Startup operation of optional electric reheat elements may activate facility alarm and fire
94. filter box package A WARNING Risk of high speed moving parts Can cause injury or death Disconnect all local and remote electric power supplies before working in the unit Do not operate upflow units without installing a plenum ductwork or guard over the blower opening s on the top surface of the unit cabinet Ductwork must be connected to the blower s or a plenum must be installed on the blower deck for protection from rotating blower wheel s on upflow units Figure 5 Upflow ducting configurations A Straight section of duct off of unit to be 1 5 to 2 5 times the longest blower dimension YA Typical ducting shown ducting may run to either side DPNO01156 Follow standard practices on all duct work Rev 0 NOTE Drain traps are qualified to a return duct static of negative 1 5 i w g 1 5 i w g Pre Installation Guidelines 3 4 Connections and System Setup Plan the routing of wiring piping and ductwork to the unit See Figure 55 and Figures 66 through 79 for unit connection locations Water glycol and GLYCOOL units utilizing a drycooler may require an optional aquastat setting See Tables 58 through 57 aquastat setting guidelines Applications with the optional stat set ting require field piping to be insulated to prevent condensation The unit requires a drain which must comply with all applicable codes This drain line may con tain boiling water See 8 1 1 Condensate Piping Field Installed for de
95. ght for upflow air cooled 28 42kW 8 12 ton scroll or digital scroll compressor models Weights for upflow water glycol GLYCOOL 28 42kW 8 12 ton all compressor models Weights for upflow air cooled 53 77kW 15 22 ton semi hermetic compressor models Weight for upflow air cooled 53 77kW 15 22 ton scroll or digital scroll compressor models Weights for upflow water glycol GLYCOOL 53 77kW 15 22 ton all compressor models Weights upflow air cooled 105kW 30 ton all Weights upflow water glycol GLYCOOL 105kW 30 ton all compressors Floor stand and floor planning dimensions downflow 28 42kW 8 12 ton models Floor stand and floor planning dimensions downflow 53 77kW 15 22 ton models Floor stand and floor planning dimensions downflow 105kW 30 ton models Dimensions for upflow 28 42kW 8 12 ton 0 0 cence ees Blower outlet and deck dimensions for upflow 53 77kW 15 22 ton 00000 eee Blower outlet and deck dimensions upflow 105kW 30t0D 0 00 0 cece eee ee eee Rear return filter box dimensions 0 ccc ee nee eee eee ees Upflow unit plenum dimensions aaaea c cc cee eee eee e ees Component weights downflow air cooled 28 42kW 8 12 ton semi hermetic Component weights downflow air cooled 28 42kW 8 12 ton scroll digital scroll Component weights downflow water glycol GLYCOOL
96. gurations use a filter box that attaches to the back of the Liebert DS Refer to rear return installation sheet 187230P1 located inside rear return filter box package 41 Disassembling the Liebert DS for Transport 6 0 DISASSEMBLING THE LIEBERT DS FOR TRANSPORT 6 1 6 2 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 This procedure requires four or more people for lifting the filter and electric box assembly on down flow units and for lifting the blower and electric box assembly on upflow units A WARNING Risk of explosive discharge from high pressure refrigerant Can cause injury or death This unit contains fluids and or gases under high pressure Relieve pressure before working with piping compressors or other internal components A WARNING Risk of top heavy unit falling over Improper handling can cause equipment damage injury or death Read all instructions before attempting to move or lift unit Installation and service of this equipment should be done only by properly trained and qualified personnel who have been specially trained in the installation of air conditioning equ
97. he compressor section on its side during or after removing it from the Liebert DS Do not remove shipping blocks from semi hermetic compressors until the Liebert DS is fully reassembled and ready for installation NOTE Emerson recommends using piano jacks when moving this section 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 Coil top blocker will remain with top section for rigidity 4 Remove coil access plates from the left side of the Liebert DS 5 Remove the four thread cutting bolts securing the filter and electric box assembly to the blower and coil assembly There are two on the left and two on the right 6 Separate the unit sections with caution NOTICE Risk of improper handling The filter and electric box section should be moved forward and set on the floor Make sure to lift the coil plate over the Schrader fittings on the headers Emerson recommends using four people to remove this section Special care is required when moving this section because the legs are not designed to withstand strong shocks The blower and coil assembly mus
98. ials The drain line must comply with all local codes Supplied on Dual Cool systems only 4 pipe system 98 Piping Schematics Figure 74 Primary connection locations upflow air cooled 28 42kw 8 12 ton semi hermetic compressor models All dimensions from 22 1 2 rear corner of unit NOTES 572mm including panels 1 Drawing not to scale 2 Tolerance on all piping dimensions BI is 1 2 13mm eqn 6 m A Field routed alternatives for refrigerant 35 386mm gas and liquid line connection points 889mm See submittal page DPN001120 for a E blower outlet and deck dimensional data 4 102mm BN La 86 2184mm Top View X Lt L2 GT G2 16 7 16 418mm Front of Unit 152mm 17 3 16 20 1 16 L1 L2 437mm 509mm j ZZZZZZX LL LLL 14 1 4 Keng i E 15 7 8 Factory Location Front Section View 403mm Left Front Panel Not Shown DPN001114 Left Side Section View Rev 02 X Y Connection Size Opening Point Description inches mm inches mm inches mm RIA Refrigerant Access Top 60 11 16 1542 1 7 8 48 22 1 2 x 15 3 16 572 x 386 R2A Refrigerant Access Bottom 63 1600 13 13 16 351 16 7 16 x 4 418 x 102 L1 Liquid Line System 1 79 3 16 2011 16 3 4 425 1 2 Cu Sweat L2 Liquid Line Syst
99. il Supply 56 1423 7 5 16 186 1 5 8 Cu Sweat ECR Econ O Coil Return 56 1423 4 1 2 114 1 5 8 Cu Sweat El Electrical Connection High Voltage 52 3 8 1330 30 762 2 1 2 E2 Electrical Connection High Voltage 46 7 8 1191 30 762 2 1 2 LV1 Electrical Connection Low Voltage 19 1 2 495 29 1 16 738 718 LV2 Electrical Connection Low Voltage 19 1 2 495 30 1 2 775 7 8 LV3 Electrical Connection Low Voltage 19 1 2 495 31 15 16 811 718 Field pitch condensate drain line a minimum of 1 8 3 2 mm per foot 305 mm All units contain a factory installed condensate trap Do not trap external to the unit Drain line may contain boiling water Select appropriate drain system materials The drain line must comply with all local codes Supplied on Dual Cool systems only 4 pipe system 100 Piping Schematics Figure 76 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 Field routed alternatives for water glycol connections See submittal page DPN00 1120 for blower outlet All dimensions from rear corner of unit including and deck dimensional data panels 0 35 889mm 203mm Y 86 2184mm Top View of Unit Front CGD Front Section View
100. in the high side refrigerant circuit 75 Piping 8 2 1 Piping Guidelines Air Cooled Units Indoor unit ships with a nitrogen holding charge do not vent the evaporator until all refrigerant piping is in place ready for connection to the unit and condenser Use copper piping with high temperature brazed joints Isolate piping from building using vibration isolating supports Refer to Table 45 for piping sizes Refer to condenser installation manual for charging information Install traps on hot gas discharge lines at the base of vertical risers and every 25 feet 7 6m of vertical rise Consult factory if condenser is installed more than 15 feet 4 6m below the evaporator Consult factory if piping run exceeds 150 feet 46m equivalent length Keep piping clean and dry especially on units with R 407C refrigerant Avoid piping runs through noise sensitive areas Do not run piping directly in front of airstream Refrigerant oil do not mix oil types see 12 7 1 Compressor Oil Refer to ASHRAE Refrigeration Handbook for general good practice refrigeration piping Table 45 Recommended refrigerant line sizes OD copper inches Standard Scroll Models Non Digital Scroll Model 028 035 042 053 070 077 105 Equivalent Gas Liquid Gas Liquid Gas Liquid Gas Liquid Gas Liquid Gas Liquid Gas Liquid Length Line Line Line Line Line Line Line Line Line Line Line Line Line Line 50 ft
101. inches mm inches mm inches mm R1A Refrigerant Access Top 83 3 4 2127 1 7 8 48 22 1 2 x 15 3 16 572 x 386 R2A Refrigerant Access Bottom 86 2184 13 7 8 352 16 7 16 x 4 418 x 102 53kW 15 ton 70 amp 77kW 20 8 22 ton L1 Liquid Line System 1 97 2464 16 3 4 425 1 2 5 8 Cu Sweat L2 Liquid Line System 2 93 5 16 2370 16 3 4 425 1 2 5 8 Cu Sweat G1 Hot Gas Discharge 1 90 5 8 2302 16 5 8 422 7 8 1 1 8 Cu Sweat G2 Hot Gas Discharge 2 88 2235 16 5 8 422 7 8 1 1 8 Cu Sweat R3A Refrigerant Access Side 6 x 17 3 16 152 x 437 CGD Condensate Gravity Drain 3 4 FPT CPD Condensate Pump Discharge Opt 79 5 16 2015 11 7 8 302 1 2 Cu Sweat HUM Humidifier Supply Line 79 5 16 2015 9 7 8 251 1 4 Cu Sweat ECS Econ O Coil Supply 78 5 8 1998 7 7 8 200 2 1 8 Cu Sweat ECR Econ O Coil Return 78 5 8 1998 4 5 8 117 2 1 8 Cu Sweat E1 Electrical Connection High Voltage 75 3 8 1915 30 762 2 1 2 E2 Electrical Connection High Voltage 69 7 8 1775 30 762 2 1 2 LV1 Electrical Connection Low Voltage 19 1 2 495 29 1 16 738 7 8 LV2 Electrical Connection Low Voltage 19 1 2 495 30 1 2 775 7 8 LV3 JElectrical Connection Low Voltage 19 1 2 495 31 15 16 811 718 Field pitch condensate drain line a minimum of 1 8 3 2 mm per foot 305 mm All units contain a factory installed condensate trap Do not trap external to the unit Drain line may contain
102. ing t Lifting Distance E e Equal Distance Equal 181659P1 Rev 5 Figure 35 Using rigging to lift Liebert DS off skid CENTER OF GRAVITY 40 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 Repeat for remaining feet and recheck all when done 5 4 Placing the Unit on a Floor Stand Liebert Floor Stand Ensure that the optional turning vane is installed in the floor stand if included prior to placing the unit Refer to the floor stand installation sheet 182278P1 located inside the floor stand package Lower the unit onto the floor stand Refer to Detail A in Figure 36 Be sure to align the welded tabs on top of the floor stand with the inside of the unit frame base Figure 36 Setting the unit on a floor stand Welded Tab DETAIL A Liebert Floor Stand front discharge shown Upflow rear return confi
103. ing 3 4 Bezels 9mm ml 1 Top View Minimum required Secondary Entrance Secondary Entrance for filter replacement High Volt Connection s Low Volt Connections 76 1930mm gt 864mm Shaded area indicates a recommended minimum clearance for component l au Front View access DPN000796 51mm 72 Rev 2 1829mm Table 4 Weights for downflow air cooled 28 42kW 8 12 ton scroll compressor models Dry Weight Ib kg Approximate Model No 028 035 042 Air Cooled 1470 668 Dual Cool 1620 736 12 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 Notes Filters are accessible through top of unit only Downflow electrical 33 24 3 8 connections can be made 838mm 619mm from top or bottom of unit 35 Opening 889mm y Bezels Hamm Required for condenser cleanout Secondary Condenser Top View Fluid Piping Entrance Secondary Entrance L Secondary Entrance Low Volt Connections 24 High Volt Connection s 610mm 86 2184mm Minimum required for filter replacement 76 1930mm 34 864mm Shaded area indicates a recommended minimum L clearance for component 1 i access DPN000894 2 Front View 51mm 85 2159mm T Rev 3 Tabl
104. ing liquid refrigerant to an operating system it may be necessary to add the refrigerant through the compressor suction service valve Care must be exercised to avoid damage to the compressor Emerson recommends connecting a sight glass between the charging hose and the compressor suction service valve This will permit adjustment of the cylinder hand valve so that liquid can leave the cylinder while allowing vapor to enter the compressor Turn on unit disconnect switch Operate the unit for 30 minutes using the charging function for System 1 and System 2 in the diagnostic section of the COM control see COM user manual SL 18835 The charging function operates the compressor at full capacity and energizes the blower motor and the liquid line solenoid valve The reheat and humidifier are disabled A minimum 20psig 138kPa must be established and maintained for the compressor to operate The charging function can be reset as many times as required to complete unit charging Table 49 Fan speed suction pressure transducer settings R 22 R 407C Gauge Sea Level Absolute Gauge Sea Level Absolute Function psiG kPa psiA kPa psiG kPa psiA kPa Pump Down Cutout T 20 138 35 241 2003 35 241 Pump Down Reset 65 448 80 552 65 448 80 552 Minimum to Start Cooling 35 241 50 344 35 241 50 344 Low Pressure Cutout DX only 48 331 63 434 52 358 67 461 6 Charge the unit until
105. ions in mm Compressor Type A B C D Filters 28 42kW 8 12 ton Air Cooled Scroll and Air Cooled Digital Scroll Models 4 1 4 108 50 3 4 1289 18 457 47 5 8 1210 4 28 42kW 8 12 ton Semi Hermetic and all Water Glycol GLYCOOL Models 4 1 4 108 50 3 4 1289 31 787 47 5 8 1210 4 53 77kW 15 22 ton Air Cooled Scroll and Air Cooled Digital Scroll Models 3 1 4 83 75 1 2 1918 19 1 4 489 72 3 8 1838 6 53 77kW 15 22 ton Semi Hermetic and all Water Glycol GLYCOOL Models 3 1 4 83 75 1 2 1918 30 1 4 768 72 3 8 1838 6 105kW 30 ton All Models 2 1 4 57 100 1 4 2546 29 1 2 749 97 1 8 2467 8 33 Liebert DS Dimensions and Weights Figure 29 Upflow unit plenum dimensions Front Views Check One 1 O with Grille L Without Grille Left Side Views Check One 1 C With Grille L Without Grille Side View Unit With Plenum Notes 1 Typical 53 77kW 15 22ton unit orientation shown with grille plenum num selection View varies by unit size and ple Panel removable for condenser cleanout access water glycol GLYCOOL models only Rear Views Check One 1 C With Grille L Without Grille Front View Unit With Plenum 2 All plenums are shipped flat and must be field assembled 3 Optional grille plenum kits must include front or rear grille 4 Non grille plenum
106. ipment A CAUTION Risk of sharp edges and heavy parts Can cause personal injury Only properly trained and qualified personnel wearing appropriate safety headgear gloves shoes and glasses should attempt to move lift remove packaging from or prepare unit for installation NOTICE Disassembling this unit requires substantial work including reclaiming refrigerant and charging the unit cutting and brazing refrigerant lines cutting and brazing water lines disconnecting and reconnecting electrical lines and moving heavy bulky equipment One member of the crew disassembling the unit must be qualified in wiring brazing and refrigeration Improperly disassembling or reassembling the Liebert DS may affect warranty Required Equipment e Piano jacks Stepladder for downflow units Refrigeration tools Disassembly Downflow Units For detailed views of downflow units see Figures 37 through 45 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 Some cable ties must be cut and replaced Refer to the unit s wiring schematic on the unit s deadfront panel for details 42 Disassembling the Liebert DS for Trans
107. ital scroll Dry Weight Approximate Ib kg Component Air Cooled Dual Cool Compressor Assembly 490 223 490 223 Filter amp Electric Box Assembly 210 96 210 96 Blower amp Coil Assembly 770 350 920 418 Disassembling the Liebert DS for Transport Figure 39 Component dimensions downflow water glycol GLYCOOL 28 42kW 8 12 ton all compressor models RS NE y lo SS N U sE Compressor Assembly Blower amp Coil XS O 76 1930mm TN O 33 838mm 3 Filter amp Electric Box Assembly Assembly 26 660mm 59 1499mm 85 2159mm Assembled Length 991mm d 76 1930mm Assembled Height 60 3 16 1529mm 37 940mm NOTES Drawing views are simplified with panels removed to show overall dimensions See disassembly and handling instructions in installation manual DPN000899 Rev 1 Table 29 Component weights downflow water glycol GLYCOOL 28 42kW 8 12 ton all Dry Weight Approximate Including Panels Ib kg Semi Hermetic Compressor Scroll or Digital Scroll Compressor Component Water Glycol GLYCOOL Dual Cool Water Glycol GLYCOOL Dual Cool Compressor Assembly 950 432 950 432 800 364 800 364 Filter amp Electric Box Assembly 210 96 210 96 210 96 210 96 Blower amp Coil Assembly 770 350 920 418 770 350 920 418
108. l valve During unloaded operation the pressure changes during each digital cycle could result in excessive repositions with a pressure operated water regulating valve The control algorithm for the motorized ball valve uses an intelligent sampling rate and adjustable pressure thresholds to reduce valve repositions The valve assembly consists of the brass valve linkage and actuator Control The valve actuator operates on 24VAC power and is controlled by a 2 10VDC proportional control sig nal The valve full open to full close time is 60 seconds At 2VDC the valve is closed at 10VDC the valve is fully open There is a 20 second delay to position the motorized ball valve before starting the compressor Control Method The control utilizes an upper and lower pressure threshold with a 35 PSI 241 kPa deadband to reduce valve movement If the liquid pressure is between the upper and lower threshold the valve remains at the current position If the liquid pressure exceeds the upper threshold the valve opens and if the pressure falls below the lower threshold the valve closes There are multiple adjustment bands to ease discharge pressure back into control range Adjustment Both pressure thresholds can be shifted simultaneously over a 50 PSI 345 kPa range the 35 PSI 241 kPa differential remains constant The ball valve setpoint offset parameter in the Service menu can be adjusted from 0 to 50 PSI 345 kPa to raise or lower the control band
109. led 53 77kW 15 22 ton semi hermetic compressor models Dry Weight Ib kg approximate Model 053 070 077 Air cooled 2350 1069 2500 1134 Dual Cool 2530 1150 2680 1216 22 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 Alternate Refrigerant Piping Entrance 3 4 Minimum required 19mm for blower replacement Bezels Top View Low Volt High Volt Connection s Connection s 1 1 2 T ae Shaded area indicates a recommended minimum clearance for component au access 51mm enon Note Front air return unit shown For rear return unit Front View in addition to front service area shown also include 25 635mm on one side of unit for access to rear return filter box See DPN001196 Figure 28 DPNO001166 Rev 1 Table 15 Weight for upflow air cooled 53 77kW 15 22 ton scroll or digital scroll compressor models Dry Weight Ib kg approximate Model No 053 070 077 Air Cooled 2070 939 Dual Cool 2250 1021 23 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 3 4 19mm Required for Bezels condenser cleanout Alternate Condenser Fluid Piping
110. ly open dry contacts are closed across terminals 94 and 95 and 96 and 97 for remote indication 1A 24VAC max load Use Class 1 field supplied wiring Main fan auxiliary switch On closure of main fan contactor normally open dry contact is closed across terminals 84 and 85 for remote indication 1A 24VAC max load Use Class 1 field supplied wiring Liebert Liqui tect shutdown and dry contact On Liebert Liqui tect activation normally open dry contact is closed across terminals 58 and 59 for remote indication Liebert Liqui tect sensor ordered separately 1A 24VAC max load Use Class 1 field supplied wiring NOTE Refer to specification sheet for total unit full load amps wire size amps and maximum overcurrent protective device size 71 Piping 8 0 PIPING 8 1 8 1 1 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 Refer to specific text and detailed diagrams in this manual for other unit specific piping require ments All piping below the elevated floor must be located so that it offers the least resistance to air flow Careful planning of the piping layout under
111. main breaker and check with a meter 8 Replace all fuses you removed in Step 2 9 Restore power to unit turn ON the main unit disconnect switch press the on button 10 Check and record the current draw on all line voltage components and match with serial tag NOTE Electric Reheat See Warning on page 108 Activate for a minimum of five 5 minutes 11 Check for unusual noises and vibration Note on warranty inspection form s comments section y D 12 Check all refrigerant and water lines for leaks Note on warranty inspection form s comments section 13 Record all of the following on the warranty inspection form All component voltages and current draws All air water temperatures indoor and outdoor All refrigerant and water glycol pressures All levels of refrigerant and oil in sight glasses Record refrigerant pressure switch settings and operating pressures Record superheat and sub cooling R GR op NOTE Unit superheat cannot be adjusted but should be in the range of 10 to 20 F 12 to 6 C 14 Test all control sequences and functions of your unit for proper operation UseiCOM User Manual for guide to system control operations 15 Complete the warranty inspection form with sign off data Return Completed Startup Form to Your Local Emerson Sales Office Local Emerson sales offices and air product support contacts can be found on the Liebert Web site www liebert com or call 1 800 LIEBERT for Air Pr
112. mes as required to complete unit charging Table 50 Lee Temp suction pressure transducer settings R 22 R 407C Gauge Reading Gauge Reading Sea Level Absolute Sea Level Absolute Function psiG kPa psiA kPa psiG kPa psiA kPa Pump Down Cutout 20 138 35 241 20 138 35 241 Pump Down Reset 65 448 80 552 65 448 80 552 Minimum to Start Cooling 50 345 65 448 50 345 65 448 Low Pressure Cutout DX only 48 331 63 434 52 358 67 461 6 Charge the unit until the liquid line sight glass becomes clear Then add one additional pound 2 2 kg of refrigerant NOTE A digital scroll compressor will have a clear sight glass only when operating at 100 capacity When operating below 100 the sight glass may show bubbles with each 15 second unloading cycle Lee Temp Receiver Refrigerant Level On each receiver at the condenser are two refrigerant level sight glasses Refrigerant level will vary with outside temperature Check refrigerant level after the unit has been on for at least 15 minutes 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 81 Piping Schematics 9 0 PIPING SCHEMATICS Figure 57 Piping schematic air cooled semi hermetic compressor models Relief Valve l Inverted trap on discharge and liquid Servi
113. minimum of 1 8 3 2mm per foot 305mm All units contain a factory installed condensate trap Do not trap external to the unit Drain line may contain boiling water Select appropriate drain system materials The drain line must comply with all local codes Supplied on Dual Cool systems only 4 pipe system 93 Piping Schematics Figure 69 Primary connection locations downflow air Cooled 53 77kW 15 22 ton semi hermetic compressor models Note Drawing not to scale All dimensions Tolerance on all from rear corner piping dimensions 4 orumi including E anels is 1 2 13mm A Front View A P X Section A A lt _ __ 0 j Blower 16116 Blower Outlet 408 mm Outlet 4 102mm R L1 L2 G1 G2 0000 Tl kesz Front of Unit E1 E2 ee Blower Outlet 15 x 11 54 3 8 1381 18 1 16 459 109 2769mm DPN000928 Rev 2 Xx Y Connection Size Opening Point Description inches mm inches mm inches mm R Refrigerant Access 82 3 4 2102 13 7 8 352 16 7 16 x 4 418 x 102 53kW 15ton 70 amp 77kW 20 amp 22ton L1 Liquid Line System 1 97 2464 16 7 8 428 1 2 5 8 Cu Sweat L2 Liquid Line System 2 93 5 16 2370 16 7 8 428 1 2 5 8 Cu Sweat G1 Hot Gas Discharge 1 90 5 8 2302 16 5 8 422 7 8 1 1 8 Cu Sweat G2 Hot Gas Discharge 2 88 2235 16 5 8 422 7 8 1 1 8 Cu Sweat cD Condensate Drai
114. mm Assembled Filter amp Coil Height Assembly 76 1930mm L aar 15 La porra oi EI 838mm 381mm 97 2464mm Assembled Length NOTES Drawing views are simplified with panels removed to show overall dimensions See disassembly and handling instructions in installation manual DPN001210 Rev 0 Table 40 Component weights upflow air cooled 53 77kw 15 22 ton scroll digital scroll compressor models Dry Weight Approximate Including Panels Ib kg Component Air Cooled Dual Cool Compressor Assembly 540 246 540 246 Blower amp Electric Box Assembly 770 349 770 349 Filter amp Coil Assembly 760 345 940 426 63 Disassembling the Liebert DS for Transport Figure 51 Component dimensions upflow water glycol GLYCOOL 53 77kw 15 22 ton all compressor models Na gt d IIA A p Y Blower Electric Box Assembly 76 1930mm Assembled Filter 8 Coil Height Assembly i El TH ac MEA y 45 13 16 1163mm 838mm a 2083mm 108 2743mm Assembled Length NOTES Drawing views are simplified with panels removed to show overall dimensions See disassembly and handling instructions in installation manual Ben etan Table 44 Component weights upflow water glycol GLYCOOL 53 77kW 15 22 ton all compressor models Dry Weight Approximate Including Panels Ib kg Semi Hermetic C
115. models cece eens Piping schematic air cooled scroll compressor models 0 00 cece cence eee eee Piping schematic water glycol semi hermetic compressor models eee eee Piping schematic water glycol with scroll compressor models 0c cece eee Piping schematic GLYCOOL semi hermetic compressor modela 0 000 cece Piping schematic GLYCOOL with scroll compressor models 0 000 cece eee es Piping schematic water glycol with digital scroll compressor modela GLYCOOL with digital scroll compressor models 0 0 cece ee ene eens Optional piping schematic for Econ O Coil o Primary connection locations downflow air cooled 28 42kW 8 12 ton semi hermetic Compressor Models a tits Primary connection locations downflow air Cooled 28 42kW 8 12 ton with scroll Compressor models Dia A AA Cin A ERRER RE T Primary connection locations downflow water glycol GLYCOOL 28 42kW 8 12 ton alkkcompressor models 3 a ii A A A RER title Primary connection locations downflow air Cooled 53 77kW 15 22 ton semi hermetic compressor models ai a tt da ta aos Figure 70 Figure 71 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 Primary connection locations downflow air Cooled 53 77kW 15 22 ton with scroll Compressor madele 6 R R nee oe Z TREE Bw alan e SE SR es 95 Primary conn
116. n 69 1 4 1759 30 762 3 4 FPT W Optional Pump 69 1 4 1759 30 762 1 2 Cu Sweat HUM Humidifier Supply Line 76 1 2 1943 29 736 1 4 Cu Sweat ECS Econ O Coil Supply 78 5 8 1997 22 1 4 565 2 1 8 Cu Sweat ECR Econ O Coil Return 72 1829 29 737 2 1 8 Cu Sweat HS Hot Water Reheat Supply Consult Factory HR Hot Water Reheat Return Consult Factory E1 Electrical Connection High Volt 78 1 2 1994 31 1 8 790 2 1 2 E2 Electrical Connection High Volt 75 3 8 1915 31 1 8 790 2 1 2 LV1 Electrical Connection Low Volt 1 7 8 48 28 1 2 724 7 8 LV2 Electrical Connection Low Volt 1 7 8 48 30 1 4 768 7 8 LV3 Electrical Connection Low Volt 1 7 8 48 32 813 7 8 E Blower Outlet 15 x 15 23 1 8 587 18 1 16 459 18 3 4 x 16 1 16 476 x 408 Blower Outlet 15 x 11 27 3 4 705 18 1 16 459 14 3 4 x 16 1 16 375 x 408 B2 Blower Outlet 15 x 15 50 3 8 1280 18 1 16 459 18 3 4 x 16 1 16 476 x 408 14 3 4 x 16 1 16 375 x 408 Field pitch condensate drain line a minimum of 1 8 3 2mm per foot 305mm All units contain a factory installed condensate trap Do not trap external to the unit Drain line may contain boiling water Select appropriate drain system materials The drain line must comply with all local codes Supplied on Dual Cool systems only 4 pipe system 94 Piping Schematics Figure 70 Primary connection locations downflow air Cooled 53 77kW 15 22 ton with scroll com
117. n speed control operation __ 11 Motor amp draw 1 L1 L2 L3 L1 and L2 on Fan Speed Control Motor 2 L1 L2 L3 3 L1 L2 L3 4 L1 L2 L3 5 L1 L2 L3 6 L1 L2 L3 7 L1 L2 L3 8 L1 L2 L3 9 L1 L2 L3 10 L1 L2 L3 Glycol Pump ___ 1 Check pump rotation ___ 2 Check for glycol leaks __ 3 Pump pressures 1 Suction Discharge 2 Suction Discharge 3 Suction Discharge _ 4 Amp Draw 1 L1 L2 L3 2 L1 L2 L3 3 L1 L2 L3 5 Pump changeover if multiple pumps Notes Signature Company Make photocopies for your records Compare readings information to previous maintenance work sheet To locate your local Emerson representative for Liebert engineered parts check the Liebert Web site www liebert com or call 1 800 LIEBERT 124 Ensuring The High Availability Of Mission Critical Data And Applications SS ts I Emerson Network Power the global leader in enabling business critical Technical Support Service continuity ensures network resiliency and adaptability through _ Web Site a family of technologies including Liebert power and cooling www liebert com Monitoring technologies that protect and support business critical systems Liebert solutions employ an adaptive architecture that responds papi monitoring emersonnetworkpower com to changes in criticality density an
118. nding on refrigerant type 2 Refrigerant charging requires unit operation Refer to 10 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 46 and 47 eigh in as much of the system charge as possible before starting the unit 4 W A CAUTION Risk of improper refrigerant charging Can cause equipment damage Refrigerant R407C is a blend of three components and must be introduced and charged from the cylinder only as a liquid When adding liquid refrigerant to an operating system it may be necessary to add the refrigerant through the compressor suction service valve Care must be exercised to avoid damage to the compressor Emerson recommends connecting a sight glass between the charging hose and the compressor suction service valve This will permit adjustment of the cylinder hand valve so that liquid can leave the cylinder while allowing vapor to enter the compressor 5 Turn on unit disconnect switch Operate the unit for 30 minutes using the charging function for System 1 and System 2 in the diagnostic section of the iCOM control The charging function operates the compressor at full capacity and energizes the blower motor and liquid line solenoid valve The reheat and humidifier are disabled A minimum 20psig 138kPa must established and maintained for the compressor to operate The charging function can be reset as many ti
119. nect refrigeration gauges to the suction and discharge service valves of both compressors For scroll and digital scroll compressors connect refrigerant gauges to the suction rotalock valves and discharge line Schrader valves see Note above on both compressors Starting with Circuit 1 open the service valves and place a 150 PSIG 1034 kPa of dry nitrogen with a tracer of refrigerant Check system for leaks with a suitable leak detector With pressure still in Circuit 1 open the compressor service valves in Circuit 2 If pressure increases in Circuit 2 the system is cross circuited and must be rechecked for proper piping If there is no pressure increase repeat the leak check procedure for Circuit 2 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 80 Piping 8 After four hours check the pressure readings and if they have not changed break vacuum with dry nitrogen Pull a second R 407C and R 22 and third R407C only vacuum to 250 microns or less Recheck the pressure after two hours After completing this step proceed to Fan Speed Charging on page 79 9 Remove the jumper hose installed previously from between the service valve fitting and the condenser After completing this step proceed to Lee Temp Charging Lee Temp Charging 1 Check unit nameplate for refrigerant type to be used Unit control configurations differ depe
120. nsions A is 1 2 13mm W S O WR Front View Section A A Blower Outlet All dimensions from rear corner of unit including panels 16 1 16 Y LD 35 i 889mm Front of Unit aa 86 gt a roan DPNO00900 Rev 2 Xx Y Connection Size Opening Point Description inches mm inches mm inches mm W Water Glycol GLYCOOL Access 79 15 16 2030 9 1 16 230 3 1 2 x 8 89 x 203 WS Water Glycol GLYCOOL Supply 82 15 16 2107 10 15 16 278 1 5 8 Cu Sweat WR Water Glycol GLYCOOL Return 82 15 16 2107 14 1 16 357 1 5 8 Cu Sweat en Condensate Drain 46 1168 29 1 2 749 3 4 FPT W Optional Pump 46 1168 29 1 2 749 1 2 Cu Sweat HUM Humidifier Supply Line 53 1 2 1359 29 737 1 4 Cu Sweat ECS Econ O Coil Supply 54 7 8 1394 22 9 16 573 1 5 8 Cu Sweat ECR Econ O Coil Return 49 13 16 1265 28 1 2 724 1 5 8 Cu Sweat HS Hot Water Reheat Supply Consult Factory HR Hot Water Reheat Return Consult Factory E1 Electrical Connection High Volt 55 1 2 1410 31 1 4 794 2 1 2 E2 Electrical Connection High Volt 52 7 16 1332 31 1 4 794 2 1 2 LV1 Electrical Connection Low Volt 2 1 4 57 27 686 7 8 LV2 Electrical Connection Low Volt 2 1 4 57 29 737 7 8 LV3 Electrical Connection Low Volt 2 1 4 57 31 787 7 8 B Blower Outlet 21 15 16 557 18 1 16 459 18 3 4 x 16 1 16 476 x 408 Field pitch condensate drain line a
121. oduct Support 110 Maintenance 12 0 MAINTENANCE 12 1 A 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 A WARNING Risk of improper wiring piping moving lifting and handling Can cause equipment damage injury or death Only qualified service personnel should work on this equipment Read all installation operating and safety instructions before proceeding Read and follow all warnings in this manual The Liebert DS product is a single component in the facility heat removal system The system includes air distribution raised floors duct systems outdoor heat rejection condensers pumps dry coolers cooling towers piping heat rejection fluid ambient temperature etc and indoor cooling and humidity loads equipment load location outside air infiltration Proper application and mainte nance of the entire system is critical to the life and reliability of the Liebert DS Good maintenance practices are essential to minimizing operation costs and maximizing product life Read and follow monthly and semi annual maintenance schedules included in this manual These MINIMUM maintenance intervals may need to be more frequent base
122. ompressor Scroll or Digital Scroll Compressor Component Water Glycol GLYCOOL Dual Cool Water Glycol GLYCOOL Dual Cool Compressor Assembly 1270 578 1270 578 840 382 840 382 Blower amp Electric Box Assembly 770 349 770 349 770 349 770 349 Filter amp Coil Assembly 760 345 940 426 760 345 940 426 64 Disassembling the Liebert DS for Transport Figure 52 Component dimensions upflow air cooled 105kW 30 ton semi hermetic compressor models nh YQ ws Waza NY AD gt ARY ON Blower amp Electric Box Assembly 31 1 4 He 0 el 794mm E R a 4 Compressor Assembly 76 1930mm Assembled Filter amp Coil Assembly Height 45 13 16 1164mm L 33 si L L 105 2667mm 838mm 131 3327mm Assembled Length NOTES Drawing views are simplified with panels removed to show overall dimensions See disassembly and handling instructions in installation manual DPN001254 REVO Table 42 Component weights upflow air cooled 105kW 30 ton semi hermetic compressor models Dry Weight Approximate Including Panels Ib kg Component Air Cooled Dual Cool Compressor Assembly 950 431 950 431 Blower amp Electric Box Assembly 1080 490 1080 490 Filter amp Coil Assembly 970 440 1300 590 65 Disassembling the Liebert DS for Transport Figure 53 Component dimensions upfl
123. oning motor base 114 Correct orientation of float switch 0 0 ce eee nee ene enas 115 vi Table 1 Table 2 Table 3 Table 4 Table 5 Table 6 Table 7 Table 8 Table 9 Table 10 Table 11 Table 12 Table 13 Table 14 Table 15 Table 16 Table 17 Table 18 Table 19 Table 20 Table 21 Table 22 Table 23 Table 24 Table 25 Table 26 Table 27 Table 28 Table 29 Table 30 Table 31 Table 32 Table 33 Table 34 Table 35 Table 36 Table 37 Table 38 Table 39 Table 40 Table 41 Table 42 TABLES Shipping dimensions domestic and export inches mmi Shipping weights approximate kg 6 eee eee eens Weights for downflow air cooled 28 42kW 8 12 ton semi hermetic compressor models Weights for downflow air cooled 28 42kW 8 12 ton scroll compressor models Weights for downflow water glycol GLYCOOL 28 42kW 8 12 ton all compressor models Weights for downflow air cooled 53 77kW 15 22 ton semi hermetic compressor models Weights for downflow air cooled 53 77kW 15 22 ton scroll compressor models Weights for downflow water glycol GLYCOOL 53 77kW 15 22 ton all compressor models Weights for downflow air Cooled 105kW 30 ton all compressor models Weights for downflow water glycol GLYCOOL 105kW 30 ton all compressor models Weight for upflow air cooled 28 42kW 8 12 ton semi hermetic compressor models Wei
124. onn High Volt 98 1 2 2502 30 762 2 1 2 E2 Electrical Conn High Volt 93 2362 30 762 2 1 2 LV1 Electrical Conn Low Volt 41 1 8 1045 30 3 8 772 7 8 LV2 Electrical Conn Low Volt 38 7 8 987 30 3 8 772 7 8 LV3 Electrical Conn Low Volt 35 1 8 892 30 3 8 772 7 8 LV4 Electrical Conn Low Volt 31 5 8 803 30 3 8 772 7 8 Field pitch condensate drain line a minimum of 1 8 3 2 mm per foot 305 mm All units contain a factory installed condensate trap Do not trap external to the unit Drain line may contain boiling water Select appropriate drain system materials The drain line must comply with all local codes 106 Checklist for Completed Installation 10 0 CHECKLIST FOR COMPLETED INSTALLATION 10 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 Ifthe equipment has been disassembled for installation unit must be reassembled per instructions 10 2 Electrical ___ 1 Supply voltage and phase matches equipment nameplate __ 2 Wiring connections completed between disconnect switch evaporator unit and heat rejection equipment 3 Power line circuit breakers or fuses have proper ratings for equipment installed 4 Control wiring connections completed between indoor evaporator and heat rejection eq
125. opper alloys that require appropriate corrosion protection Contact a local water consultant regarding water quality corrosion and freeze protection requirements Water chemistry varies greatly by location as do the required additives called inhibitors that reduce the corrosive effect of the fluids on the piping systems and components The chemistry of the water used must be considered because water from some sources may contain corrosive elements that reduce the effectiveness of the inhibited formulation Preferably surface waters that are classified as soft and are low in chloride and sulfate ion content should be employed Proper inhibitor maintenance must be performed in order to prevent corrosion of the system Consult glycol manufacturer for testing and maintenance of inhibitors Commercial ethylene glycol Union Carbide Ucartherm Dow Chemical Dowtherm SR 1 and Texaco E G Heat Transfer Fluid 100 when pure is generally less corrosive to the common metals of construction than water itself It will however assume the corrosivity of the water from which it is prepared and may become increasingly corrosive with use if not properly inhibited CAUTION Risk of oxide layer formation Can cause equipment damage Idle fluid allows the collection of sediment that prevents the formation of a protective oxide layer on the inside of tubes Keep unit switched ON and system pump operating 74 Piping 8 2 Leak Checking of Unit an
126. orklift s tines must be equally spaced on either side of the center of gravity indicator 1 Space the slings equidistant on either side of the center of gravity indicator see Figure 34 Figure 34 Locate center of gravity marker and place slings Lifting gt Lifting Sling Sling CENTER OF GRAVITY Illustration shows one possible center of gravity The center of gravity on the Liebert DS varies with the options and the model s size Equal Equal 181659P1 Distance Distance Rev 5 2 Place the slings between the bottom rails of the Liebert DS and the top of the skid NOTE Unit is shown without packaging These instructions may be applied with the outer packaging in place 3 Use spreader bars or a similar device and padding to ensure the Liebert DS will not be damaged when the unit is lifted Lifting will force the slings toward the Liebert DS and the slings may damage the unit unless it is properly protected 4 Remove the lag bolts from the bracket securing the Liebert DS to the shipping skid 5 Remove the brackets NOTE Depending on final installation location the skid may need to remain under the unit Therefore the lag bolts and brackets would not yet be removed 6 Lift the Liebert DS off the skid 7 Move the skid from under the unit 39 Equipment Inspection and Handling E E Sl
127. otor comes pre lubricated from factory and does NOT require initial lubrication Emerson recommends a 5 year lubrication interval for motor bearings that have grease fittings Greases of different bases may not be compatible when mixed Contact specific motor manufacturer to determine type of grease to be used Blower Wheel Check to see if wheel s are tightly mounted on fan shaft Rotate wheel s and make sure they do not rub against fan housing The wheel s should be periodically cleaned of dirt and debris 114 Maintenance 12 3 Humidifier 12 3 1 Infrared Humidifier During normal humidifier operation deposits of mineral solids will collect in humidifier pan and on the float switch These must be cleaned periodically to ensure proper operation Frequency of cleaning must be locally established since it is dependant on humidifier usage and local water quality A spare pan is recommended to reduce maintenance time at unit The Liebert autoflush system can greatly increase the time between cleanings but does not eliminate the need for periodic checks and mainte nance see iCOM user manual SL 18835 for autoflush setup To help reduce excessive scaling in loca tions with difficult water quality the use of Vapure is recommended contact your local Emerson representative 12 3 2 Cleaning Humidifier Pan and Float Switch Before turning off unit With unit operating remove call for humidification at iCOM control Let blower o
128. ow air cooled 105kW 30 ton scroll digital scroll compressor models Blower amp Electric Box Assembly Compressor Assembly 76 1930mm Assembled Filter amp Coil Assemb Height 45 13 16 1164mm 26 L 105 660mm 2667mm 131 3327m Assembled Length DPN001255 NOTE Drawing views are simplified with panels removed to show overall dimensions REVO See disassembly and handling instructions in installation manual Table 43 Component weights upflow air cooled 105kW 30 ton scroll digital scroll compressor models Dry Weight Approximate Including Panels Ib kg Component Air Cooled Dual Cool Compressor Assembly 830 376 830 376 Blower amp Electric Box Assembly 1080 490 1080 490 Filter amp Coil Assembly 970 440 1300 590 66 Disassembling the Liebert DS for Transport Figure 54 Component dimensions upflow water glycol GLYCOOL 105kW 30 ton all compressor models N s a a 4 Blower amp Electric Box Assembly 4 31 1 4 794mm Compressor Assembly 227 76 l 1930mm EJ f l Assembled imc Filter amp Coil Assembly Height TG e H i El Sil BI Tea A RAR ARRE 45 13 16 1164mm Lr 838mm 26 660mm 105 131 3327mm Assembled Length 2667mm NOTES Drawing views are simplified with panels removed to show overall dimensions
129. perate 5 minutes to allow humidifier and water to cool If unit has a condensate pump turn unit OFF at iCOM control Pull out humidifier standpipe in pan Inspect O ring replace if necessary Let pan drain and condensate pump operate if applicable Disconnect power from unit Disconnect drain coupling from bottom of pan 0500 pest 02 SOU OS Remove thermostat from bottom of pan and retaining screws from sides of pan Slide pan out Loosen scale on side and bottom of pan with a stiff nylon brush or plastic scraper Flush with water Carefully clean scale on float switch make sure to reinstall correctly see Figure 85 h hp W G LA A Reinstall pan thermostat standpipe drain coupling and screws into humidifier Operate humidifier and check for leaks pa a Figure 85 Correct orientation of float switch Correct Switch Orientation Incorrect Switch Orientation DPNO00996 Rev 0 115 Maintenance 12 3 3 Changing Humidifier Lamps NOTE Touching quartz lamps with bare hands will severely shorten bulb life Skin oils create hot O po SIS Qt ES b 10 spots on lamp surface Wear clean cotton gloves when handling lamps Remove humidifier pan see 12 3 2 Cleaning Humidifier Pan and Float Switch Steps 1 through 10 Disconnect power from unit At humidifier remove screws and cover from high voltage compartment Disconnect one end of purple jumper wires Using a continuity mete
130. port CpI E s 11 12 13 14 15 16 17 18 NOTICE Do not lay the compressor section on its side It must remain upright The coil section also must remain upright Label the three quick connect plugs from the compressor compartment and disconnect them Disconnect the compressor wire harness including the crankcase heater wires if present from the contactor in the electric box Pull the conduit and wires into the compressor compartment Disconnect the fan motor wire harness from the bottom of the contactor in the electric box Pull the conduit and wires into the bottom section of the Liebert DS Reheat Optional Component a Disconnect the reheat wire harness from the bottom of the contactor in the electric box b Unplug the low voltage quick connect for the reheat safety wires c Pull the conduit and wires into the unit s blower and coil assembly section Humidifier Optional Component a Disconnect the humidifier wire harness from the bottom of the contactor in the electric box b Remove the humidifier low voltage connections 35 5 and 35 6 by disconnecting the quick connect plug c Disconnect 35 3 and 35 4 from the control board d Pull the conduit and wires into the unit s blower and coil assembly section Condensate Pump Optional Component a Disconnect the condensate pump s high voltage wiring harness b Remove the low volt wires from terminal strips 24 and 55 c Pull th
131. pressor models Note Drawing not to scale Tolerance on all piping dimensions A is 1 2 13mm 4 102mm Front View Section A A Blower Outlet B2 16 1 16 408mm Blower Outlet All dimensions from rear corner of unit including panels Blower Outlet 15 x 11 54 3 8 1381 18 1 16 459 o0 E1 E2 Front of Unit 98 2489mm DPN000929 Rev 2 X Y Connection Size Opening Point Description inches mm inches mm inches mm R Refrigerant Access 81 3 4 2076 14 3 4 374 12 3 16 x 4 310 x 102 53kW 15ton 70 amp 77kW 20 amp 22ton L1 Liquid Line System 1 94 11 16 2405 16 3 4 425 1 2 5 8 Cu Sweat L2 Liquid Line System 2 91 7 8 2334 16 3 4 425 1 2 5 8 Cu Sweat G1 Hot Gas Discharge 1 88 3 4 2254 16 3 8 416 7 8 1 1 8 Cu Sweat G2 Hot Gas Discharge 2 85 9 16 2173 16 3 8 416 7 8 1 1 8 Cu Sweat 66 Condensate Drain 69 1 4 1759 30 762 3 4 FPT W Optional Pump 69 1 4 1759 30 762 1 2 Cu Sweat HUM Humidifier Supply Line 76 1 2 1943 29 736 1 4 Cu Sweat ECS Econ O Coil Supply 78 5 8 1997 22 1 4 565 2 1 8 Cu Sweat ECR Econ O Coil Return 72 1829 29 737 2 1 8 Cu Sweat HS Hot Water Reheat Supply Consult Factory HR Hot Water Reheat Return Consult Factory El Electrical Connection High Volt 78 1 2 1994 31 1 8 790 2 1 2 E2 Electrical Connection High Volt 75 3 8 1915 31 1 8
132. pressors Model 105 i l Water Glycol 3370 1529 Semi Hermetic Compressor GLYCOOL Dual Cool 3700 1678 Scroll or Digital Scroll Water Glycol 3250 1474 Compressor GLYCOOL Dual Cool 3580 1624 26 Liebert DS Dimensions and Weights Figure 22 Floor stand dimensions downflow 28 42kW 8 12 ton models A 1 1 2 38mm with feet 47 15 16 1218mm 34 1 2 876mm Supply ai with feet a discharge 25mm TYP Gussets supplied on floor stands 12 305 mm tall and greater Optional turning vane shown as front air discharge El 1 de 7 8 Turning vane air outlet 23mm 3 Optional turning vane can be field installed 76mm in supply air discharge opening for front or rear air discharge NOTE Right side of paneled unit is flush with right side of floorstand All other paneled sides overhang floor stand 1 25mm Leveling feet are provided with 1 1 2 38mm adjustment from nominal height C pgpinnnpg2a REV 2 Table 19 Floor stand and floor planning dimensions downflow 28 42kW 8 12 ton models Dimensions in mm Height in mm Model A B C D Turning Vane 9 229 4 111 Air Cooled Semi Hermetic Models and 85 26 All Water Glycol GLYCOOL Models 2159 660 12 305 TTS 15 381 10 264 18 457 13 340 Air Cooled Scroll Models and 72 13 Air Cooled Digital Scroll Models 1829 330 21 533 16210 24 6
133. r locate burned out lamp Remove lamp brackets under lamps Loosen two screws securing lamp lead wires to junction block Pull bulb straight down and discard Wrap lead wires once around new lamp s metal ends This will support lamp and allow for thermal expansion Insert lead wires into junction block and torque screws to 30 in lb Reassemble by reversing Steps 1 through 9 Figure 9 Infrared humidifier lamps Infrared Bulbs 12 4 Condensate Drain and Condensate Pump Systems 12 4 1 Condensate Drain Check and clear obstructions in tubing during routine maintenance 12 4 2 Condensate Pump Disconnect power to unit using disconnect switch A WARNING Risk of electric shock Can cause injury or death The iCOM microprocessor does not isolate power from the unit even in the Unit Off mode Some internal components require and receive power even during the unit off mode of iCOM control Disconnect local and remote power supplies before working within Check and clear obstructions in gravity lines leading to condensate pump Remove sump and clean with a stiff nylon brush and flush with water Inspect and clear clogs in discharge check valve and float mechanism Reassemble and check for leaks 116 Maintenance 12 5 Air Cooled Condenser and Drycoolers 12 6 12 7 12 7 1 12 7 2 12 7 3 Clear coil surface of all debris that will inhibit airflow Check for bent or d
134. r bottom of unit 24 318 Openin 619mm Pens 3 4 Bezels 19mm Minimum required for filter replacement Nui 864mm Shaded area indicates a recommended minimum clearance for component access DPN001012 Rev 2 Table 9 Weights for downflow air Cooled 105kW 30 ton all compressor models Dry Weight Ib kg approximate Compressor Type Model 105 l l Air Cooled 3040 1382 Semi Hermetic Compressor Dual Cool 3400 1545 Air Cooled 2920 1327 Scroll Compressor Dual Cool 3280 1491 17 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 Notes Filters are accessible only through top of unit Downflow electrical connections can be made from top or bottom of unit 102 13 16 2611mm Opening 33 838mm Air Inlet Openin 24 3 8 ee 619mm CPening 889mm 3 4 i Bezels Top View E S Secondary Entrance Low Volt Connections Required for Secondary Entrance High Volt Connection s condenser cleanout 24 132 a Minimum required 3353mm for filter replacement Secondary Condenser Fluid Entrance 1930mm 864mm Front View Shaded area indicates a 131 recommended minimum 3327mm clearance for component access DPNO01013 Rev 2 Tabl
135. r detailed views of upflow units see Figures 46 through 54 L 2 3 10 11 12 13 14 15 16 17 Remove the unit from its skid Remove all panels except top front accent Remove all filters on front return units This allows easier access to items located in the filter and coil assembly 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 Reference unit wiring schematic on deadfront panel for details Label the 3 quick connect plugs from the compressor compartment and disconnect them Disconnect compressor wire harness including crankcase heater wires 1f applicable from contactor in electric box Pull conduit and wires into compressor compartment Reheat optional component Disconnect reheat wire harness from bottom of contactor in electric box Unplug low voltage quick connect for reheat safety wires Pull conduit and wires into filter and coil assembly section of unit Humidifier optional component Disconnect humidifier wire harness from bottom of contactor in electric box Remove humidifier low voltage connections 35 5 and 35 6 by disconnecting quick connect plug disconnect 35 3 and 35 4 from control board Pull conduit and wires into filter and coil assembly section of unit Condensate pump optional component Disconnect condensate pump high voltage wire harness Remove low volt wires from terminal strip
136. r original location Facility Fluid and Piping Maintenance Facility water and glycol quality remain a requirement throughout the life of the piping system Fluid and piping system maintenance schedules must be established and performed A local fluid mainte nance program must be established that will evaluate fluid chemistry and apply necessary treatment A periodic leak inspection of facility and unit fluid piping is recommended Refer to 8 1 3 Require ments of Systems Using Water or Glycol 118 Maintenance 12 10 Paradenser Water Cooled Condenser During normal Paradenser operation deposits will collect on inside wall of condenser tubes It must be cleaned periodically to ensure proper operation Frequency of cleaning must be locally established because it varies according to Paradenser usage and local fluid quality See 12 9 Facility Fluid and Piping Maintenance 12 10 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 Remove the 1 2 drain plugs using two wrenches to prevent damage to drain lines 6 Locate and remove the 3 diameter clean ou
137. re 24V interlock connection between unit and condenser Condenser legs four with 1 fan 2 fan and 3 fan models six with 4 fan models Fan Speed Control Leak Check and Evacuation Procedure Proper leak check and evacuation can be accomplished only with all system solenoid valves open and check valves accounted for NOTE Q Systems with scroll or digital scroll compressors include a factory installed check valve and an additional downstream Schrader valve with core in the compressor discharge line Proper evacuation of the condenser side of the compressor can be accomplished only using the downstream Schrader valve See piping schematic Figures 57 and 59 1 If unit power is available open the unit liquid line solenoid valves using the evacuation function for System 1 and System 2 in the diagnostic section of the iCOM control refer to the iCOM user manual SL 18835 If unit power is not available a field supplied 24VAC 75VA power source must be directly connected to each of the unit solenoid valves 2 For semi hermetic compressors connect refrigeration gauges to the suction and discharge service valves of both compressors 3 For scroll and digital scroll compressors connect refrigerant gauges to the suction rotalock valves and discharge line Schrader valves see Note above on both compressors 4 Starting with Circuit 1 open the service valves and place a 150 PSIG 1034 kPa of dry nitrogen with a tracer of refrigerant Check sy
138. re safety switch in the high side refrigerant circuit A A WARNING Risk of high speed moving parts Can cause injury or death Disconnect all local and remote electric power supplies before working in the unit Do not operate upflow units without installing a plenum ductwork or guard over the blower opening s on the top surface of the unit cabinet Ductwork must be connected to the blower s or a plenum must be installed on the blower deck for protection from rotating blower wheel s on upflow units 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 leaking water Can cause equipment and building damage This unit requires a water drain connection It may also require an external water supply to operate Improper installation application and service practice can result in water leakage from the unit Water leakage can result in severe property damage and loss of critical data center equipment Do not locate unit directly above any equipment that could sustain water damage Emerson recommends installing leak detection equipment for unit and supply lines
139. ressor s model and serial number Record unit configuration and verify with the startup document 109 Initial Startup Checks and Commissioning Procedure for Warranty Inspection 11 3 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 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 Turn ON the main unit disconnect switch and check secondary voltage at transformer T1 Voltage at T1 must be 24VAC 2 5VAC check at TB1 1 and TB1 5 T1 voltage must not exceed 28VAC Change primary tap if necessary 5 Push the ON button Blower will start and On lamp will light Check fan rotation if not correct make necessary changes to the line side of the unit disconnect with power Off The unit is phased from the factory 6 Your unit will operate at the factory set configuration for all component operations the operator may set the values for temperature and humidity setpoints the proportional band the deadband The User Menu may used to set the alarms and other control functions Refer to COM User manual SL 18835 for large or small display operation and settings 7 Turn Off the unit by the On Off button and then remove power from main unit disconnect and
140. rmetic and Standard Scroll Compressors 119 12 11 2 Motor Ball Valve Digital Scroll Compressors 0 0 000 teen eee 120 12 113 Drycooler Settin es T exc ERE soon ah ed li Shoe ead 121 HVAC MAINTENANCE CHECKLIST 0 000 eee eee ee eee ee eee eee eee 122 iii 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 FIGURES Downflow model component locations ence eee nee es Upflow model component locations Liebert DS model number nomenclature 00 eee eens Downflow unit ducting and plenum ducting 0 00 tenes Upflow ducting configurations se pea ms kade ia eena ce eee nee ee eee een ne ha Cabinet and floor planning dimensions downflow air cooled 28 42kW 8 12 ton semi hermetic compressor Models Cabinet and floor planning dimensions downflow air cooled 28 42kW 8 12 ton scroll compressor models Cabinet and floor planning dimensions downflow water glycol GLYCOOL 28 42kW 8 12 ton all compressor models 0 eens Cabinet and floor planning dimensions downflow air cooled 53 77kW 15 22 ton semi hermetic compressor Models
141. ropriate drain system materials The drain line must comply with all local codes Supplied on Dual Cool systems only 4 pipe system 96 Piping Schematics Figure 72 Primary connection locations downflow air cooled 105kW 30 ton all compressor models 4 102mm Note Drawing not to scale Front View All dimensions from rear corner Tolerance on all of unit including piping dimensions l panels is 1 2 13mm Section A A X o 15 11 16 y G1G2R 398mm O G o i L1 L2 Rad E H 418mm Blower Outlet 3327mm DPNO01014 Rev 2 X Y Connection Size Opening Point Description inches mm inches mm inches mm R Refrigerant Access 109 2769 15 3 4 400 16 7 16 x 4 418 x 102 L1 Liquid Line System 1 121 3 4 3092 16 3 4 425 5 8 Cu Sweat L2 Liquid Line System 2 118 1 8 3000 16 3 4 425 5 8 Cu Sweat G1 Hot Gas Discharge 1 118 1 4 3004 14 1 4 362 1 1 8 Cu Sweat G2 Hot Gas Discharge 2 115 5 8 2937 14 1 4 362 1 1 8 Cu Sweat eD Condensate Drain 83 13 16 2129 30 762 3 4 FPT W Optional Pump 83 13 16 2129 30 762 1 2 Cu Sweat HUM Humidifier Supply Line 102 3 4 2610 31 3 4 806 1 4 Cu Sweat ECS Econ O Coil Supply 101 7 8 2588 29 737 2 5 8 Cu Sweat ECR Econ O Coil Return 94 9 16 2402 29 737 2 5 8 Cu Sweat HS Hot Water Reheat Supply Consult Factory HR Hot Water Reheat Return Consult Factory El
142. s Oil level can be viewed at the sight glass on semi hermetic compressors Normal operating oil level is 1 4 to 3 4 up the sight glass After a compressor has been idle for an extended length of time foaming will usually be present when compressor first starts Wait until compressor has been operating for at least five minutes before viewing the oil level If oil level is low the cause must be corrected and oil level returned to its proper level Scroll and Digital Scroll Compressors Hermetic scroll and digital scroll compressors do not have an oil sight glass 117 Maintenance 12 8 12 8 1 12 8 2 12 8 3 12 9 Compressor Replacement Replacement compressors are available through your local Emerson office Compressors are shipped in reusable packaging If unit is under warranty complete and include Liebert Service Credit Appli cation LSCA with the compressor that is being returned The original compressor should be returned in the same packaging Compressor Motor Burnout If a burnout has occurred a full system clean out is required if not compressor and system problems will continue For clean out warnings and procedures see Copeland Application Engineering Bulletin 24 1105 Principles of Cleaning Refrigeration Systems or Carlyle Service Guide Literature 020 611 Digital Compressor Unloading Solenoid s Models 028 035 and 042 When replacing a digital scroll compressor digital solenoid valve
143. s refer to 12 11 3 Drycooler Settings Optional Dual Pump System Shown Liebert Expansion Customer Heat Rejection Heat Rejection Tank Glycol Pumps Check Valves n Drycooler Pressure N on Dual Pump 1 Systems onl Vcooting Tower Aquastat Port X X X y y and Pump Sensing Gate Valves System by 4 U Others J Raa Airy TL Shutoff Valve 1 4 enis typical H Flow Switch RS H Supplied with Dual Pump Systems Return Supply Pressure Port Flow Regulating Valve Liebert DS Unit en era and associated piping Hot Gas Reheat L Return Supply aii Optional Shutoff Valve 3 Way Shutoff Valve Sensing Evaporator Regulating Cylinder Bulb Coil Ke 4 Unloader s Suction nee iV Ml C Hot Gas Reheat Valve a D E les Compressor 4 Check Valve noil Service Equalize Valve Discharge Valve Paradenser Rx ae Condenser x not van gt lt Expansion A Valve Relief valve s Sensor supplied with50Hz Solenoid EU CE units rated To Second Valve Filter maximum 480 PSIG Refrigeration Dryer 33 Bar Circuit Regulating Factory Piping Components are not supplied by Field Piping Liebert but are recommended for Optional Factory Piping proper circuit operation and V Service Schrader Access Connection No Valve Core maintenance Field installed at highest point Service Schrader Access Connection With Valve Core In s
144. s are open on the top and not designed with duct flange Table 26 Upflow unit plenum dim ensions Right Side Views Check One 1 C With Grille _ C Without Grille DPN001187 Rev 0 Plenum Dimensions in mm Grille Size in mm Nominal 28 42kW 8 12 ton Air Cooled Scroll and Air Cooled Digital Scroll Models A 59 1 4 1505 B 13 3 4 349 28 42kW 8 12 ton Semi Hermetic and all Water Glycol GLYCOOL Models 59 1 4 1505 26 3 4 679 20 508 Front Rear Grilles 18 x 55 457 x 1397 Side Grille 18 x 20 457 x 508 18 x 55 457 x 1397 18 x 20 457 x 508 53 77kW 15 22 ton Air Cooled Scroll and Air Cooled Digital Scroll Models 82 1 4 2089 15 3 4 400 53 77kW 15 22 ton Semi Hermetic and all Water Glycol GLYCOOL Models 82 1 4 2089 26 3 4 679 24 610 18 x 78 457 x 1981 18 x 20 457 x 508 18 x 78 457 x 1981 18 x 20 457 x 508 105kW 30 ton All Models 105 1 4 2673 26 3 4 679 36 914 1 18 x 20 457 x 508 1 18 x 78 457 x 1981 18 x 20 457 x 508 34 Equipment Inspection and Handling 5 0 EQUIPMENT INSPECTION AND HANDLING 5 1 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 ac
145. sor modelados a E AE mnie Skis doa ads shia HE a Component weights upflow air cooled 105kW 30 ton semi hermetic compressor models vii 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 Component weights upflow air cooled 105kW 30 ton scroll digital scroll compressor MOE Sek a eel a asin cad aah eke a ech GMa io ello hie WGC dante eke Beane See RE aes tia eI oe Component weights upflow water glycol GLYCOOL 105kW 30 ton all compressor Models a he Mare SG hehe a es ee Recommended refrigerant line sizes OD copper inches o o ooooooooooooooooo Indoor unit approximate refrigerant charge for R 22 or R 407C ees Line charges refrigerant per 100 ft 30m of Type L copper tube ooooooo o Outdoor condenser approximate refrigerant charge lb kg per circuit u nuana nunun Fan speed suction pressure transducer settingS 0 0 cee tee eee ene Lee Temp suction pressure transducer sSettidgS ooooooorooooroorrrr Piping data upflow air cooled 105kW 30 ton all Piping data upflow upflow water glycol GLYCOOL 105kW 80 ton all Filter quantities downflow units er teer riei tea Ea RRR eee AS Filter quantities upflow UNItS o Compressor oil types teere errer reren Recommended refrigerant pressures se
146. ssor Assembly 76 1930mm Loser a b s 838mm 330mm 1499mm 72 1829mm Assembled Length NOTES Drawing views are simplified with panels removed to show overall dimensions DPNO01172 See disassembly and handling instructions in installation manual Rev 0 76 1930mm Assembled Filter amp Coil Assembly Height 45 13 16 1163mm Table 37 Component weights upflow air cooled 28 42kW 8 12 ton scroll digital scroll compressor models Dry Weight Approximate Including Panels Ib kg Component Air Cooled Dual Cool Compressor Assembly 490 223 490 223 Blower amp Electric Box Assembly 510 231 510 231 Filter amp Coil Assembly 520 236 670 304 60 Disassembling the Liebert DS for Transport Figure 48 Component dimensions upflow water glycol GLYCOOL 28 42kW 8 12 ton all compressor models Blower amp Electric Box Assembly 76 1930mm Filter amp Coil Assembly eee ee eig 45 13 16 1163mm 26 59 660mm 1499mm 85 2159mm Assembled Length NOTES Drawing views are simplified with panels removed to show overall dimensions DPN001173 See disassembly and handling instructions in installation manual Rev 0 Table 38 Component weights upflow water glycol GLYCOOL 28 42kW 8 12 ton all compressor models Dry Weight Approximate Including Panels Ib kg Semi Hermetic Compressor Scroll Compressor Component Water
147. stem for leaks with a suitable leak detector 5 With pressure still in Circuit 1 open the compressor service valves in Circuit 2 If pressure increases in Circuit 2 the system is cross circuited and must be rechecked for proper piping If there is no pressure increase repeat the leak check procedure for Circuit 2 6 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 7 After four hours check the pressure readings and if they have not changed break vacuum with dry nitrogen Pull a second R 407C and R 22 and third R407C only vacuum to 250 microns or less Recheck the pressure after two hours After completing this step proceed to Fan Speed Charging 78 Piping Fan Speed Charging 1 2 4 Check unit nameplate for refrigerant type to be used Unit control configurations differ depending on refrigerant type Refrigerant charging requires unit operation Refer to 10 0 Checklist for Completed Installation Calculate the amount of charge for the system Refer to the unit condenser and refrigerant line charge data in Tables 46 47 and 48 Weigh in as much of the system charge as possible before starting the unit CAUTION Risk of improper refrigerant charging Can cause equipment damage Refrigerant R407C is a blend of three components and must be introduced and charged from the cylinder only as a liquid When add
148. suo nunnur eee eee teen nes Water glycol system conditions requiring optional settings for aquastats Aquastat settings two fan through four fan drycoolers 00000 cee eee eens Aquastat settings six fan drycoolers 0 0c eee teen e eens Aquastat settings eight fan drycoolers 00 teen ee eee nes viii 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 Follow all operating and user instructions A A A 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 The COM microprocessor does not isolate power from the unit even in the unit off mode Some internal components require and receive power even during the unit off mode ofiCOM control The factory supplied optional disconnect switch is inside the unit The line side of this
149. switch contains live high voltage The only way to ensure that there is NO voltage inside the unit is to install and open a remote disconnect switch Refer to unit electrical schematic Follow all local codes WARNING Risk of explosive discharge from high pressure refrigerant Can cause injury or death This unit contains fluids and gases under high pressure Relieve pressure before working with piping WARNING Risk of refrigerant system rupture or explosion from overpressurization Can cause equipment damage injury or death If a pressure relief device is not provided with the condenser unit the system installer must provide and install a discharge pressure relief valve rated for a maximum of 500 psig 34bar in the high side refrigerant circuit Do not install a shutoff valve between the compressor and the field installed relief valve One or more additional pressure relief valves are required downstream of any and all field installed isolation valves as shown in Figures 57 and 58 Do not isolate any refrigerant circuits from overpressurization protection For systems requiring EU CE compliance 50Hz the pressure relief valve must be CE certified to the EU Pressure Equipment Directive by an EU Notified Body NOTE A pressure relief valve is provided with Liebert Lee Temp condensers A fusible plug is provided on Liebert Fan Speed Control condensers The Liebert indoor cooling unit has a factory installed high pressu
150. t 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 DPN000994 Do NOT use long pleat filter construction as shown at Rev 0 right above because it can result in filter collapse Do Not Use 12 2 Blower Drive System Blower drive system components that are part of the maintenance schedule include the blower wheel s drive shaft bearings pulley belts sheave motor auto tension base and motor See Blower Section on page 122 A WARNING Risk of crushing and pinching action from spring loaded motor base Can cause serious injury to hands and fingers Improper drive belt removal may cause the motor base to slam down suddenly Read the directions in this manual and on the unit instruction labels before servicing the belts motors or pulleys Follow all directions when servicing the unit 112 Maintenance 12 2 1 Upflow Motor Access 1 2 3 4 Remove the lateral support sheet metal channel under electric box by removing two screws at each end Removed the hinged deadfront panel 30 ton units have open access to the motor 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 Swing open low voltage electric box to gain access to the motor Figure 83 Upflow motor access Deadfront Lo
151. t plugs on top of shell assemblies use Craftsman 1 3 16 drag link socket Sears item 00944514000 or similar 7 Brush and flush each of the nominal 5 8 inner diameter rifled copper tubes Recommend using John R Robinson Inc or similar e Motorized Tube Cleaner Model JR3800 1200 Nylon brush 9 16 diameter Model JRRB211N 916 Flexible shaft Model JRRFS702 25 8 Reinstall 1 2 drain plugs 6 to 7 turns using Loctite 567 PST Thread Sealant as instructed by the manufacturer 9 Wipe clean the machine threads and sealing surfaces of 3 diameter clean out plugs 10 Remove and install new O rings Liebert part number 180750P1 on the 3 diameter clean out plugs Do not use thread sealant 11 Hand tighten 3 diameter clean out plugs and torque using drag link socket to 25 ft lb 12 Leak check fluid system refer to Leak Checking of Unit and Field Piping on page 75 13 Bleed system using Schrader ports near the top of the Paradenser 14 Ensure that condensing fluid isolation valves are fully open 15 Unit is ready to be put on line 12 11 Water Glycol Control Valves 12 11 1Regulating Valves Semi Hermetic and Standard Scroll Compressors The water regulating valves automatically regulate the amount of fluid necessary to remove the heat from the refrigeration system permitting more water to flow when load conditions are high and less fluid to flow when load conditions are low The valve consists of a brass body bal
152. t remain upright The coil is not secured to the blower and coil assembly Secure the coil to the bottom section with straps or a similar method before moving the section 7 Move each section of the Liebert DS to the installation location 44 Disassembling the Liebert DS for Transport 6 3 6 3 1 Reassembly Downflow Units 1 g 1 1 0 1 Replace the top section Make sure to clear the Schrader valves on the coil header Reconnect the filter and electric box assembly to the blower and coil assembly using thread cutting bolts Torque the bolts to 225 in lb 25Nm Reattach the evaporator top cover plate there are eight screws on each side Reattach the filter support plate to the filter and electric box assembly there is one screw on each side Reattach the tags to the Schrader fittings on top of the coil headers Replace the compressor section Insert all compressor thread cutting bolts before tightening any of the bolts Reinstall the pull bar to support the accent panel Reattach the low voltage plugs in the compressor section Reconnect the wiring for the compressor fan motor reheat humidifier condensate pump smoke detector and air sail switch Reattach the sensing tube to the top of the smoke detector On GLYCOOL and dual cool units reattach the plug connection at the actuator and reroute the sensor wire back through the electric box and onto the control board Reconnecting Piping
153. tails Three phase electrical service is required for all models Electrical service must conform to national and local electrical codes See equipment nameplate for details If seismic requirements apply consult your local Emerson representative for information about a seismic rated floor stand 3 5 Operating Conditions The Liebert DS must be operated in a conditioned space within the operating envelope ASHRAE recommends for data centers Maximum temperature of 77 F 25 C DB and 55 RH or maxi mum WB of 65 5 F 18 6 C Operating outside this envelope can decrease equipment reliability Return air to the unit must be no cooler than the ASHRAE recommendation of 68 F 20 C DB and 40 RH or minimum WB of 54 F 12 2 C for proper unit operation Operating below this can decrease equipment reliability Refer to ASHRAE s publication Thermal Guidelines for Data Processing Environments Liebert DS Dimensions and Weights 4 0 LIEBERT DS DIMENSIONS AND WEIGHTS Table 1 Shipping dimensions domestic and export inches mm 028 035 042 053 070 077 105 Model Number LxWxH in mm LxWxH in mm LxWxH in mm DS VSAS DS VSAD DS VSAR DS VSAG 102x42x82 DS VSDS DS VSDD DS VSDR DS VSDG 2591x1067x2083 DS VSAU DS VSAM DS VSDU DS VSDM 90x42x82 136x42x82 DS VSWS DS VSWD DS
154. the Optional Stat Setting require field piping to be insulated to prevent condensa tion Table 57 shows acceptable applications where stats must be adjusted to Optional Setting Aqu astats 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 Lie bert DS units with digital compressors These units have a D or G in the seventh character DS VS xxxxD or DS VS xxxxG Table 57 Water glycol system conditions requiring optional settings for aquastats Cooling Type Glycool Glycol Flow Control MBV WRV MBV WRV Drycoolers in Loop 1 Multiple 1 Multiple 1 Multiple 1 Multiple Stat Setting Optional Optional Optional Optional Optional Factory Factory Factory Insulate Field Piping Yes Yes Yes Yes Yes No No No See Tables 58 through 60 MBV motor ball valve WRV water regulating valve Table 58 Aquastat settings two fan through four fan drycoolers Dial Setting Stat Open Temp Set for Mid Differential 8 F 4 4 C Rise to Close Factory Setting Optional Setting Aquastat Fans Glycol see Notes 1 and 2 GLYCOOL see Note 3 oaa Fr 6 F B3C 35 F 1 7 C AQ2 F2 amp F3 75 F 23 9 C 45 F 7 2 C AQ3 F4 70 F 21 1 C 40 F 4 4 C Table 59 Aquastat settings six fan drycoolers Dial Setting
155. the raised floor is required to prevent the air flow from being blocked When installing piping on the subfloor it is recommended that the pipes be mounted in a horizontal plane rather than stacked one above the other Whenever possible the pipes should be run parallel to the air flow Fluid Connections NOTICE This unit requires a water drain connection It may require an external water supply to operate Improper installation application and service practices can result in water leakage from the unit Water leakage can cause severe property damage and loss of critical data center equipment Do not locate unit directly above any equipment that could sustain water damage Emerson recommends installing leak detection equipment for unit and supply lines Condensate Piping Field Installed Do not reduce drain lines Do not expose drain line to freezing temperatures Drain line may contain boiling water Use copper or other suitable material Drain line must comply with local building codes Emerson recommends installing under floor leak detection equipment Gravity Drain 3 4 NPT drain connection is provided on units without optional factory installed condensate pump Pitch drain line toward drain a minimum of 1 8 8mm per 1 foot 305mm of length e Drain is trapped internally Do not trap external to equipment Drain line must be sized for 2 gpm 7 6 lm flow NOTICE The drain line must not be trapped outside the unit or w
156. ting valve operation Cap tubes not rubbing 2 3 Check for water glycol leaks 4 Entering water temperature 5 Leaving water Compressor Section 1 Check oil level Check for oil leaks Check compressor mounts springs bushings Cap tubes not rubbing Compressor operation vibration noise Suction Pressure Circuit 1 2 3 4 5 Check wire connections inside compressor box 6 7 8 Discharge Pressure Circuit 1 Superheat Circuit 1 Circuit 1 Circuit 1 Circuit 1 ___ 10 Low pressure switch cut out ___ 11 Low pressure cut in 12 High pressure cut out ___ 13 Amp draw Circuit 1 _ a L1L2L3 Circuit 2 _ a L1L2L3 Electrical Panel __ 1 Check fuses __ 2 Check contactors for pitting __ 3 Check wire connections Controls 1 Check Verify Control Operation Sequence Check humidifier high water alarm operation Check operation of the air safety switch 2 3 4 Check setting operation of the filter clog switch 5 Check test changeover device s 6 Check test water detection device s Circuit 2 Circuit 2 Circuit 2 Circuit 2 Circuit 2 Circuit 2 123 HVAC Maintenance Checklist Air Cooled Condenser Drycooler 1 Coil clean Motor mounts tight Bearings in good condition motor Piping support clamps secure 2 3 4 5 Check wire connections 6 Stat settings 7 Refrigerant level Lee Temp 8 Glycol level Glycol solution 10 Fa
157. tly low below room temperature Cooling is provided by circulating cold glycol through this second coil reducing compressor operation Dual Cool This system has all of the features of a compressorized system but adds a second cooling coil that is connected to a source of chilled water Cooling is provided by circulating water through this second coil and reducing compressor operation 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 Install the units as close as possible to the largest heat load Allow at least the minimum recommended clearances for maintenance and service See Figures 6 through 21 for dimensions Emerson recommends installing an under floor water detection system Contact your local Emer son representative for information 3 2 Air Distribution Downflow Units Verify that the raised floor has been properly sized for the unit s airflow and the room is free of airflow restrictions Perforated floor tiles in the raised floor should ensure minimal pressure loss
158. uipment 5 Allinternal and external high and low voltage wiring connections are tight 6 Confirm that unit is properly grounded to an earth ground ___ 7 Control transformer setting matches incoming power 8 Electrical service conforms to national and local codes __ 9 Check blowers and compressors scroll only for proper rotation _ 10 Upflow units only Field installed low volt wiring routed with loop to allow electric box to swing 10 3 Piping __ 1 Piping completed to refrigerant or coolant loop if required __ 2 Piping had been leak checked evacuated and charged if required 8 Piping is properly sized sloped trapped as shown in the piping schematics 4 Check piping inside and outside of equipment for proper support 5 Ensure that factory clamps have been reinstalled 6 Drain line connected and pitched per local code ___ 7 Water supply line connected to humidifier 10 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 ___ 7 Compressor shipping blocks removed and springs adjusted see 5 3 Semi Herm
159. upflow air cooled 28 42kW 8 12 ton scroll or digital scroll compressor models Alternate Refrigerant Piping Entrance T 33 838mm 35 889mm 3 4 19mm J Bezels TOP VIEW K l Minimum required ene Low Volt Connection s for blower ene y EA 73 38mm 1854mm 76 1930mm Shaded area indicates a recommended minimum clearance for component LE access 2 RONT VIEW Note Front air return unit shown For rear 51mm 72 return unit in addition to front service area 1829mm shown also include 25 635mm on one side of unit for access to rear return filter box See DPN001196 Figure 28 DPN001163 Rev 1 Table 12 Weight for upflow air cooled 28 42kW 8 12 ton scroll or digital scroll compressor models Dry Weight Ib kg approximate Model No 028 042 Air Cooled 1520 689 Dual Cool 1670 758 20 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 return unit in addition to front service area shown also include 25 635mm on one side of unit for access to rear return filter box 33 See DPN001196 Figure 28 838mm 35 889mm 3 4 19mm Bezels Required for L1 AA condenser cleanout Alternate Refrigerant TOP VIEW Minimum require
160. ure 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 Component dimensions downflow air cooled 28 42kW 8 12 ton semi hermetic compressor models gc shee si hoes ee Sea E Baie E ae SGN ein WEG We UA Shale ESE RN eae Component dimensions downflow air cooled 28 42kW 8 12 ton scroll digital scroll COMpressor MOdEl Seis lt ar A a OEE RS Component dimensions downflow water glycol GLYCOOL 28 42kW 8 12 ton all compressor Models essien rrean A EE Soe ale YEE R RT eo Component dimensions downflow air cooled 53 77kW 15 22 ton semi hermetic compressor models serria trienen GS Satie ote hob beaks gaa ah a Ae a ects Aa abd Component dimensions downflow air cooled 53 77kW 15 22 ton scroll digital scroll compressor models Component dimensions downflow water glycol GLYCOOL 53 77kW 15 22 ton all compressor models cinara a ee de T eee be ee nee PE eG be reed ne ee mee ees Component dimensions downflow air cooled 105kW 30 ton semi hermetic compressor models a Aen hi Batt il o Rates do la ee secs TT Component dimensions downflow air cooled 105kW 30 ton scroll compressor models Component dimensions downflow water glycol GLYCOOL 105k
161. ves Front seating the valves keeps the nitrogen or refrigerant charge in the compressor and prevents moisture from contaminating the compressor oil This is particularly important with units using R 407C refrigerant 43 Disassembling the Liebert DS for Transport 6 2 1 6 2 2 19 Cut the insulation and pull it back from the piping 20 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 21 Unsweat or cut all copper water pipes that interconnect unit sections 22 Immediately cap and seal all piping that has been cut including the suction and liquid lines as well as the fluid piping on GLYCOOL and dual cool units Remove the Compressor Assembly 1 Secure the compressor wire harness to the compressor assembly 2 Remove the 10 thread cutting bolts holding the compressor section assembly to the filter and electric box assembly and the blower and coil assembly There are five bolts in the front four in the back and one on the top at the middle of the unit a Begin removing bolts at the bottom of the unit and progress toward the top Use this method for the front and back bolts b Stabilize the compressor section before removing the top middle bolt NOTICE The compressor section is top heavy and has a small base It must remain upright Do not lay t
162. w Voltage Electric Box Screws DPN001221 Lateral Support Rev 0 Screws 12 2 2 Belt Removal 12 2 3 1 4 Disconnect power to unit Do not pry the belts off sheave or pulley Refer to instruction labels on unit near motor base Turn adjustment nut see Figure 84 counterclockwise left to loosen belts and bring motor base internal spring out of compression Remove belts Belt Installation and Tensioning 1 Select the appropriate replacement of belts matched set and position on drive package To maximize performance and reliability of Liebert DS equipment use only Liebert belts Contact your local Emerson representative for replacement belts Ensure pulley grooves are properly aligned If adjustment is required loosen do not remove four nuts in adjustment slots see Figure 84 holding motor base to unit frame and slide motor base assembly into alignment Tension belts by turning adjustment nut clockwise right until motor base carriage stops moving downward Ensure minimum 1 2 12 7mm clearance exists from motor base carriage to base front flange see Figure 84 If the clearance is less than 1 2 12 7mm select shorter belts Mark the adjustment nut and rotate clockwise right five additional full turns This sets internal spring for proper belt tension no readjustments necessary 113 Maintenance Figure 84 Auto belt tensioning motor base
163. wnflow Units 1 2 5 6 Disconnect power from the Liebert DS Using a stepladder remove filters from the top of the unit The optional downflow return air plenum includes a filter access door Replace with new filters install the filters in the proper direction of the airflow see Figure 82 Test the operation of the filter clog switch The unit panels must be in place and closed to find this point Start the blower and turn the switch counterclockwise until the alarm is energized Turn the adjusting knob one turn clockwise or to the desired filter change point 12 1 2 Filter Replacement Procedure Upflow Units 1 2 5 6 Figure 82 Disconnect power from the Liebert DS Remove the lower front access panel and remove the filters For upflow front return units remove the lower front access panels lift filters to the top of the fil ter rack and tilt forward for removal For upflow rear return units remove filters using filter access door in rear return filter box Replace with new filters install the filters in the proper direction of the airflow see Figure 82 Test the operation of the filter clog switch The unit panels must be in place and closed to find this point Start the blower and turn the switch counterclockwise until the alarm is energized Turn the adjusting knob one turn clockwise or to the desired filter change point Proper filter pleat direction a 25 635mm 7 IFA Shor
164. ystem on return line to pumps Note Schematic representation shown This schematic does not imply or define elevations n Locate S tops of all dake and any and component location unless specifically noted intermediate system high points Two refrigeration circuits provided Single refrigeration circuit shown for clarity DPNO0895 Rev 2 84 Piping Schematics Figure 60 Piping schematic water glycol with scroll compressor models For systems with drycoolers refer to 12 11 3 Drycooler Settings LIEBERT EXPANSION Optional Dual Pump System shown CUSTOMER HEAT REJECTION TANK GLYCOL HEAT REJECTION Check Valves on Dual Pum a DRYCOOLER Pressure E on ol COOLING TOWER Glycol Port x AND PUMP Aquastat Gate Valves SYSTEM Sensing 2 BY OTHERS Bulbs Hose Air Vents Pressure Port Bib typical Flow Switch E with Dual 1 ee 1 Pump Systems Flow Regulating Shutoff Valve RETURN SUPPLY E RETURN ER LIEBERT DS 7 SUPPLY and associated piping HOD GhS REHEAT RETURN k Optional Spon Valve ES X Shutoff Valve 3 Way Regulating a Hose LT LT Hose N U ds Bib i my Bib LIQUID Sensing Bulb EVAPORATOR COIL eo y Hot Gas Reheat Valve AS Service Valve External 2 Way Equalizer Regulating Valve Valve COMPRESSOR DISCHARGE PARADENSER CONDENSER

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