Precision Cooling For Business-Critical Continuity

Liebert DS
User Manual28-105kW, 8-30 Tons, Upflow and Downflow, 50/60Hz

TABLE OF CONTENTS
IMPORTANT SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 SAVE THESE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 1.0 2.0 3.0
3.1 3.2 3.3 3.4 3.5

LIEBERT DS COMPONENTS AND NOMENCLATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 COOLING CONFIGURATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 PRE-INSTALLATION GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Room Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Air DistributionDownflow Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Air DistributionUpflow Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Connections and System Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

4.0 5.0
5.1

LIEBERT DS DIMENSIONS AND WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 EQUIPMENT INSPECTION AND HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Packaging Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.2 Unpacking the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.2.1 5.2.2 5.2.3 5.2.4 Removing the Unit from the Skid With a Forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Moving the Unit to the Installation Location with Piano Jacks . . . . . . . . . . . . . . . . . . . . . . . Removing Piano Jacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing Liebert DS from Skid Using Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 40 40 41

5.3 5.4

Semi-Hermetic Compressor Spring Isolation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Placing the Unit on a Floor Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

6.0
6.1 6.2

EC FANSLOWERING AND REMOVING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Lowering the EC Fans into the Floor Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Removing the EC Fans. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

7.0
7.1 7.2

DISASSEMBLING THE LIEBERT DS FOR TRANSPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Required Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 DisassemblyDownflow Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
7.2.1 7.2.2 Remove the Compressor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Remove the Filter and Electric Box Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Reconnecting Piping, Charging and Replacing Panels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

7.3 7.4 7.5

ReassemblyDownflow Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
7.3.1

Reassembly Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 DisassemblyUpflow Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

7.5.1 7.5.2 Remove Compressor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Remove Blower and Electric Box Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
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7.6 7.7

ReassemblyUpflow Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Reassembly Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

8.0
8.1

ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Variable Speed Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
8.1.1 8.1.2 8.1.3 VSD Power SupplyField-Adjustment May Be Required. . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Wye-Connected Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Delta-Connected Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

9.0
9.1

PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
Fluid Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
9.1.1 9.1.2 9.1.3 9.1.4 Condensate PipingField-Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Humidifier Supply WaterOptional Infrared . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Humidifier Supply WaterOptional Steam Generating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Requirements of Systems Using Water or Glycol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 84 84 84

9.2

Refrigeration Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
9.2.1 9.2.2 Piping GuidelinesAir-Cooled Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Scroll and Digital ScrollAdditional Oil Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Air-Cooled Condenser with Variable Fan Speed Head Pressure Control Systems . . . . . . . . 89 Air-Cooled Condenser with Liebert Lee-Temp Flooded Condenser Head Pressure Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Water/Glycol Cooled System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

9.3

Dehydration/Leak Test and Charging Procedures for R-407C and R-22 . . . . . . . . . . . . . . . 89

9.3.1 9.3.2 9.3.3

10.0 11.0
11.1 11.2 11.3 11.4

PIPING SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 CHECKLIST FOR COMPLETED INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Moving and Placing Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Other . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

12.0
12.1 12.2 12.3 12.4

INITIAL STARTUP CHECKS AND COMMISSIONING PROCEDURE FOR WARRANTY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126
Information for Warranty InspectionRemove Power From Unit Disconnect . . . . . . . . . 127 Startup Checks With Panels Removed and Main Disconnect Off . . . . . . . . . . . . . . . . . . . . 127
12.2.1 Inspect and Record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 Commissioning Procedure With Panels On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

13.0
13.1

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
13.1.1 Filter Replacement ProcedureDownflow Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 13.1.2 Filter Replacement ProcedureUpflow Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

ii

13.2

Blower Drive SystemCentrifugal Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

13.2.1 13.2.2 13.2.3 13.2.4 Upflow Motor Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Belt Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Belt Installation and Tensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Variable Speed Drive - Inverter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 133 134 135

13.3

Blower Drive SystemEC Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

13.3.1 Fan Impellers and Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 13.3.2 Protective Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

13.4

HumidifierInfrared . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
13.4.1 Cleaning Humidifier Pan and Float Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 13.4.2 Changing Humidifier Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

13.5 13.6

HumidifierSteam Generating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

13.5.1 Replacing the Steam Generating Humidifier Canister . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

Condensate Drain and Condensate Pump Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

13.6.1 Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 13.6.2 Condensate Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

13.7 13.8 13.9

Air-Cooled Condenser and Drycoolers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 ReheatElectric Reheat (Three-Stage and SCR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 Thermostatic Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
13.9.1 Determine Suction Superheat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 13.9.2 Adjust Superheat Setting with the TEV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

13.10 Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

13.10.1 Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 13.10.2 Semi-Hermetic Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 13.10.3 Scroll and Digital Scroll Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

13.11 Compressor Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

13.11.1 Compressor Motor Burnout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 13.11.2 Digital Compressor Unloading Solenoid(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 13.11.3 Compressor Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

13.12 Facility Fluid and Piping Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 13.13 ParadenserWater-Cooled Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
13.13.1 Cleaning Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

13.14 Water/Glycol Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

13.14.1 Regulating Valves Semi Hermetic and Standard Scroll Compressors . . . . . . . . . . . . . . . . 147 13.14.2 Motor Ball ValveDigital Scroll Compressors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 13.14.3 Drycooler Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

14.0

HVAC MAINTENANCE CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

COMPLIANCE WITH EUROPEAN UNION DIRECTIVES . . . . . . . . . . . . . . . . . . . . . . INSIDE BACK COVER

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FIGURES
Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 Figure 18 Figure 19 Figure 20 Figure 21 Figure 22 Figure 23 Figure 24 Figure 25 Figure 26 Figure 27 Figure 28 Figure 29 Figure 30 Figure 31 Figure 32 Figure 33 Figure 34 Figure 35 Figure 36 Downflow model component locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Upflow model component locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Liebert DS model number nomenclature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Downflow unit ducting and plenum ducting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Upflow ducting configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Cabinet and floor planning dimensionsdownflow, air-cooled, 28-42kW (8-12 ton), semi-hermetic compressor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Cabinet and floor planning dimensionsdownflow, air-cooled, 28-42kW (8-12 ton), scroll compressor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Cabinet and floor planning dimensionsdownflow, water/glycol/GLYCOOL, 28-42kW (8-12 ton), all compressor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Cabinet and floor planning dimensionsdownflow, air-cooled, 53-77kW (15-22 ton), semi-hermetic compressor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Cabinet and floor planning dimensionsdownflow, air-cooled, 53-77kW (15-22 ton), scroll compressor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Cabinet and floor planning dimensionsdownflow, water/glycol/GLYCOOL, 53-77kW (15-22 ton), all compressor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Cabinet and floor planning dimensionsdownflow, air-cooled, 105kW (30 ton), all compressor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Cabinet and floor planning dimensionsdownflow, water/glycol/GLYCOOL, 105kW (30 ton), all compressor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Cabinet and floor planning dimensionsupflow, air-cooled 28-42kW (8-12 ton), semi-hermetic compressor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Cabinet and floor planning dimensionsupflow, air-cooled 28-42kW (8-12 ton), scroll or digital scroll compressor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Cabinet and floor planning dimensionsupflow, water/glycol/GLYCOOL, 28-42kW (8-12 ton), all compressor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Cabinet and floor planning dimensionsupflow, air-cooled, 53-77kW (15-22 ton), semi-hermetic compressor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Cabinet and floor planning dimensionsupflow, air-cooled, 53-77kW (15-22 ton), scroll or digital scroll compressor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Cabinet and floor planning dimensionsupflow, water/glycol/GLYCOOL, 53-77kW (15-22 ton), all compressor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Cabinet and floor planning dimensionsupflow, air-cooled, 105kW (30 ton), all . . . . . . . . . . . . 25 Cabinet and floor planning dimensionsupflow water/glycol/GLYCOOL 105kW (30 ton), all compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Floor stand dimensionsdownflow, 28-42kW (8-12 ton) models. . . . . . . . . . . . . . . . . . . . . . . . . . 27 Floor stand dimensionsdownflow, 53-77kW (15-22 ton) models. . . . . . . . . . . . . . . . . . . . . . . . . 28 Floor stand and floor planning dimension, downflow 53-77kW (15-22 tons) models with EC fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Floor stand dimensionsdownflow, 105kW (30 ton) models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Floor stand and floor planning dimension, downflow 105kW (30 tons) models with EC fans . . . 31 Blower outlet and deck dimensionsupflow, 28-42kW (8-12 ton). . . . . . . . . . . . . . . . . . . . . . . . . 32 Blower outlet and deck dimensionsupflow, 53-77kW (15-22 ton). . . . . . . . . . . . . . . . . . . . . . . . 33 Blower outlet and deck dimensionsupflow 105kW (30ton) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Rear return filter box dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Upflow unit plenum dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Equipment recommended for handling Liebert DS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Removing packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Remove the unit from the skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Moving the unit to its installation location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Locate center of gravity marker and place slings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

iv

Figure 37 Figure 38 Figure 39 Figure 40 Figure 41 Figure 42 Figure 43 Figure 44 Figure 45 Figure 46 Figure 47 Figure 48 Figure 49 Figure 50 Figure 51 Figure 52 Figure 53 Figure 54 Figure 55 Figure 56 Figure 57 Figure 58 Figure 59 Figure 60 Figure 61 Figure 62 Figure 63 Figure 64 Figure 65 Figure 66 Figure 67 Figure 68 Figure 69 Figure 70 Figure 71

Using rigging to lift Liebert DS off skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting the unit on a floor stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lowering EC fans into floor stand, Steps 1 through 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lowering EC fans into floor stand, Steps 7 through 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the EC fans, Steps 1 through 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the EC fans, Steps 6 through 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component dimensionsdownflow, air-cooled, 28-42kW (8-12 ton), semi-hermetic compressor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component dimensionsdownflow, air-cooled, 28-42kW (8-12 ton), scroll/digital scroll compressor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component dimensionsdownflow, water/glycol/GLYCOOL, 28-42kW (8-12 ton), all compressor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component dimensionsdownflow, air-cooled, 53-77kW (15-22 ton), semi-hermetic compressor models; forward-curved and EC fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component dimensionsdownflow air-cooled, 53-77kW (15-22 ton), scroll/digital scroll compressor models; forward-curved and EC fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component dimensionsdownflow water/glycol, GLYCOOL, 53-77kW (15-22 ton), all compressor models; forward-curved and EC fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component dimensionsdownflow, air-cooled, 105kW (30 ton), semi-hermetic compressor models; forward-curved and EC fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component dimensionsdownflow, air-cooled, 105kW (30 ton), scroll compressor models; forward-curved and EC fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component dimensionsdownflow, water/glycol/GLYCOOL, 105kW (30 ton), forward-curved and EC fan, all compressor models; forward-curved and EC fan . . . . . . . . . . . . Component dimensionsupflow, air-cooled, 28-42kW (8-12 ton), semi-hermetic compressor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component dimensionsupflow, air-cooled, 28-42kW (8-12 ton), scroll/digital scroll compressor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component dimensionsupflow, water/glycol/GLYCOOL, 28-42kW (8-12 ton), all compressor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component dimensionsupflow, air-cooled, 53-77kw (15-22 ton), semi-hermetic compressor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component dimensionsupflow, air-cooled, 53-77kw (15-22 ton), scroll/digital scroll compressor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component dimensionsupflow water/glycol/GLYCOOL 53-77kw (15-22 ton), all compressor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component dimensionsupflow, air-cooled, 105kW (30 ton), semi-hermetic compressor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component dimensionsupflow, air-cooled, 105kW (30 ton), scroll/digital scroll compressor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component dimensionsupflow, water/glycol/GLYCOOL, 105kW (30 ton), all compressor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical field connections for upflow and downflow models . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wye-connected power diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Delta-connected power diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disconnecting EMC filter for operation with Delta-connected power size C & D inverters. . . . . Figure bb Disconnecting EMC filter for operation with Delta-connected power Type 2 inverters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gravity drain for downflow and upflow units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piping schematicair-cooled, semi-hermetic compressor models . . . . . . . . . . . . . . . . . . . . . . . . . Piping schematicair-cooled, scroll compressor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Piping schematicwater/glycol, semi-hermetic compressor models . . . . . . . . . . . . . . . . . . . . . . . Piping schematicwater/glycol with scroll compressor models. . . . . . . . . . . . . . . . . . . . . . . . . . . Piping schematicGLYCOOL semi-hermetic compressor models . . . . . . . . . . . . . . . . . . . . . . . .

42 43 45 46 48 49 55 56 57 58 59 60 61 62 63 67 68 69 70 71 72 73 74 75 77 79 80 81 81 83 94 95 96 97 98

Figure 72 Figure 73 Figure 74 Figure 75 Figure 76 Figure 77 Figure 78 Figure 79 Figure 80 Figure 81 Figure 82 Figure 83 Figure 84 Figure 85 Figure 86 Figure 87 Figure 88 Figure 89 Figure 90 Figure 91 Figure 92 Figure 93 Figure 94 Figure 95 Figure 96 Figure 97 Figure 98 Figure 99 Figure 100 Figure 101 Figure 102 Figure 103 Figure 104 Figure 105 Figure 106

Piping schematicGLYCOOL with scroll compressor models . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Piping schematicwater/glycol with digital scroll compressor models. . . . . . . . . . . . . . . . . . . . 100 GLYCOOL with digital scroll compressor models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Optional piping schematic for Econ-O-Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Primary connection locationsdownflow, air-cooled, 28-42kW (8-12 ton), semi-hermetic compressor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Primary connection locationsdownflow, air-Cooled, 28-42kW (8-12 ton) with scroll compressor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Primary connection locationsdownflow water/glycol/GLYCOOL 28-42kW (8-12 ton), all compressor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Primary connection locationsdownflow, air-Cooled, 53-77kW (15-22 ton), semi-hermetic compressor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Primary connection locations downflow air cooled 53-77kW (15-22 tons) semi-hermetic compressor models, with EC fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Primary connection locationsdownflow, air-Cooled, 53-77kW (15-22 ton) with scroll compressor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Primary connection locationsdownflow, air-Cooled, 53-77kW (15-22 ton) with scroll compressor models, with EC fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Primary connection locationsdownflow, water/glycol/GLYCOOL, 53-77kW (15-22 ton), all compressor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Primary connection locationsdownflow, water/glycol/GLYCOOL, 53-77kW (15-22 ton), all compressor models, with EC fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Primary connection locationsdownflow, air-cooled, 105kW (30 ton), all compressor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 Primary connection locationsdownflow, air-cooled, 105kW (30 ton), all compressor models, with EC fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Primary connection locationsdownflow, water/glycol/GLYCOOL, 105kW (30 ton), all compressor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Primary connection locations downflow water/glycol/GLYCOOL 105kW (30 tons) all compressor models, with EC fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Primary connection locationsupflow, air-cooled, 28-42kw (8-12 ton), semi-hermetic compressor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Primary connection locationsupflow, air-Cooled, 28-42kW (8-12 ton), semi-hermetic compressor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Primary connection locationsupflow, water/glycol/GLYCOOL, 28-42kW (8-12 ton), all compressor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Primary connection locationsupflow, air-cooled, 53-77kW (15-22 ton), semi-hermetic compressor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Primary connection locationsupflow, air-cooled, 53-77kW (15-22 ton), scroll compressor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Primary connection locationsupflow, water/glycol/GLYCOOL, 53-77kW (15-22 ton), all compressor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Primary connection locationsupflow, air-cooled, 105kW (30 ton), all. . . . . . . . . . . . . . . . . . . . 122 Primary connection locationsupflow, water/glycol/GLYCOOL, 105kW (30 ton), all . . . . . . . . 123 Proper filter pleat direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 Upflow motor access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 Auto-belt tensioning motor base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 Correct orientation of float switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 Infrared humidifier lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 Steam generating humidifier canister . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 Removing the old canister . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 Drain valve assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 Canister plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 Circuit board diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

vi

TABLES
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 Shipping dimensionsdomestic and export, inches (mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shipping weightsapproximate, kg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . Weight 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 . . . . Weightsupflow, air-cooled, 105kW (30 ton), all . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Weightsupflow water/glycol/GLYCOOL 105kW (30 ton), all compressors. . . . . . . . . . . . . . . . . Floor stand and floor planning dimensionsdownflow, 28-42kW (8-12 ton) models . . . . . . . . . . Floor stand and floor planning dimensionsdownflow, 53-77kW (15-22 ton) models . . . . . . . . . Floor stand and floor planning dimensionsdownflow, 53-77kW (15-22 ton) models with EC fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Floor stand and floor planning dimensionsdownflow, 105kW (30 ton) models . . . . . . . . . . . . . Floor stand and floor planning dimensionsdownflow, 105kW (30 ton) models with EC fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Blower outlet and deck dimensional data for upflow, 28-42kW (8-12 ton) . . . . . . . . . . . . . . . . . . Blower outlet and deck dimensional data upflow, 53-77kW (15-22 tons) . . . . . . . . . . . . . . . . . . . Blower outlet and deck dimensionsupflow 105kW (30ton) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear return filter box dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Upflow unit plenum dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component weightsdownflow, air-cooled, 28-42kW (8-12 ton), semi-hermetic . . . . . . . . . . . . . Component weightsdownflow, air-cooled, 28-42kW (8-12 ton), scroll/digital scroll. . . . . . . . . . Component weightsdownflow, water/glycol/GLYCOOL, 28-42kW (8-12 ton), all . . . . . . . . . . . Component weightsdownflow, air-cooled, 53-77kW (15-22 ton), semi-hermetic; forward-curved and EC fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component weightsdownflow, air-cooled, 53-77kW (15-22 ton), scroll/digital scroll; forward-curved and EC fan59 Component weightsdownflow water/glycol, GLYCOOL, 53-77kW (15-22 ton), all . . . . . . . . . . Component weightsdownflow, air-cooled, 105kW (30 ton), semi-hermetic compressors; forward-curved and EC fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component weightsdownflow, air-cooled, 105kW (30 ton), scroll compressor models; forward-curved and EC fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component weightsdownflow, water/glycol/GLYCOOL, 105kW (30 ton), all compressor models; forward-curved and EC fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component weightsupflow, air-cooled, 28-42kW (8-12 ton), semi-hermetic compressor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component weightsupflow, air-cooled, 28-42kW (8-12 ton), scroll/digital scroll compressor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
vii

10 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 55 56 57 58

60 61 62 63 67 68

Table 40 Table 41 Table 42 Table 43 Table 44 Table 45 Table 46 Table 47 Table 48 Table 49 Table 50 Table 51 Table 52 Table 53 Table 54 Table 55 Table 56 Table 57 Table 58 Table 59 Table 60 Table 61 Table 62 Table 63 Table 64 Table 65 Table 66 Table 67 Table 68 Table 69

Component weightsupflow, water/glycol/GLYCOOL, 28-42kW (8-12 ton), all compressor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Component weightsupflow air-cooled 53-77kw (15-22 ton), semi-hermetic compressor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Component weightsupflow, air-cooled, 53-77kw (15-22 ton), scroll /digital scroll compressor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Component weightsupflow water/glycol/GLYCOOL, 53-77kW (15-22 ton) all compressor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Component weightsupflow, air-cooled, 105kW (30 ton), semi-hermetic compressor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Component weightsupflow, air-cooled, 105kW (30 ton), scroll/digital scroll compressor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Component weightsupflow, water/glycol/GLYCOOL, 105kW (30 ton), all compressor models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Electrical field connection descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Inverter type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Recommended refrigerant line sizes - OD copper (inches)* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 Indoor unit approximate refrigerant charge for R-22 or R-407C . . . . . . . . . . . . . . . . . . . . . . . . . . 86 R-22 and R-407C refrigerant required, approximate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Interconnecting piping refrigerant charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Additional oil required per refrigerant charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Fan speed suction pressure transducer settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Lee-Temp suction pressure transducer settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Water/Glycol-cooled and GLYCOOL suction pressure transducer settings . . . . . . . . . . . . . . . . . 93 Piping dataupflow, air-cooled 105kW (30 ton), all. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Piping dataupflow, upflow, water/glycol/GLYCOOL, 105kW (30 ton), all . . . . . . . . . . . . . . . . 123 Filter quantities, downflow units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 Filter quantities, upflow units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 Humidifier canister part numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 Steam generating humidifier status lamps: causes, corrective action. . . . . . . . . . . . . . . . . . . . . 142 Steam generating humidifier troubleshooting guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 Compressor oil types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 Recommended refrigerant pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 Water/glycol system conditions requiring optional settings for aquastats . . . . . . . . . . . . . . . . . 149 Aquastat settingstwo-fan through four-fan drycoolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 Aquastat settingssix-fan drycoolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 Aquastat settingseight-fan drycoolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

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.

! WARNING Can cause injury or death. Risk of electric shock.

Disconnect local and remote power supplies before working within. Customer must provide earth ground to unit, per NEC, CEC and local codes, as applicable. 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 Liebert 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 Liebert iCOM control. The factory-supplied optional disconnect switch is inside the unit. The line side of this 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 from high-pressure refrigerant. Can cause injury or death. Risk of explosive discharge
This unit contains fluids and gases under high pressure. Relieve pressure before working with piping.

! WARNING rupture or explosion from overpressurization. Can cause Risk of refrigerant system
equipment damage, injury or death. For systems requiring EU CE compliance (50Hz), 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. The pressure relief valve must be CE-certified to the EU Pressure Equipment Directive by an EU Notified Body.

! WARNING Risk of contact with 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 unit with any or all cabinet panels removed. 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 hot surfaces. Can cause injury. Risk of contact with

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 and lengthy parts. Can cause personal injury and equipment damage. Risk of handling heavy
Cabinet panels can exceed 5ft. (1.5m) in length and weigh more than 35lb. (15.9kg). Follow relevant OSHA lifting recommendations and consider using a two-person lift for safe and comfortable removal and installation of cabinet panels. Only properly trained and qualified personnel wearing appropriate safety headgear, gloves and shoes should attempt to remove or install cabinet panels. NOTE The Liebert indoor cooling unit has a factory-installed high-pressure safety switch in the high side refrigerant circuit. A pressure relief valve is provided with Liebert Lee-Temp condensers. Consult local building codes to determine whether the Liebert Fan Speed Control and VFD condensers will require field provided pressure relief devices.

NOTICE
Risk of clogged or leaking drain lines. Can cause equipment and building damage. This unit requires a water drain connection. Drain lines must be inspected regularly and maintenance must be performed to ensure that drain water runs freely through the drain system and that lines are clear and free of obstructions and in good condition with no visible sign of damage or leaks. This unit may also require an external water supply to operate. Improper installation, application and service practices 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.

NOTICE
Risk of a leaking coil due to freezing and/or corrosion. Can cause equipment and serious building damage. Cooling and heat rejection coils, heat exchangers and piping systems that are connected to open cooling towers or other open water/glycol systems are at high risk for freezing and premature corrosion. Fluids in these systems must contain the proper antifreeze and inhibitors to prevent freezing and premature coil corrosion. The water or water/glycol solution must be analyzed by a competent water treatment specialist before startup to establish the inhibitor requirement. The water or water/glycol solution must be analyzed every six months to determine the pattern of inhibitor depletion. The complexity of water-caused problems and their correction makes it important to obtain the advice of a water treatment specialist and follow a regularly scheduled maintenance program.

Liebert DS Components and Nomenclature

1.0

LIEBERT DS COMPONENTS AND NOMENCLATURE

Downflow model component locations

Figure 1

14 3 17 11 2 9 1

13 15 4 16 10 12 6 8 5
1. Liebert iCOM 2. Electric Box 3. Filters 4. Evaporator Coil 5. Motor 6. Blower 7. Fan Pulley 8. Motor Sheave and Belts 9. Compressor Section

18 10. Infrared Humidifier, optional 11. Disconnect, optional 12. Condensate Pump, optional 13. Smoke Sensor, optional 14. Condenser Cleanout Plugs, fluid-cooled units only 15.Condenser Drain Plugs, fluid-cooled units only 16. Econ-O-Coil Valve, GLYCOOL/Dual Cooling 17. Variable Frequency Drive (optional on DPN000958 digital scroll units only) Rev. 3 18. EC Fans, optional

18

Liebert DS Components and Nomenclature

Figure 2

Upflow model component locations

14

6 11 7 8 9 1 2 5

15 16

17 12 13

10

1. Liebert iCom Control Display 2. Electric Box 3. Filters 4. Evaporator Coil 5. Motor 6. Blower 7. Fan Pulley 8. Motor Sheave and Belts

9. 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) 17. Variable Frequency Drive (optional on DPN001222 Digital Scroll units only)

Rev. 1

Liebert DS Components and Nomenclature

Figure 3

Liebert DS model number nomenclature

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Air Distribution DS = Downflow Standard VS = Upflow Standard Nominal kW 028,035, 042, 053, 070, 077, 105 Cooling Type A = Air-Cooled D = Dual-Cooling, Air-Cooled W = Water/Glycol K = GLYCOOL H = Dual-Cooling (Water/Glycol) Compressor Type U - Semi-hermetic with four-step, R-407C S - Scroll, R-407C D - Digital Scroll, R-407C Voltage M - Semi-hermetic A - 460/3/60 with four-step, R-22 B - 575/3/60 R - Scroll, R-22 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

Factory Configuration Number

Humidification 0 - None I - Infrared S - Steam Generating Canister

Reheat Type 0 - None E - Three-stage electric S - SCR W - Hot water

Fan Type 0 = Centrifugal fans 1 = Electrically Commutated fans

Cooling Configurations

2.0

COOLING CONFIGURATIONS
NOTE All field-installed piping must comply with applicable local, state and federal codes.

Air-Cooled Air-cooled unit piping is spun closed from the factory and contain a nitrogen holding charge. Each installation requires refrigerant piping to a condenser.

Glycol-Cooled Glycol-cooled units are factory-charged and tested. Field-installed piping is required from the unit to the drycooler and pump package.

GLYCOOL GLYCOOL units are factory-charged and tested. Field-installed piping is required from the unit to the drycooler and pump package. An additional coil is included for use when fluid temperatures are sufficiently low (below room temperature). Cooling is provided by circulating cold glycol through this second coil, reducing compressor operation.

Water-Cooled Water-cooled units are factory-charged and tested. Field-installed water piping is required from the unit to the cooling tower.

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
3.1

PRE-INSTALLATION GUIDELINES
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 Emerson representative for information.

3.2

Air DistributionDownflow Units

Verify that the raised floor has been properly sized for the units airflow and the room is free of airflow restrictions. Perforated floor tiles in the raised floor should ensure minimal pressure loss. 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

Field-Fabricated Ductwork Field Service Access for filter replacement (minimum height of 12" [305mm]; minimum distance from unit, 2" [51mm])

Provided Condenser Access (water, glycol and GLYCOOL units only)

Field-Fabricated Ductwork

Provided Service Access Door for filter replacement

DIRECT UNIT DUCTING

Optional Liebert Plenum

Provided Condenser Access (water, glycol and GLYCOOL units only) Liebert Plenum - Refer to plenum installation sheet 186582P1 included in the plenum package.
7

PLENUM DUCTING

Pre-Installation Guidelines

3.3

Air DistributionUpflow Units

Various configurations are available: Front return Rear return Top-front supply Top-rear supply

For in-room applications with supply and return grilles, several feet of clearance must be maintained at the intake and discharge of the unit. Upflow rear-return configurations use a filter box attached to the back of the Liebert DS. Allow 25" (635 mm) on one side of the unit for access to the rear return filter box. Refer to the rear return installation sheet, 187230P1, inside the rear return filter box package.

! WARNING parts. Can cause injury or death. Risk of high-speed moving

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
2

1 1

1 Straight section of duct off of unit to be 1.5 to 2.5 times the longest blower dimension. 2 Typical ducting shown; ducting may run to either side. * Follow standard practices on all duct work.

DPN001156 Rev. 0

NOTE Drain traps are qualified to a return duct static of negative 1.5 i.w.g. (-1.5 i.w.g).
8

Pre-Installation Guidelines

3.4

Connections and System Setup

Plan the routing of wiring, piping and ductwork to the unit. See Figure 61 and Figures 76 through 96 for unit connection locations. Water/glycol and GLYCOOL units utilizing a drycooler may require an optional aquastat setting. See Tables 66 through 69 for aquastat setting guidelines. Applications with the optional stat setting 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 contain boiling water. See 9.1.1 - Condensate PipingField-Installed for details. 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. NOTE Seal openings around piping and electrical connection to prevent air leakage. Failure to do so could reduce the units cooling performance.

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 77F (25C) DB and 55% RH or maximum WB of 65.5F (18.6C). Operating outside this envelope can decrease equipment reliability. Return air to the unit must be no cooler than the ASHRAE recommendation of 68F (20C) DB and 40% RH or minimum WB of 54F (12.2C) for proper unit operation. Operating below this can decrease equipment reliability. Refer to ASHRAEs publication, Thermal Guidelines for Data Processing Environments.

Liebert DS Dimensions and Weights

4.0

LIEBERT DS DIMENSIONS AND WEIGHTS

Table 1 Shipping dimensionsdomestic and export, inches (mm)
028 / 035/ 042 Model Number
DS/VSAS, DS/VSAD, DS/VSAR, DS/VSAG, DS/VSDS, DS/VSDD, DS/VSDR, DS/VSDG DS/VSAU, DS/VSAM, DS/VSDU, DS/VSDM DS/VSWS, DS/VSWD, DS/VSWR, DS/VSWG DS/VSHS, DS/VSHD, DS/VSHR, DS/VSHG DS/VSWU, DS/VSWM, DS/VSHU, DS/VSHM

053/ 070 / 077 L xW x H, in (mm)

102x42x82 (2591x1067x2083

105 Lx W x H, in (mm)

L x W xH, in (mm)

90x42x82 (2286x1067x2083)

114x42x82 (2896x1067x2083)

136x42x82 (3454x1067x2083)

Table 2
Size

Shipping weightsapproximate, kg
Cooling Type
Air Air D/C

Compressor Type
Semi Scroll Semi Scroll Semi Scroll Semi Scroll Semi Scroll Semi Scroll Semi Scroll Semi Scroll Semi Scroll Semi Scroll Semi Scroll Semi Scroll Semi Scroll Semi Scroll Semi Scroll Semi Scroll Semi Scroll Semi Scroll Semi Scroll Semi Scroll

Downflow Unit Weight, lb Domestic

1918 1608 2068 1758 2068 1918 2218 2068 2512 2070 2692 2250 2812 2382 2992 2562 2562 2120 2742 2300 2862 2432 3042 2612 2612 2170 2792 2350 2912 2470 3092 2650 3223 3103 3583 3463 3593 3473 3953 3833

Upflow Unit Weight, lb Domestic

1968 1658 2118 1808 2118 1968 2268 2118 2512 2220 2692 2400 2812 2532 2992 2712 2662 2220 2842 2400 2962 2532 3142 2712 2662 2220 2842 2400 2962 2532 3142 2712 3183 3063 3513 3393 3553 3433 3883 3763

Export
2088 1778 2238 1928 2238 2088 2388 2238 2712 2260 2892 2440 3012 2582 3192 2762 2762 2310 942 2490 3062 2632 3242 2812 2812 2360 2992 2540 3112 2660 3292 2840 3443 3323 3803 3683 3813 3693 4173 4053

Export
2138 1828 2288 1978 2288 2138 2438 2288 2712 2410 2892 2590 3012 2732 3192 2912 2862 2410 3042 2590 3162 2732 3342 2912 2862 2410 3042 2590 3162 2732 3342 2912 3403 3283 3733 3613 3773 3653 4103 3983

8-12 Ton
W/G G/C Air Air D/C

15 Ton
W/G G/C Air Air D/C

20 Ton
W/G G/C Air Air D/C

22 Ton
W/G G/C Air Air D/C

30 Ton
W/G G/C

10

Liebert DS Dimensions and Weights

Figure 6

Cabinet and floor planning dimensionsdownflow, air-cooled, 28-42kW (8-12 ton), semi-hermetic compressor models
Secondary Refrigerant Piping Entrance 56-7/8" Opening (1445mm)

33" (838mm) 35" (889mm) Air Inlet Opening

Notes: Filters are accessible through top of unit only. 24-3/8" Opening (619mm) Downflow electrical connections can be made from top or bottom of unit.

Top View
Secondary Entrance High Volt Connection(s) 86" (2184mm)

3/4" (19mm) Bezels Secondary Entrance Low Volt Connections

Minimum clearance required for filter replacement

15" (381mm)

76" (1930mm)

2" (51mm)

Front View
85" (2159mm)

Shaded areas indicate a recommended minimum clearance for component access.

34" (864mm)

DPN000795 Rev. 3

Table 3

Weights for downflow, air-cooled, 28-42kW (8-12 ton), semi-hermetic compressor models Dry Weight - lb. (kg), Approximate

Model No. Air-Cooled Dual-Cool

028, 035, 042 1780 (809) 1930 (877)

11

Liebert DS Dimensions and Weights

Figure 7

Cabinet and floor planning dimensionsdownflow, air-cooled, 28-42kW (8-12 ton), scroll compressor models

Secondary Refrigerant Piping Entrance 56-7/8" Opening (1445mm)

33" (838mm) 35" (889mm)

Air Inlet Opening

Notes: Filters are accessible through top of unit only. Downflow electrical connections can be made 24-3/8" from top or bottom of unit. (619mm) Opening

Secondary Entrance High Volt Connection(s)

Top View

73" (1854mm)

3/4" Bezels (19mm) Minimum required Secondary Entrance for filter replacement Low Volt Connections

15" (381mm) 76" (1930mm) 34" (864mm) Shaded area indicates a recommended minimum clearance for component access. DPN000796 Rev. 2

2" (51mm)
Table 4

Front View 72" (1829mm)

Weights for downflow, air-cooled, 28-42kW (8-12 ton), scroll compressor models

Dry Weight, lb (kg), Approximate Model No. Air-Cooled Dual-Cool 028, 035, 042 1470 (668) 1620 (736)

12

Liebert DS Dimensions and Weights

Figure 8

Cabinet and floor planning dimensionsdownflow, water/glycol/GLYCOOL, 28-42kW (8-12 ton), all compressor models

Condenser Cleanout Access

56-7/8" Opening (1445mm)

33" (838mm) 35" (889mm)

Air Inlet Opening

Notes: Filters are accessible through top of unit only. Downflow electrical 24-3/8" connections can be made (619mm) from top or bottom of unit. Opening 3/4" Bezels (19mm) Required for condenser cleanout

Secondary Condenser Top View Fluid Piping Entrance Secondary Entrance High Volt Connection(s) 86" (2184mm)

Secondary Entrance Low Volt Connections

24" (610mm)

Minimum required for filter replacement 15" (381mm)

76" (1930mm) 34" (864mm) Shaded area indicates a recommended minimum clearance for component access. DPN000894 Rev. 3

2" (51mm)
Table 5

Front View 85" (2159mm)

Weights for downflow, water/glycol/GLYCOOL, 28-42kW (8-12 ton), all compressor models Dry Weight - lb. (kg), Approximate
Compressor Type Model Water/Glycol GLYCOOL/Dual-Cool Water/Glycol GLYCOOL/Dual-Cool 028, 035, 042 1930 (877) 2080 (945) 1780 (809) 1930 (877)

Semi-Hermetic Compressor Scroll or Digital Scroll Compressor

13

Liebert DS Dimensions and Weights

Figure 9

Cabinet and floor planning dimensionsdownflow, air-cooled, 53-77kW (15-22 ton), semi-hermetic compressor models
Second Refrigerant Piping Entrance 80" Opening (2032mm)

33" (838mm) 35" (889mm)

Air Inlet Opening

Notes: Filters are accessible through top of unit onl y. Downflow electrical connections can be made 24-3/8" Opening from top or bottom of unit. (619mm) 3/4" Bezels (19mm) Secondary Entrance Low Volt Connections Minimum required for filter replacement

Secondary Entrance High Volt Connection(s)

Top View 109" (2769mm)

15" (381mm)

76" (1930mm)

34" (864mm) Front View 108" (2743mm) Shaded area indicates a recommended minimum clearance for component yaccess.

2" (51mm)

DPN000924 Rev. 2

Table 6
Model Air-Cooled Dual-Cool

Weights for downflow, air-cooled, 53-77kW (15-22 ton), semi-hermetic compressor models
Dry Weight, lb (kg) Approximate 053 2350 (1069) 2530 (1150) 070 2400 (1091) 2580 (1173) 077 2450 (1114) 2630 (1196)

14

Liebert DS Dimensions and Weights

Figure 10 Cabinet and floor planning dimensionsdownflow, air-cooled, 53-77kW (15-22 ton), scroll compressor models
Secondary Refrigerant Piping Entrance Notes: Filters are accessible only through top of unit. Downflow electrical connections can be made from top or bottom of unit. 24-5/8" (625mm Opening 3/4" (19mm) Bezels Secondary Entrance High Volt Connection(s)

80" Opening (2032mm)

33" (838mm) 35" (889mm)

Air Inlet Opening

Top View
98" (2489mm)

Secondary Entrance Low Volt Connections

Minimum required for filter replacement

15" (381mm)

76" (1930mm)

34" (864mm) 2" (51mm) Shaded area indicates a recommended minimum clearance for component access.

97" (2464mm)

Front View
Table 7
Model No. Air-Cooled Dual-Cool Dry Weight, lb (kg) Approximate 053 1920 (873) 2100 (955) 070 1970 (896) 2150 (978) 077 2020 (919) 2200 (1000)

DPN000925 Rev. 1

Weights for downflow, air-cooled, 53-77kW (15-22 ton), scroll compressor models

15

Liebert DS Dimensions and Weights

Figure 11 Cabinet and floor planning dimensionsdownflow, water/glycol/GLYCOOL, 53-77kW (15-22 ton), all compressor models
Condenser Cleanout Access 80" (2032mm) Opening 33" (838mm) 35" (889mm Notes: Filters are accessible through top of unit onl y. Downflow electrical connections can be made from top or bottom of unit. 3/4" (20mm) Bezels Required for condenser cleanout Minimum required for filter replacement

Air Inlet Opening

24-5/8" (625mm) Opening

Secondary Condenser Fluid Piping Entrance Secondary Entrance High Volt Connection(s)

Top View
109" (2769mm)

Secondary Entrance Low Volt Connections

24" (610mm)

15" (381mm)

76" (1930mm)

108" (2743mm) 2" (51mm)

Front View

Shaded area indicates a recommended minimum clearance for component access.

34" (864mm)

DPN000931 Rev. 3

Table 8

Weights for downflow, water/glycol/GLYCOOL, 53-77kW (15-22 ton), all compressor models
Dry Weight, lb (kg), Approximate Model Water/Glycol GLYCOOL/Dual-Cool Water/Glycol GLYCOOL/Dual-Cool 053 2650 (1205) 2830 (1287) 2220 (1010) 2400 (1091) 070 2700 (1228) 2880 (1310) 2270 (1032) 2450 (1114) 077 2750 (1250) 2930 (1332) 2320 (1055) 2500 (1137)

Compressor Type Semi-Hermetic Compressor Scroll or Digital Scroll Compressor

16

Liebert DS Dimensions and Weights

Figure 12 Cabinet and floor planning dimensionsdownflow, air-cooled, 105kW (30 ton), all compressor models
Secondary Refrigerant Piping Entrance 102-13/16" (2611mm)
Opening 33" (838mm) 35" (889mm)

Notes: Filters are accessible only through top of unit. Downflow electrical connections can be made from top or bottom of unit. 24-3/8" Opening (619mm) 3/4" Bezels (19mm)
Secondary Entrance Low Volt Connections

Air Inlet Opening

Top View
Secondary Entrance High Volt Connection(s)
132" (3353mm)

Minimum required for filter replacement 15" (381mm)

76" (1930mm)

34" (864mm)

Front View
131" (3327mm)

Shaded area indicates a recommended minimum clearance for component access.

DPN001012 Rev. 3

Table 9

Weights for downflow, air-Cooled, 105kW (30 ton), all compressor models
Dry Weight, lb (kg) approximate Model 105 Forward-Curved Fans 3040 (1382) 3400 (1545) 2920 (1327) 3280 (1491) EC Fans 2774 (1258) 3134 (1422) 2654 (1204) 3014 (1367)

Compressor Type Semi-Hermetic Compressor Scroll Compressor

Fan Type Air-Cooled Dual-Cool Air-Cooled Dual-Cool

17

Liebert DS Dimensions and Weights

Figure 13 Cabinet and floor planning dimensionsdownflow, water/glycol/GLYCOOL, 105kW (30 ton), all compressor models
Condenser Cleanout Access 102-13/16" (2611mm) Opening
33" (838mm)

Notes: Filters are accessible through top of unit onl y. Downflow electrical connections can be made from top or bottom of unit 24-3/8" (619mm) Opening 3/4" (19mm) Bezels Secondary Entrance Low Volt Connections 24" (610mm)

AIR INLET OPENING

35" (889mm)

TOP VIEW Secondary Condenser Fluid Entrance Secondary Entrance High Volt Connection(s)

Required for condenser cleanout Minimum required for filter replacement

132" (3353mm) 15" (381mm)

76" (1930mm)

FRONT VIEW 131" (3327mm)

Shaded area indicates a recommended minimum clearance for component access

34" (864mm)

DPN001013 Rev. 3

Table 10

Weights for downflow, water/glycol/GLYCOOL, 105kW (30 ton), all compressor models
Dry Weight, lb (kg) approximate Model Water/Glycol GLYCOOL/Dual-Cool Water/Glycol GLYCOOL/Dual-Cool 105 3410 (1550) 3770 (1714) 3290 (1495) 3650 (1659)

Compressor Type Semi-Hermetic Compressor Scroll Compressor

18

Liebert DS Dimensions and Weights

Figure 14 Cabinet and floor planning dimensionsupflow, air-cooled 28-42kW (8-12 ton), semi-hermetic compressor models
Alternate Refrigerant Piping Entrance

33" (838mm) 35" (889mm)

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. See DPN001196, Figure 30.
3/4" (19mm) Bezels

Top View
High Volt Connection(s) Low Volt Connection(s) Minimum required for blower replacement

1-1/2" (38mm)

86" (2184mm)

24" (610mm)

76" (1930mm)

34" (864mm) Shaded area indicates a recommended minimum clearance for component access. 2" (51mm) 85" (2159mm)

Front View
Dry Weight, lb (kg) approximate

DPN001162 Rev. 1

Table 11

Weight for upflow, air-cooled, 28-42kW (8-12 ton), semi-hermetic compressor models

Model No. Air-Cooled Dual-Cool

028-042 1830 (830) 1980 (898)

19

Liebert DS Dimensions and Weights

Figure 15 Cabinet and floor planning dimensionsupflow, air-cooled 28-42kW (8-12 ton), scroll or digital scroll compressor models
Alternate Refrigerant Piping Entrance
Note: Front air return unit shown. For rear 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. See DPN001196, Figure 30.

33" (838mm) 35" (889mm)

3/4" (19mm) Bezels

TOP VIEW
High Volt Connection(s) 1-1/2" (38mm) 73" (1854mm) Low Volt Connection(s)

Minimum required for blower replacement

24" (610mm)

76" (1930mm)

34" (864mm) Shaded area indicates a recommended minimum clearance for component access. 2" (51mm) 72" (1829mm)

FRONT VIEW
Dry Weight, lb (kg) approximate

DPN001163 Rev. 1

Table 12

Weight for upflow, air-cooled, 28-42kW (8-12 ton), scroll or digital scroll compressor models

Model No. Air-Cooled Dual-Cool

028-042 1520 (689) 1670 (758)

20

Liebert DS Dimensions and Weights

Figure 16 Cabinet and floor planning dimensionsupflow, water/glycol/GLYCOOL, 28-42kW (8-12 ton), all compressor models
Condenser Cleanout Access

33" (838mm) 35" (889mm)

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. See DPN001196, Figure 30

3/4" (19mm) Bezels Alternate Refrigerant Piping Entrance High Volt Connection(s) 1-1/2" (38mm)

Required for condenser cleanout Minimum required for blower replacement

TOP VIEW
Low Volt Connection(s) 86" (2184mm)

24" (610mm)

76" (1930mm)

Shaded area indicates a recommended minimum clearance for component access. 2" (51mm) 85" (2159mm)

34" (864mm)

FRONT VIEW
Dry Weight, lb (kg) approximate

DPN001164 Rev. 1

Table 13

Weights for upflow, water/glycol/GLYCOOL, 28-42kW (8-12 ton), all compressor models
Model Water/Glycol GLYCOOL/Dual-Cool Water/Glycol GLYCOOL/Dual-Cool 028-042 1980 (898) 2130 (966) 1830 (830) 1980 (898)

Compressor Type Semi-Hermetic Scroll or Digital Scroll

21

Liebert DS Dimensions and Weights

Figure 17 Cabinet and floor planning dimensionsupflow, air-cooled, 53-77kW (15-22 ton), semi-hermetic compressor models

Alternate Refrigerant Piping Entrance

33" (838mm)

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. See DPN001196, Figure 30.

35" (889mm)

3/4" (19mm) Bezels TOP VIEW Low Volt Connection(s) High Volt Connection(s)

Minimum required for blower replacement

1-1/2" (38mm)

109" (2769mm)
24" (610mm)

76" (1930mm) 34" (864mm)

Shaded area indicates a recommended minimum clearance for component access.

2" (51mm)
Table 14

108" (2743mm) FRONT VIEW

Dry Weight, lb (kg) approximate

DPN001165 Rev. 1

Weights for upflow, air-cooled, 53-77kW (15-22 ton), semi-hermetic compressor models

Model

053

070, 077

Air-Cooled Dual-Cool

2350 (1069) 2530 (1150)

2500 (1134) 2680 (1216)

22

Liebert DS Dimensions and Weights

Figure 18 Cabinet and floor planning dimensionsupflow, air-cooled, 53-77kW (15-22 ton), scroll or digital scroll compressor models

Alternate Refrigerant Piping Entrance

33" (838mm)

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. See DPN001196, Figure 30.

35" (889mm)

3/4" (19mm) Bezels High Volt Connection(s) TOP VIEW 98" (2489mm) Low Volt Connection(s)

Minimum required for blower replacement

1-1/2" (38mm)

24" (610mm)

76" (1930mm)

34" (864mm)
Shaded area indicates a recommended minimum clearance for component access.

2" (51mm)
Table 15

97" (2464mm) FRONT VIEW

DPN001166 Rev. 1

Weight for upflow, air-cooled, 53-77kW (15-22 ton), scroll or digital scroll compressor models
Dry Weight, lb (kg) approximate 053, 070, 077 2070 (939) 2250 (1021)

Model No. Air-Cooled Dual-Cool

23

Liebert DS Dimensions and Weights

Figure 19 Cabinet and floor planning dimensionsupflow, water/glycol/GLYCOOL, 53-77kW (15-22 ton), all compressor models

Condenser Cleanout Access

33" (838mm)

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. See DPN001196, Figure 30.

35" (889mm)

Alternate Condenser Fluid Piping Entrance High Volt Connection(s) 1-1/2" (38mm)

TOP VIEW

3/4" Required for (19mm) condenser cleanout Bezels Minimum required for blower replacement Low Volt Connection(s)

109" (2769mm)
24" (610mm)

76" (1930mm) 34" (864mm)

Shaded area indicates a recommended minimum clearance for component access.

2" (51mm)
Table 16

108" (2743mm) FRONT VIEW

DPN001167 Rev. 1

Weights for upflow, water/glycol/GLYCOOL, 53-77kW (15-22 ton), all compressor models
Dry Weight, lb (kg) approximate Model Water/Glycol GLYCOOL/Dual-Cool Water/Glycol GLYCOOL/Dual-Cool 053 2650 (1205) 2830 (1287) 070, 077 2800 (1270) 2980 (1352)

Compressor Type Semi-Hermetic Compressor Scroll or Digital Scroll Compressor

2370 (1075) 2550 (1157)

24

Liebert DS Dimensions and Weights

Figure 20 Cabinet and floor planning dimensionsupflow, air-cooled, 105kW (30 ton), all
Alternate Refrigerant Piping Entrance 33" (838mm) 35" (889mm)

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. See DPN001196, Figure 30.
3/4" (19mm) Bezels

High Volt onnection(s) 1-1/2" (38mm)

TOP VIEW
132" (3353mm)

Low Volt Connection(s)

Minimum required for blower replacement

24" (610mm) 76" (1930mm)

34" (864mm) 2" (51mm) 131" (3327mm)

FRONT VIEW

Shaded area indicates a recommended minimum clearance for component access.

DPN001168 REV 0

Table 17

Weightsupflow, air-cooled, 105kW (30 ton), all

Dry Weight, Approximate, lb (kg)

Model
Semi- Hermetic, Air-Cooled Semi-Hermetic, Dual-Cool Scroll or Digital Scroll, Air-Cooled Scroll or Digital Scroll, Dual-Cool

105

3000 (1361) 3330 (1510) 2880 (1306) 3210 (1456)

25

Liebert DS Dimensions and Weights

Figure 21 Cabinet and floor planning dimensionsupflow water/glycol/GLYCOOL 105kW (30 ton), all compressors
Alternate Refrigerant Piping Entrance 33" (838mm) 35" (889mm) Alternate Condenser Fluid Piping Entrance High Volt Connection(s) 1-1/2" (38mm) 132" (3353mm)

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. See DPN001196, Figure 30.
Required for condenser cleanout

3/4" (19mm) Bezels

TOP VIEW
Low Volt Connection(s)

Minimum required for blower replacement

24" (610mm)

76" (1930mm)

2" (51mm)

131" (3327mm)

FRONT VIEW

Shaded area indicates a recommended minimum clearance for component access.

34" (864mm) DPN001169 REV 0

Table 18

Weightsupflow water/glycol/GLYCOOL 105kW (30 ton), all compressors

Model 105
3370 (1529) 3700 (1678) 3250 (1474) 3580 (1624) Water/Glycol GLYCOOL/Dual-Cool Water/Glycol GLYCOOL/Dual-Cool

Semi-Hermetic Compressor Scroll or Digital Scroll Compressor

26

Liebert DS Dimensions and Weights

Figure 22 Floor stand dimensionsdownflow, 28-42kW (8-12 ton) models

A+1-1/2" (38mm) (with feet) A B 47-15/16" (1218mm) 4-1/2" (114mm)

33" (838mm) 34-1/2" (876mm) (with feet) 1" (25mm) TYP.

16-3/4" (425mm) Supply air discharge opening

Gussets supplied on floor stands 12" (305 mm) tall and greater

Supply air discharge opening

7/8" (23mm)

3" (76mm)

Turning vane air outlet Optional turning vane can be field-installed in supply air discharge opening for front or rear air discharge.

Optional turning vane shown as front air discharge.

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.

DPN000820 REV 2

Table 19

Floor stand and floor planning dimensionsdownflow, 28-42kW (8-12 ton) models
Dimensions, in. (mm) Model A 85 (2159) B 26 (660) Height, in. (mm) C* 9 (229) D Turning Vane 4 (111) 7 (187) 10 (264) 13 (340) 16 (416) 19 (492)

Air-Cooled Semi-Hermetic Models and All Water/Glycol/GLYCOOL Models

12 (305) 15 (381) 18 (457)

Air-Cooled Scroll Models and Air-Cooled Digital Scroll Models

72 (1829)

13 (330)

21 (533) 24 (610)

27

Liebert DS Dimensions and Weights

Figure 23 Floor stand dimensionsdownflow, 53-77kW (15-22 ton) models

A+1-1/2" (38mm) (with feet) A B 69-3/4" (1772mm) 4-1/2" (114mm) 16-3/4" (425mm)

34-1/2" (876mm) (with feet)

33" (838mm)

1" (25mm) TYP. Gussets supplied on floor stands 12" (305 mm) tall and greater

Supply air discharge opening

Supply air discharge opening

7/8" (23mm) 3" Turning vane air outlet (76mm) Optional turning vane can be field-installed in supply air discharge opening for front or rear air discharge. 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. Optional turning vane shown as front air discharge.

DPN000930 REV 1

Table 20

Floor stand and floor planning dimensionsdownflow, 53-77kW (15-22 ton) models
Dimensions, in. (mm) Model A 108 (2743) B 26 (660) Height, in. (mm) C* 9 (229) D Turning Vane 4 (111) 7 (187) 10 (264) 13 (340) 16 (416) 19 (492)

Air-Cooled Semi-Hermetic Models and All Water/Glycol/GLYCOOL Models

12 (305) 15 (381) 18 (457)

Air-Cooled Scroll Models and Air-Cooled Digital Scroll Models

97 (2464)

15 (381)

21 (533) 24 (610)

28

Liebert DS Dimensions and Weights

Figure 24 Floor stand and floor planning dimension, downflow 53-77kW (15-22 tons) models with EC fans
A B 3/4" (19mm) Piping access area

31-1/2" (800mm)

32" (813mm) Center Feet

3/4" (19mm) 3/4" (19mm)

62-3/4" (1594mm) 95-1/2" (2426mm) Support Feet Centers 97" (2464mm)

7/8" (23mm) 3" (76mm)

See Note 4 1" (25mm) 33" (838mm)

98-1/2" (2502mm) NOTES: 1) This floor stand should be used when EC fans are intended to be C* lowered under a raised floo r. The standard Liebert DS floor stand can be used if the fans are to remain in their original, raised position. 2) Right side of paneled unit is flush with right side of floor stand. All other paneled sides overhang floor stand 1" (25mm). 3) The floor stand used with EC units is not symmetrical, and its orientation to the Liebert DS is critical for lowering the EC fans. Unless the floor stand is installed in the correct position, the blowers will not lower into the floor stand. 4) Jack and jack support are shipped loose and are intended to be placed into position under each fan and used to lower or raise that fan as needed. *Leveling feet are provided with 1-1/2" (38mm) adjustment from nominal height C.

35" (889mm) Overall Depth

DPN002151 REV 0

Table 21

Floor stand and floor planning dimensionsdownflow, 53-77kW (15-22 ton) models with EC fans
Height, Dimension C in. (mm) 24 (610) 30 (762) 36 (914) 42 (1067) 48 (1219)

29

Liebert DS Dimensions and Weights

Figure 25 Floor stand dimensionsdownflow, 105kW (30 ton) models

132-1/2" (3366mm) (with feet) 131" (3327mm) 91-3/4" (2330mm)

26" (660mm)

4-1/2" (114mm) 16-3/4" (425mm)

34-1/2" (876mm) (with feet) 33" (838mm) 1" (25mm) TYP.

Supply air discharge opening

Supply air discharge opening

Gussets supplied on floor stands 12" (305 mm) tall and greater 7/8" (23mm) Optional turning vane shown as front air discharge. Turning vane air outlet C* Optional turning vane can be field-installed in supply air discharge opening for front or rear air discharge. 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. 3" (76mm)
D

DPN001059 REV 1

Table 22
C* 9 (229) 12 (305) 15 (381) 18 (457) 21 (533) 24 (610)

Floor stand and floor planning dimensionsdownflow, 105kW (30 ton) models
D turning vane 4 (111) 7 (187) 10 (264) 13 (340) 16 (416) 19 (492)

Height, in. (mm)

30

Liebert DS Dimensions and Weights

Figure 26 Floor stand and floor planning dimension, downflow 105kW (30 tons) models with EC fans

132-1/2" (3366mm) (with feet) 131" (3327mm) 25" (635mm) 34-1/2" (876mm) 33" (with feet) (838mm) 74" (1880mm) Gussets supplied on floor stands 12" (305 mm) tall and greater 1" (25mm) Typ.

7/8" (23mm) 3" (76mm) NOTE: 1) This floor stand should be used when EC fans are intended to be lowered under a raised floor. The standard Liebert DS floor stand can be used if the fans are to remain in their original raised position. 2) Right side of paneled unit is flush with right side of floor stand. All other paneled sides overhang floor stand 1" (25mm). 3) The floor stand used with EC units is not symmetrical and its orientation to the Liebert DS is critical for lowering the EC fans. Unless the floor stand is installed in the correct position, the blowers will not lower into the floor stand. 4) Jack and jack support are shipped loose and are intended to be placed into position under each fan and utilized to lower or raise that fan as needed. * Leveling feet are provided with 1-1/2" (38mm) adjustment from nominal height A See Note 4

A*

35" (889mm) Overall Depth

DPN002152 Rev. 0

Table 23

Floor stand and floor planning dimensionsdownflow, 105kW (30 ton) models with EC fans

Height, Dimension A in. (mm) 24 (610) 30 (762) 36 (914) 42 (1067) 48 (1219)

31

Liebert DS Dimensions and Weights

Figure 27 Blower outlet and deck dimensionsupflow, 28-42kW (8-12 ton)

73" (1854mm) or 86" (2184mm) Ref Blower Outlet *
E C

35" (889mm) Ref

Blower Outlet Location - Top View

* Duct flange not provided

Top of Unit
Blower Deck
D

1-1/2" (38mm)

76" (1930mm) Ref

Front or Rear Throw Air Supply

Table 24
Model

DPN001120 Rev. 2

Blower outlet and deck dimensional data for upflow, 28-42kW (8-12 ton)
Dimensional data, in. (mm) Blower 15 x 15 Supply Front Throw Rear Throw Front Throw Rear Throw A 15-7/8 (404) 15-7/8 (404) 15-7/8 (404) 15-7/8 (404) B 18-5/8 (472) 18-5/8 (472) 14-1/2 (368) 14-1/2 (368) C 2-1/8 (54) 11-5/8 (295) 2-1/8 (54) 11-5/8 (295) D 25-5/8 (651) 25-5/8 (651) 25-5/8 (651) 25-5/8 (651) E 25 (635) 25 (635) 25 (635) 25 (635)

28-42kW (8-12ton) 15 x 11

32

Liebert DS Dimensions and Weights

Figure 28 Blower outlet and deck dimensionsupflow, 53-77kW (15-22 ton)

97" (2464mm) or 108" (2743mm) F E Blower Outlets* C

35" (889mm) Ref

Blower Outlet - Top View Preferred Connection Location

Front of Unit

2-1/8" (54mm)

35" Ref. (889mm)

Blower Deck - Top of Unit

Front of Unit

* Duct flanges not provided. Top of Unit Blower Deck D

1-1/2" (38mm)

76" (1930mm) Ref. DPN001191 Rev. 4

Front or Rear Air Throw Supply

Table 25
Models

Blower outlet and deck dimensional data upflow, 53-77kW (15-22 tons)
Dimensional Data, inches (mm) Blower 15 x 15 Supply Front Throw Rear Throw Front Throw Rear Throw A 15-7/8 (404) 15-7/8 (404) 15-7/8 (404) 15-7/8 (404) B 18-5/8 (472) 18-5/8 (472) 14-11/16 (373) 14-11/16 (373) C 2-1/8 (54) 11-5/8 (295) 2-1/8 (54) 11-5/8 (295) D 25-5/8 (651) 25-5/8 (651) 25-5/8 (651) 25-5/8 (651) E 27-3/4 (705) 27-3/4 (705) 31-3/8 (797) 31-3/8 (797) F 55-1/2 (1410) 55-1/2 (1410) 58-7/16 (1484) 58-7/16 (1484) G 25-1/8" (638mm) 25-1/8" (638mm) 27-3/4" (705mm) 27-3/4" (705mm) H 50-1/2" (1283mm) 50-1/2" (1283mm) 47" (1194mm) 47" (1194mm)

53-77kW (15-22 Tons) 15 x 11

33

Liebert DS Dimensions and Weights

Figure 29 Blower outlet and deck dimensionsupflow 105kW (30ton)

132" (3353mm) Blower Outlets * G F E C

A B

A B

A B

35" (889mm) Ref

Blower Outlet Location TOP VIEW * Duct Flanges Not Provided Top of Unit Blower Deck D 1-1/2" (38mm) 76" (1930mm) Ref Front or Rear Throw Air Supply
Table 26
Models 105kW (30 ton)

Front of Unit

DPN001192 Rev. 0

Blower outlet and deck dimensionsupflow 105kW (30ton)

Dimensions, in. (mm) Blower Supply Front Throw Rear Throw A 15-7/8 (404) 15-7/8 (404) B 14-11/16 (373) 14-11/16 (373) C 2-1/8 (54) 11-5/8 (295) D 25-5/8 (651) 25-5/8 (651) E 30-3/4 (781) 30-3/4 (781) F 54-1/2 (1384) 54-1/2 (1384) G 78-1/8 (1984) 78-1/8 (1984)

15 x 11

34

Liebert DS Dimensions and Weights

Figure 30 Rear return filter box dimensions

Filter Access Door

Filter Access Door

7-15/16" (202mm) 76" 40" (1930mm) (1016mm)

38-1/4" (971mm) Duct Size

3-1/2" (89mm)

D Duct Size C

A B NOTES: 1. Filters can be accessed from either side. 2. 25" (635mm) minimum clearance provided on one side for filter access. 3. Filter boxes are shipped flat and must be field assembled.
Table 27 Rear return filter box dimensions
Dimensions, in (mm) Compressor Type 28-42kW (8-12 ton) Air-Cooled Scroll and Air-Cooled Digital Scroll Models 28-42kW (8-12 ton) Semi-Hermetic and all Water/Glycol/GLYCOOL Models 53-77kW (15-22 ton) Air-Cooled Scroll and Air-Cooled Digital Scroll Models 53-77kW (15-22 ton) Semi-Hermetic and all Water/Glycol/GLYCOOL Models 105kW (30 ton) All Models A 4-1/4 (108) 4-1/4 (108) 3-1/4 (83) 3-1/4 (83) 2-1/4 (57) B 50-3/4 (1289) 50-3/4 (1289) 75-1/2 (1918) 75-1/2 (1918) 100-1/4 (2546) C 18 (457) 31 (787) 19-1/4 (489) 30-1/4 (768) 29-1/2 (749) D

DPN001196 Rev. 0

# Filters 4 4 6 6 8

47-5/8 (1210) 47-5/8 (1210) 72-3/8 (1838) 72-3/8 (1838) 97-1/8 (2467)

35

Liebert DS Dimensions and Weights

Figure 31 Upflow unit plenum dimensions

Front Views Check One (1):

Rear Views Check One (1):

With Grille

With Grille

Without Grille Left Side Views Check One (1): 34" (864mm) 1" (25mm) With Grille

Panel removable for condenser cleanout access (water/glycol / GLYCOOL models only) B A

Without Grille Right Side Views Check One (1): H With Grille 76" (1930mm)

Without Grille

Without Grille

Front View Unit With Plenum Notes: 1. Typical 53-77kW (15-22ton) unit orientation shown with grille plenum . View varies by unit size and plenum selection . 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 plenums are open on the top and not designed with duct flange .
Table 28 Upflow unit plenum dimensions
Plenum Dimensions, in (mm) A 28-42kW (8-12 ton) Air-Cooled Scroll and Air-Cooled Digital Scroll Models B H 20 (508)

Side View Unit With Plenum

DPN001187 Rev. 0
Grille Size, in (mm) - Nominal

Front/Rear Grilles 18 x 55 (457 x 1397) 18 x 55 (457 x 1397) 18 x 78 (457 x 1981) 18 x 78 (457 x 1981) (1) 18 x 20 (457 x 508) (1) 18 x 78 (457 x 1981)

Side Grille 18 x 20 (457 x 508) 18 x 20 (457 x 508) 18 x 20 (457 x 508) 18 x 20 (457 x 508) 18 x 20 (457 x 508)

59-1/4 (1505) 13-3/4 (349)

28-42kW (8-12 ton) Semi-Hermetic 59-1/4 (1505) 26-3/4 (679) and all Water/Glycol/GLYCOOL Models 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 82-1/4 (2089) 26-3/4 (679) and all Water/Glycol/GLYCOOL Models 105kW (30 ton) All Models 105-1/4 (2673) 26-3/4 (679)

24 (610) 36 (914)

36

Equipment Inspection and Handling

5.0

EQUIPMENT INSPECTION AND HANDLING

Upon arrival of the unit and before unpacking it, verify that the labeled equipment matches the bill of lading. Carefully inspect all items for damage, either visible or concealed. For initial access use a 7/32" Allen wrench for panel removal. Damage should be immediately reported to the carrier and a damage claim filed with a copy sent to Emerson Network Power or to your sales representative.

5.1

Packaging Material
All material used to package this unit is recyclable. Please save for future use or dispose of the material appropriately.

SAFETY INFORMATION

! WARNING falling over. Can cause equipment damage, injury or death. Risk of top-heavy unit
Read all of the following instructions before attempting to move the unit, lift it, remove packaging or prepare the unit for installation.

! CAUTION splinters and exposed fasteners. Can cause personal injury. Risk of sharp edges,
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 7.0 - 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/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. Figure 32 Equipment recommended for handling Liebert DS

Forklift

Pallet Jack

Spreader Bars and Slings Piano Jacks

37

Equipment Inspection and Handling

If possible, transport the Liebert DS with a forklift or pallet jacks. If that is not possible, use a crane with belts or cables, slings and spreader bars. If using a forklift or pallet jack, make sure that the forks (if adjustable) are spread to the widest allowable distance that will fit under the skid. Ensure the fork length is suitable for the unit length. 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 forkliftIf 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 36).

5.2

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 protective 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 33 Removing packaging

Step 1

Step 2

Step 3 181659P1 Rev. 5

38

Equipment Inspection and Handling

5.2.1

Removing the Unit from the Skid With a Forklift

1. Align a forklift with either the front or rear side of the unit.

! WARNING Can cause equipment damage, injury or death. Risk of improper moving.
Use the center of gravity indicators on the unit to determine the entry points for the tines (see Figure 36). The center of gravity varies depending on the unit size and selected options. The forklifts 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.

! WARNING Can cause equipment damage, injury or death. Risk of improper moving.
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 skidno more than 6" (152mm)and remove the skid. Figure 34 Remove the unit from the skid
Step 1 Step 2

Step 3 Step 4

181659P1 Rev. 5

39

Equipment Inspection and Handling

5.2.2

Moving the Unit to the Installation Location with Piano Jacks

1. With the Liebert DS elevated, place two piano jacks into positionone at either end of the unit. 2. Lower the unit to a height suitable for the piano jacks and place protective material between the Liebert DS and the piano jacks. 3. Secure the unit to the piano jacks and remove the forklift. 4. Use the piano jacks to move the unit for installation.

Figure 35 Moving the unit to its installation location

Step 1

Step 2

Step 3

181659P1 Rev. 5

5.2.3

Removing Piano Jacks

1. Lower the unit as much as the piano jacks will allow. 2. Undo all strapping holding the piano jacks to the unit. 3. 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. 4. Repeat Step 3 to remove the piano jack on the opposite end. 5. Remove all material that might have been used to protect the unit from the piano jacks and strapping.

40

Equipment Inspection and Handling

5.2.4

Removing Liebert DS from Skid Using Rigging

! WARNING Can cause equipment damage, injury or death. Risk of improper moving.
Use the center of gravity indicators (see Figure 36) on the unit to determine the position of the slings. The center of gravity varies depending on the unit size and selected options. The forklifts 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 36). Figure 36 Locate center of gravity marker and place slings

Lifting Sling

Lifting Sling

Illustration shows one possible center of gravity. The center of gravity on the Liebert DS varies with the options and the models size.

Equal Distance

Equal Distance

181659P1 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.

41

Equipment Inspection and Handling

Figure 37 Using rigging to lift Liebert DS off skid

Lifting Sling

Lifting Sling

Equal Distance

Equal Distance

181659P1 Rev. 5

42

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 StandEnsure 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 38. Be sure to align the welded tabs on top of the floor stand with the inside of the unit frame base.

Figure 38 Setting the unit on a floor stand

Welded Tab

DETAIL A

Liebert Floor Stand (front discharge shown)

NOTE The floor stand for Liebert DS units equipped with EC fans is not symmetrical. Its orientation to the Liebert DS unit is critical for lowering the EC fans. Unless the floor stand is installed in the correct position, shown in Figures 24 and 26, the fans will not lower into the floor stand.

43

EC FansLowering and Removing

6.0

EC FANSLOWERING AND REMOVING

Liebert DS downflow models DS053, DS070, DS077 and DS105 can be equipped with EC fans that can be operated either in their fully raised position or lowered into the floor stand for increased efficiency from reduced air resistance. The fans are also removable, easing maintenance and replacement.

! WARNING and high speed rotating fan blades. Can cause injury or death. Risk of electric shock
Disconnect all local and remote electric power supplies and verify that fan blades have stopped rotating before working within.

! WARNING modules dropping downward suddenly. Can cause injury or death. Risk of very heavy fan
Support fan modules before removing mounting hardware. Use caution to keep body parts out of the fan modules pathway during repositioning. Only properly trained and qualified personnel should work on this equipment. Fan modules weigh in excess of 100 lbs (45.4kg) each. NOTE The Liebert DS unit should be used with the fans either in their original raised position or with the fans in their fully lowered position. Suspension of fans in an intermediate position will directly affect product performance and is not recommended.

6.1

Lowering the EC Fans into the Floor Stand

Tools Needed
1. 2. 1/2" hex socket & wrench Factory-supplied jack, crank and jack support cable tie cutter Remove the middle and bottom panels from the front of the unit. For ease of fan lowering, Emerson recommends removing the infrared humidifier using the approved infrared humidifier removal procedure. 3. Position the factory-supplied jack and jack support under the fan to be lowered. 4. Raise the jack to safely support the fan before removing any hardware. NOTE A properly positioned jack will be centered between the first and second set of tabs on the jack support. The jack will be biased towards the front of the unit. 5. Cut and remove the cable tie that retains the wiring loop to the blower mounting plate. All other cable ties that route the fan wiring should remain intact. 6. Remove the six 1/2" hex head screws. Retain the hardware for later use.

44

EC FansLowering and Removing

Figure 39 Lowering EC fans into floor stand, Steps 1 through 6

Remove Middle Panel from Front of Unit

Jack Location

Remove Infrared Humidifier Remove Bottom Panel from Front of Unit

Tabs

Detail A

Raise Jack to Support Fan

Section Not Shown

Fan Deck Z Bracket (not present on Liebert DS) Remove Hex Head Screws Remove Hex Head Screws Z Bracket (not present on Liebert DS) Wiring Loop Raise Jack to Support Section Fan Not Shown

Z Bracket (not present on Liebert DS units)

Cut and Remove Cable Tie Securing Wiring Loop

DPN002037 Page 1, Rev. 4

Section B-B

Top View of Fan Deck

45

EC FansLowering and Removing

7. Using the jack, lower the fan module slowly until it rests on the frame of the unit.

NOTICE
Risk of equipment snagging cables and wiring. Can damage the Liebert DS components. Monitor the position of the fan harnesses and other parts while lowering the fan to be sure that they are not caught or pinched. 8. Secure the fan module in the fully lowered position by re-installing the hex head screws directly to the frame. Screw clearance holes are provided in the fan module. NOTE Not all hardware retained will be used to secure the fans in the lowered positioned. 9. Repeat Steps 3 through 8 to lower remaining fan modules. Figure 40 Lowering EC fans into floor stand, Steps 7 through 9

C
Lowered Fan Module Resting on Frame
6

Lower Fan Module Onto Frame

Use Removed Hex Head Screws to Secure Lowered Fan to Frame

Use Removed Hex Head Screws to Secure Lowered Fan to Frame Z Brackets (not present on Liebert DS)

SECTION C-C
Fan Deck and Side Panels Not Shown
46

DPN002037 Page 2, Rev. 4

EC FansLowering and Removing

6.2

Removing the EC Fans

The EC fans in Liebert DS units can be removed for easier maintenance or for replacement.

! WARNING and high speed rotating fan blades. Can cause injury or death. Risk of electric shock
Disconnect all local and remote electric power supplies and verify that fan blades have stopped rotating before working within.

! WARNING modules dropping downward suddenly. Can cause injury or death. Risk of very heavy fan
Support fan modules before removing mounting hardware. Use caution to keep body parts out of the fan modules pathway during repositioning. Only properly trained and qualified personnel should work on this equipment. Fan modules weigh in excess of 100 lbs (45.4kg) each. NOTE The Liebert DS unit should be used with the fans either in their original raised position or with the fans in their fully lowered position. Suspension of fans in an intermediate position will directly affect product performance and is not recommended. 1. Remove the middle and bottom panels from the front of the unit. 2. For ease of fan removal, Emerson recommends removing the infrared humidifier using the approved infrared humidifier removal procedure. 3. If the fan to be removed has been lowered into the floor stand, position the factory supplied jack and jack support under the fan module so it is safely supported before removing any hardware. NOTE A properly positioned jack will be centered between the first and second set of tabs on the jack support. The jack will be biased toward the front of the unit. If the fan module is fully raised, proceed to Step 6. 4. Remove any securing hardware used to retain the fan in the lowered position. Retain hardware for fan module reinstallation. 5. Use the jack to raise the fan module slowly out of the floor stand and into the unit, ensuring that the fan motor clears the front frame channel.

NOTICE
Risk of equipment snagging cables and wiring. Can cause unit damage. Monitor the position of the fan harnesses and other parts while raising the fan to be sure that they are not caught or pinched while the fan is being raised.

47

EC FansLowering and Removing

Figure 41 Removing the EC fans, Steps 1 through 5

Remove Middle Panel from Front of Unit

Remove Infrared Humidifier Remove Bottom Panel from Front of Unit

B
Raise Jack to Support Fan Position Jack to Support Fan Position Jack to Support Fan

A
Floor Stand Partially Hidden

Tabs

Detail A
Jack Location

Remove and retain any hardware used to secure the lowered fan

SECTION B-B
Remove and retain any hardware used to secure the lowered fan DPN001695 Page 1, Rev. 5

6. Insert a field-supplied fan removal device under the fan module. The fan removal device should rest securely on the front and rear frame channels. 7. Disconnect high-voltage and low-voltage fan motor wiring from the fan motor electric component inside the electric panel. Carefully cut cable ties as needed. 8. Using the removal device, slide the fan module out through the front of the unit. 9. To reinstall the fan module, reverse the steps above. Remove the field-supplied fan removal device before resuming unit operation. NOTE Refer to the units electrical schematic for specific wire attachment points.

48

EC FansLowering and Removing

Figure 42 Removing the EC fans, Steps 6 through 9

Raise Fan Module With Jack Disconnect Hign- and Low-Voltage Wiring

Front Frame Channel

Field-Supplied Fan-Removal Devices

Front Frame Channel

Rear Frame Channel

Right Side Panel Not Shown

DPN001695 Page 2, Rev. 5

Field-Supplied Fan-Removal Devices, End View

Slide the Fan Out the Front of the Unit

DPN001695 Page 3, Rev. 5

Right Side Panel Not Shown

49

Disassembling the Liebert DS for Transport

7.0

DISASSEMBLING THE LIEBERT DS FOR TRANSPORT

The Liebert DS has a modular frame construction that allows separating the unit into three sections. Each of these sections is more easily maneuvered through tight spaces or placed in small elevators. A qualified service technician with the required tools and recommended assistance can disassemble an air-cooled unit in about four hours, assuming refrigerant evacuation is not required. This procedure requires four or more people for lifting the filter and electric box assembly on downflow units and for lifting the blower and electric box assembly on upflow units.

! WARNING from high-pressure refrigerant. Can cause injury or death. Risk of explosive discharge
This unit contains fluids and/or gases under high pressure. Relieve pressure before working with piping, compressors or other internal components.

! WARNING falling over. Improper handling can cause equipment damage, injury, Risk of top heavy unit
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 equipment.

! CAUTIONand heavy parts. Can cause personal injury. Risk of sharp edges
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.

! CAUTION and lengthy parts. Can cause personal injury and equipment damage. Risk of handling heavy
Cabinet panels can exceed 5ft. (1.5m) in length and weigh more than 35lb. (15.9kg). Follow relevant OSHA lifting recommendations and consider using a two-person lift for safe and comfortable removal and installation of cabinet panels. Only properly trained and qualified personnel wearing appropriate safety headgear, gloves and shoes should attempt to remove or install cabinet panels.

NOTICE
Risk of improper disassembly. Can cause equipment damage. 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.

7.1

Required Equipment
Piano jacks Stepladder for downflow units Refrigeration tools

50

Disassembling the Liebert DS for Transport

7.2

DisassemblyDownflow Units
For detailed views of downflow units, see Figures 43 through 51. 1. Remove the unit from its shipping skid before beginning (refer to 5.2 - Unpacking the Unit). 2. Remove all panels except the top front accent. 3. Remove all filters. This allows access to the screws for metal plate blocking off the top coil and removal of the filter plate. 4. All wires are hot-stamped and all circuit board connectors are lettered to ease connection. Some cable ties must be cut and replaced. Refer to the units wiring schematic on the units deadfront panel for details.

NOTICE
5. 6. 7. 8. 9. 10. 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. ReheatOptional 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 units blower and coil assembly section. HumidifierOptional Component a. Disconnect the humidifier wire harness from the bottom of the contactor in the electric box. b. For infrared humidifiers: Remove the quick-connect plugs from the following low-voltage connections: 35-5 and 35-6 (safety under pan), 35-3 and 35-4 (humidifier make-up valve), and 8-5 and 8-7 (high water alarm). For steam generating humidifiers: Remove the quick-connect plugs from the following low-voltage connections: 35-1, H-24H and H-24G, and 35-7 and HAR-24H. c. Disconnect 35-3 and 35-4 from the control board. d. Pull the conduit and wires into the units blower and coil assembly section. Condensate PumpOptional Component a. Disconnect the condensate pumps high-voltage wiring harness. b. Remove the low-volt wires from terminal strips #24 and #55. c. Pull the conduit and wires into the units blower and coil assembly section. GLYCOOL/Dual-CoolOptional 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 units blower and coil assembly section. Disconnect the air sail switch wires and pull them into the electric box. Smoke DetectorOptional 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.

11.

12.

13.

14. 15.

16. 17.

51

Disassembling the Liebert DS for Transport

18. Evacuate and recover all refrigerant from the Liebert DS. Air-cooled units are shipped with a nitrogen holding charge. Water, glycol and GLYCOOL units are factory-charged with refrigerant. Refer to 9.0 - Piping for piping guidelines and to the ASHRAE Refrigeration Handbook for general, good-practice refrigeration piping.

NOTICE
Risk of compressor oil contamination with moisture. Can cause equipment damage. Emerson recommends front-seating the compressor service valves. 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. 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.

7.2.1

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 the 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.

52

Disassembling the Liebert DS for Transport

7.2.2

Remove the Filter and Electric Box Assembly

1. Using a stepladder to reach the top of the Liebert DS, remove the filter support plate; it is attached to the filter and electric box assembly with two screws, one on each end. 2. Remove tags from the Schrader fittings on top of the coil headers. Retain the tags for replacement during reassembly. 3. Remove 16 screws, (8) on each side, from the evaporator top cover plate to coil assembly. 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 must 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.

7.3

ReassemblyDownflow Units
1. Replace the top section. Make sure to clear the Schrader valves on the coil header. 2. Reconnect the filter and electric box assembly to the blower and coil assembly using threadcutting bolts. Torque the bolts to 225 in-lb. (25Nm) 3. Reattach the evaporator top cover plate; there are eight screws on each side. 4. Reattach the filter support plate to the filter and electric box assembly; there is one screw on each side. 5. Reattach the tags to the Schrader fittings on top of the coil headers. 6. Replace the compressor section. Insert all compressor thread-cutting bolts before tightening any of the bolts. 7. Reinstall the pull bar to support the accent panel. 8. Reattach the low-voltage plugs in the compressor section. 9. Reconnect the wiring for the compressor, fan motor, reheat, humidifier, condensate pump, smoke detector and air sail switch. 10. Reattach the sensing tube to the top of the smoke detector. 11. 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.

53

Disassembling the Liebert DS for Transport

7.3.1

Reconnecting Piping, Charging and Replacing Panels

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Piping must be reassembled in accordance with local codes. Move insulation and plastic bushings away from the brazing area. Wrap piping with wet cloths. Use copper fittings where required. Refer to 9.0 - Piping for piping guidelines and to the ASHRAE Refrigeration Handbook for general, good-practice refrigeration piping. Open the service valves on the compressor. Reinsert the plastic bushings. Charge the Liebert DS with refrigerant; see the units nameplate for the proper charge. Reinstall the galvanized panels on the left side of the coil. Replace the filters. Replace the panels.

7.4

Reassembly Checklist
___ 1. Thread-cutting bolts reconnected and torqued to 225 in-lb. (25Nm) ___ 2. Top cover plate attached to coil ___ 3. Filter plate attached ___ 4. High-voltage wires connected to proper contactors: ___ a. Compressor ___ b. Fan motor ___ c. ___ e. Reheat, if applicable Condensate pump, if applicable ___ d. Humidifier, if applicable ___ 5. Low-voltage wires connected ___ a. Actuator ___ b. Terminal strip ___ c. Plug connections ___ d. Smoke detector, if applicable ___ 6. Coil access plates on right and left replaced ___ 7. Water lines brazed ___ 8. Suction and liquid refrigerant lines brazed ___ 9. Unit recharged ___ 10. Filters replaced ___ 11. Panels replaced

54

Disassembling the Liebert DS for Transport

Figure 43 Component dimensionsdownflow, air-cooled, 28-42kW (8-12 ton), semi-hermetic compressor models

Drawing views are simplified with panels removed to show overall dimensions. See disassembly and handling instructions in installation manual. Filter & Electric Box Assembly

39" (991mm)

Compressor Assembly

Blower & Coil Assembly

76" (1930mm) Assembled Height

76" (1930mm)

60-3/16" (1529mm)

37" (940mm)

33" (838mm)

26" (660mm)

59" (1499mm) 85" (2159mm) Assembled Length DPN000801 Rev. 1

Table 29

Component weightsdownflow, air-cooled, 28-42kW (8-12 ton), semi-hermetic

Dry Weight, Approximate, Including Panels, lb (kg) Air-Cooled 800 (364) 210 (96) 770 (350) Dual-Cool 800 (364) 210 (96) 920 (418)

Component Compressor Assembly Filter & Electric Box Assembly Blower & Coil Assembly

55

Disassembling the Liebert DS for Transport

Figure 44 Component dimensionsdownflow, air-cooled, 28-42kW (8-12 ton), scroll/digital scroll compressor models

Drawing views are simplified with panels removed to show overall dimensions. See disassembly and handling instructions in installation manual. Filter & Electric Box Assembly

39" (991mm)

Compressor Assembly

Blower & Coil Assembly

76" (1930mm) Assembled Height

76" (1930mm)

60-3/16" (1529mm)

37" (940mm)

33" (838mm)

13" (330mm)

59" (1499mm) 72" (1829mm) Assembled Length DPN000802 Rev. 1

Table 30

Component weightsdownflow, air-cooled, 28-42kW (8-12 ton), scroll/digital scroll

Dry Weight, Approximate, lb. (kg) Air-Cooled 490 (223) 210 (96) 770 (350) Dual-Cool 490 (223) 210 (96) 920 (418)

Component Compressor Assembly Filter & Electric Box Assembly Blower & Coil Assembly

56

Disassembling the Liebert DS for Transport

Figure 45 Component dimensionsdownflow, water/glycol/GLYCOOL, 28-42kW (8-12 ton), all compressor models

Drawing views are simplified with panels removed to show overall dimensions. See disassembly and handling instructions in installation manual. Filter & Electric Box Assembly

39" (991mm)

Compressor Assembly

Blower & Coil Assembly

76" (1930mm) Assembled Height

76" (1930mm)

60-3/16" (1529mm)

37" (940mm)

33" (838mm)
Table 31

26" (660mm)

59" (1499mm) 85" (2159mm) Assembled Length

DPN000899 Rev. 1

Component weightsdownflow, water/glycol/GLYCOOL, 28-42kW (8-12 ton), all

Dry Weight, Approximate, Including Panels, lb (kg) Semi-Hermetic Compressor Scroll or Digital Scroll Compressor Water/Glycol 800 (364) 210 (96) 770 (350) GLYCOOL/Dual-Cool 800 (364) 210 (96) 920 (418)

Component Compressor Assembly Filter & Electric Box Assembly Blower & Coil Assembly

Water/Glycol 950 (432) 210 (96) 770 (350)

GLYCOOL/Dual-Cool 950 (432) 210 (96) 920 (418)

57

Disassembling the Liebert DS for Transport

Figure 46 Component dimensionsdownflow, air-cooled, 53-77kW (15-22 ton), semi-hermetic compressor models; forward-curved and EC fan

Drawing views are simplified with panels removed to show overall dimensions. See disassembly and handling instructions in installation manual. Filter & Electric Box Assembly

39" (991mm)

Compressor Assembly Blower & Coil Assembly

76" (1930mm) Assembled Height

76" (1930mm)

59-7/16" (1509mm)

37" (940mm)

33" (838mm)

26" (660mm)

82" (2083mm) 108" (2743mm) Assembled Length

DPN000926 Rev. 3

Table 32

Component weightsdownflow, air-cooled, 53-77kW (15-22 ton), semi-hermetic; forward-curved and EC fan
Dry Weight, Approximate, Including Panels, lb (kg) Air-Cooled 970 (441) 250 (114) 1230 (560) Dual-Cool 970 (441) 250 (114) 1410 (641)

Component Compressor Assembly Filter & Electric Box Assembly Blower & Coil Assembly

58

Disassembling the Liebert DS for Transport

Figure 47 Component dimensionsdownflow air-cooled, 53-77kW (15-22 ton), scroll/digital scroll compressor models; forward-curved and EC fan

Drawing views are simplified with panels removed to show overall dimensions. See disassembly and handling instructions in installation manual.

Filter & Electric Box Assembly

39" (991mm)

Compressor Assembly Blower & Coil Assembly

76" (1930mm) Assembled Height

76" (1930mm)
59-7/16" (1509mm) 37" (940mm)

33" (838mm)
Table 33

15" (381mm)

82" (2083mm) 97" (2464mm) Assembled Length

DPN000927 Rev. 3

Component weightsdownflow, air-cooled, 53-77kW (15-22 ton), scroll/digital scroll; forward-curved and EC fan
Dry Weight, Approximate, Including Panels, lb (kg) Air-Cooled 540 (246) 250 (114) 1230 (560) Dual-Cool 540 (246) 250 (114) 1410 (641)

Component Compressor Assembly Filter & Electric Box Assembly Blower & Coil Assembly

59

Disassembling the Liebert DS for Transport

Figure 48 Component dimensionsdownflow water/glycol, GLYCOOL, 53-77kW (15-22 ton), all compressor models; forward-curved and EC fan

Drawing views are simplified with panels removed to show overall dimensions. See disassembly and handling instructions in installation manual.
Filter & Electric Box Assembly

39" (991mm)

Compressor Assembly

Blower & Coil Assembly

76" (1930mm) Assembled Height

76" (1930mm)

59-7/16" (1509mm) 37" (940mm)

33" (838mm)

26" (660mm)

82" (2083mm) 108" (2743mm) Assembled Length

DPN000932 Rev. 2

Table 34

Component weightsdownflow water/glycol, GLYCOOL, 53-77kW (15-22 ton), all

Semi-Hermetic Compressor Scroll Compressor Water/Glycol lb (kg) 840 (382) 250 (114) 1230 (560) GLYCOOL Dual-Cool lb (kg) 840 (382) 250 (114) 1410 (641) Water/Glycol lb (kg) 1270 (578) 250 (114) 1230 (560) GLYCOOL Dual-Cool lb (kg) 1270 (578) 250 (114) 1410 (641)

Liebert DS Section Compressor Assembly Filter and Electric Box Assembly Blower & Coil Assembly

60

Disassembling the Liebert DS for Transport

Figure 49 Component dimensionsdownflow, air-cooled, 105kW (30 ton), semi-hermetic compressor models; forward-curved and EC fan

Drawing views are simplified with panels removed to show overall dimensions. See disassembly and handling instructions in installation manual.
Filter and Electric Box Assembly

39" (991mm) 41-11/16" (1059mm)

Compressor Assembly Blower and Coil Assembly

76" (1930mm) Assembled Height

76" (1930mm)

59-7/16" (1510mm) 37" (940mm)

33" (838mm)

26" (660mm)

105" (2667mm) 131" (3327mm) Assembled Length DPN001057 Rev. 1

Table 35

Component weightsdownflow, air-cooled, 105kW (30 ton), semi-hermetic compressors; forward-curved and EC fan
Dry Weight, lb (kg) Approximate (Includes Panels) Forward Curved Fans Component Air-Cooled 950 (432) 270 (123) 1820 (827) Dual Cool 950 (432) 270 (123) 2180 (991) EC Fans Air-Cooled 950 (432) 270 (123) 1560 (708) Dual Cool 950 (432) 270 (123) 1915 (870)

Compressor Assembly Filter & Electric Box Assembly Blower & Coil Assembly

61

Disassembling the Liebert DS for Transport

Figure 50 Component dimensionsdownflow, air-cooled, 105kW (30 ton), scroll compressor models; forward-curved and EC fan

Drawing views are simplified with panels removed to show overall dimensions. See disassembly and handling instructions in installation manual.
Filter & Electric Box Assembly

39" (991mm) 41-11/16" (1059mm)

Compressor Assembly Blower and Coil Assembly

76" 1930mm Assembled Height

76" (1930mm)

59-7/16" (1510mm) 37" (940mm)

33" (838mm)

26" (660mm)

105" (2667mm) 131" (3327mm) Assembled Length

DPN001058 Rev. 1

Table 36

Component weightsdownflow, air-cooled, 105kW (30 ton), scroll compressor models; forward-curved and EC fan
Dry Weight, lb (kg) Approximate (Includes Panels) Forward Curved Fans EC Fans Air-Cooled 830 (377) 270 (123) 1560 (708) Dual Cool 830 (377) 270 (123) 1915 (870)

Component Compressor Assembly Filter & Electric Box Assembly Blower & Coil Assembly

Air-Cooled 830 (377) 270 (123) 1820 (827)

Dual Cool 830 (377) 270 (123) 2180 (991)

62

Disassembling the Liebert DS for Transport

Figure 51 Component dimensionsdownflow, water/glycol/GLYCOOL, 105kW (30 ton), forward-curved and EC fan, all compressor models; forward-curved and EC fan

Drawing views are simplified with panels removed to show overall dimensions. See disassembly and handling instructions in installation manual.
Filter & Electric Box Assembly

39" (991mm) 41-11/16" (1059mm)

Compressor Assembly Blower and Coil Assembly

76" (1930mm) Assembled Height

76" (1930mm)

59-7/16" (1510mm) 37" (940mm)

33" (838mm)

26" (660mm)

105" (2667mm) 131" (3327mm) Assembled Length DPN001060 Rev. 1

Table 37

Component weightsdownflow, water/glycol/GLYCOOL, 105kW (30 ton), all compressor models; forward-curved and EC fan
Dry Weight, Approximate, Including Panels, lb (kg) Semi-Hermetic Compressor Scroll Compressor Water/Glycol 1200 (545) 270 (123) 1820 (827) / 1560 (708) GLYCOOL/Dual-Cool 1200 (545) 270 (123) 2180 (991) /

Component Compressor Assembly Filter & Electric Box Assembly Blower & Coil Assembly, Forward-Curve Fan / EC Fan)

Water/Glycol 1320 (600) 270 (123) 1820 (827) / 1560 (708)

GLYCOOL/Dual-Cool 1320 (600) 270 (123) 2180 (991) /

1915 (870)

1915 (870)

63

Disassembling the Liebert DS for Transport

7.5

DisassemblyUpflow Units
For detailed views of upflow units, see Figures 52 through 60. 1. Remove the unit from its skid. 2. Remove all panels except top front accent. 3. Remove all filters on front return units. This allows easier access to items located in the filter and coil assembly. 4. All wires are hot stamped and all circuit board connectors are lettered for easy replacement. Cable ties will need to be cut and replaced as necessary. Reference unit wiring schematic on deadfront panel for details. 5. Label the (3) quick connect plugs from the compressor compartment, and disconnect them. 6. Disconnect compressor wire harness, including crankcase heater wires, if applicable, from contactor in electric box. Pull conduit and wires into compressor compartment. 7. 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. 8. Humidifier (optional component): a. Disconnect the humidifier wire harness from the bottom of the contactor in the electric box. For infrared humidifiers: Remove the quick-connect plugs from these low-voltage connections: 35-5 and 35-6 (safety under pan), 35-3 and 35-4 (humidifier make-up valve) and 8-5 and 8-7 (high water alarm). For steam generating humidifiers: Remove the quick-connect plugs from the following low-voltage connections: 35-1, H-24H and H-24G, and 35-7 and HAR-24H. b. Disconnect 35-3 and 35-4 from the control board. c. Pull the conduit and wires into the units filter and coil assembly section. 9. Condensate pump (optional component): Disconnect condensate pump high-voltage wire harness. Remove low volt wires from terminal strip #24 and #55. Pull conduit and wires into filter and coil assembly section of unit. 10. 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. 11. 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. 12. Filter Clog Switch: Disconnect both tubes from the filter clog switch. Pull both of the tubes into the electric box. 13. Close the electric box cover and the accent panel. 14. 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. 15. 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 9.0 - Piping for piping guidelines and to the ASHRAE Refrigeration Handbook for general, good-practice refrigeration piping.

NOTICE
Risk of compressor oil contamination with moisture. Can cause equipment damage. Emerson recommends front-seating the compressor service valves. 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. 16. Cut and pull back insulation from piping.

64

Disassembling the Liebert DS for Transport

17. Cut the refrigerant piping with a tubing cutter; if there is no Schrader fitting, let the nitrogen bleed out before cutting all the way through the pipe. NOTE Emerson does not recommend unsweating refrigerant connections. 18. Unsweat or cut all copper water pipes that interconnect unit sections. 19. 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.

7.5.1

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. Begin removing bolts at the bottom of the Liebert DS 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 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 reassembled and ready for installation. NOTE Emerson recommends using piano jacks when moving this section.

7.5.2

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.

65

Disassembling the Liebert DS for Transport

7.6

ReassemblyUpflow Unit
1. Reattach the top section using thread-cutting bolts; there are four on each side. Torque the bolts to 225 in-lb (25Nm). 2. Reinstall the motor access plate. Do not replace the left end coil access plates until brazing is finished. 3. Reattach the compressor section. Insert all compressor thread-cutting bolts before tightening them all down. 4. Reinstall the pull bar to support the accent panel. 5. Reinstall the low-voltage plugs in the compressor section. 6. Rewire the compressor, reheat, humidifier, condensate pump and smoke detector, if applicable. 7. Reattach the sensing tube to the blower inlet. 8. 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. 9. Piping must be reassembled in accordance with local codes. 10. Move the insulation and plastic bushings away from the brazing area. 11. Wrap the piping with wet cloths. Use copper fittings where required. 12. Refer to 9.0 - Piping for piping guidelines and to the ASHRAE Refrigeration Handbook for general, good-practice refrigeration piping. 13. Open service valves on compressor. 14. Reinsert plastic bushings. 15. Charge the Liebert DS with refrigerant; see the units nameplate for the proper charge. 16. Replace the galvanized panels on the left side of the coil. 17. Replace the filters. 18. Replace the panels.

7.7

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 connected: ___ a. actuator ___ b. terminal strip ___ c. 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 ___ 9. Filters replaced ___ 10. Panels replaced

66

Disassembling the Liebert DS for Transport

Figure 52 Component dimensionsupflow, air-cooled, 28-42kW (8-12 ton), semi-hermetic compressor models

Drawing views are simplified with panels removed to show overall dimensions. See disassembly and handling instructions in installation manual.

Blower & Electric Box Assembly

31-1/4" (794mm)

Compressor Assembly 76" (1930mm) Assembled Height

Filter & Coil Assembly 76" (1930mm)

45-13/16" (1163mm)

33" (838mm)

26" (660mm)

59" (1499mm) 85" Assembled Length (2159mm)

DPN001171 Rev. 0

Table 38

Component weightsupflow, air-cooled, 28-42kW (8-12 ton), semi-hermetic compressor models

Dry Weight, Approximate, Including Panels, lb (kg) Air-Cooled 800 (364) 510 (231) 520 (236) Dual-Cool 800 (364) 510 (231) 670 (304)

Component Compressor Assembly Blower & Electric Box Assembly Filter & Coil Assembly

67

Disassembling the Liebert DS for Transport

Figure 53 Component dimensionsupflow, air-cooled, 28-42kW (8-12 ton), scroll/digital scroll compressor models

Drawing views are simplified with panels removed to show overall dimensions. See disassembly and handling instructions in installation manual. Blower & Electric Box Assembly

31-1/4" (794mm)

Compressor Assembly 76" (1930mm) Assembled Height

Filter & Coil Assembly

76" (1930mm) 45-13/16" (1163mm)

33" (838mm)

13" (330mm)

59" (1499mm) 72" (1829mm) Assembled Length

DPN001172 Rev. 0

Table 39

Component weightsupflow, air-cooled, 28-42kW (8-12 ton), scroll/digital scroll compressor models
Dry Weight, Approximate, Including Panels, lb (kg) Air-Cooled 490 (223) 510 (231) 520 (236) Dual-Cool 490 (223) 510 (231) 670 (304)

Component Compressor Assembly Blower & Electric Box Assembly Filter & Coil Assembly

68

Disassembling the Liebert DS for Transport

Figure 54 Component dimensionsupflow, water/glycol/GLYCOOL, 28-42kW (8-12 ton), all compressor models

Drawing views are simplified with panels removed to show overall dimensions. See disassembly and handling instructions in installation manual.

Blower & Electric Box Assembly

31-1/4" (794mm)

Compressor Assembly

Filter & Coil Assembly 76" (1930mm)

76" (1930mm) Assembled Height

45-13/16" (1163mm)

33" (838mm)

26" (660mm)

59" (1499mm) 85" (2159mm) Assembled Length

DPN001173 Rev. 0

Table 40

Component weightsupflow, water/glycol/GLYCOOL, 28-42kW (8-12 ton), all compressor models

Dry Weight, Approximate, Including Panels, lb (kg) Semi-Hermetic Compressor Scroll Compressor Water/Glycol 800 (364) 510 (231) 520 (236) GLYCOOL/Dual-Cool 800 (364) 510 (231) 670 (304)

Component Compressor Assembly Blower & Electric Box Assembly Filter & Coil Assembly

Water/Glycol 950 (432) 510 (231) 520 (236)

GLYCOOL/Dual-Cool 950 (432) 510 (231) 670 (304)

69

Disassembling the Liebert DS for Transport

Figure 55 Component dimensionsupflow, air-cooled, 53-77kw (15-22 ton), semi-hermetic compressor models

Drawing views are simplified with panels removed to show overall dimensions. See disassembly and handling instructions in installation manual.

Blower & Electric Box Assembly

31-1/4" (794mm)

Compressor Assembly 76" (1930mm) Assembled Height

Filter & Coil Assembly

76" (1930mm) 45-13/16" (1163mm)

33" (838mm)

26" (660mm)

82" (2083mm) 108" (2743mm) Assembled Length

DPN001209 Rev. 0

Table 41

Component weightsupflow air-cooled 53-77kw (15-22 ton), semi-hermetic compressor models

Dry Weight, Approximate, Including Panels, lb (kg) Air-Cooled 970 (441) 770 (349) 760 (345) Dual-Cool 970 (441) 770 (349) 940 (426)

Component Compressor Assembly Blower & Electric Box Assembly Filter & Coil Assembly

70

Disassembling the Liebert DS for Transport

Figure 56 Component dimensionsupflow, air-cooled, 53-77kw (15-22 ton), scroll/digital scroll compressor models

Drawing views are simplified with panels removed to show overall dimensions. See disassembly and handling instructions in installation manual.

Blower & Electric Box Assembly

31-1/4" (794mm)

Compressor Assembly 76" (1930mm) Assembled Height

Filter & Coil Assembly 76" (1930mm)

45-13/16" (1163mm)

33" (838mm)

15" (381mm)

82" (2083mm) 97" (2464mm) Assembled Length

DPN001210 Rev. 0

Table 42

Component weightsupflow, air-cooled, 53-77kw (15-22 ton), scroll /digital scroll compressor models
Dry Weight, Approximate, Including Panels, lb (kg) Air-Cooled 540 (246) 770 (349) 760 (345) Dual-Cool 540 (246) 770 (349) 940 (426)

Component Compressor Assembly Blower & Electric Box Assembly Filter & Coil Assembly

71

Disassembling the Liebert DS for Transport

Figure 57 Component dimensionsupflow water/glycol/GLYCOOL 53-77kw (15-22 ton), all compressor models

Drawing views are simplified with panels removed to show overall dimensions. See disassembly and handling instructions in installation manual. Blower & Electric Box Assembly

31-1/4" (794mm)

Compressor Assembly 76" (1930mm) Assembled Height

Filter & Coil Assembly 76" (1930mm)

45-13/16" (1163mm)

33" (838mm)

26" (660mm)

82" (2083mm) 108" (2743mm) Assembled Length

DPN001211 Rev. 0

Table 43

Component weightsupflow water/glycol/GLYCOOL, 53-77kW (15-22 ton) all compressor models

Dry Weight, Approximate, Including Panels, lb (kg) Semi-Hermetic Compressor Scroll or Digital Scroll Compressor Water/Glycol 840 (382) 770 (349) 760 (345) GLYCOOL/Dual-Cool 840 (382) 770 (349) 940 (426)

Component Compressor Assembly Blower & Electric Box Assembly Filter & Coil Assembly

Water/Glycol 1270 (578) 770 (349) 760 (345)

GLYCOOL/Dual-Cool 1270 (578) 770 (349) 940 (426)

72

Disassembling the Liebert DS for Transport

Figure 58 Component dimensionsupflow, air-cooled, 105kW (30 ton), semi-hermetic compressor models

Drawing views are simplified with panels removed to show overall dimensions. See disassembly and handling instructions in installation manual. Blower & Electric Box Assembly

31-1/4" (794mm)

Compressor Assembly

Filter & Coil Assembly

76" (1930mm) Assembled Height

76" (1930mm) 45-13/16" (1164mm)

33" (838mm)

26" (660mm)

105" (2667mm) 131" (3327mm Assembled Length

DPN001254 REV 0

Table 44

Component weightsupflow, air-cooled, 105kW (30 ton), semi-hermetic compressor models

Dry Weight, Approximate, Including Panels, lb (kg) Air-Cooled 950 (431) 1080 (490) 970 (440) Dual-Cool 950 (431) 1080 (490) 1300 (590)

Component Compressor Assembly Blower & Electric Box Assembly Filter & Coil Assembly

73

Disassembling the Liebert DS for Transport

Figure 59 Component dimensionsupflow, air-cooled, 105kW (30 ton), scroll/digital scroll compressor models

Drawing views are simplified with panels removed to show overall dimensions. See disassembly and handling instructions in installation manual. Blower & Electric Box Assembly

31-1/4" (794mm)

Compressor Assembly

Filter & Coil Assembly 76" (1930mm)

76" (1930mm) Assembled Height

45-13/16" (1164mm)

33" (838mm)

26" (660mm)

105" (2667mm) 131" (3327mm Assembled Length

DPN001255 REV 0

Table 45

Component weightsupflow, air-cooled, 105kW (30 ton), scroll/digital scroll compressor models
Dry Weight, Approximate, Including Panels, lb (kg) Air-Cooled 830 (376) 1080 (490) 970 (440) Dual-Cool 830 (376) 1080 (490) 1300 (590)

Component Compressor Assembly Blower & Electric Box Assembly Filter & Coil Assembly

74

Disassembling the Liebert DS for Transport

Figure 60 Component dimensionsupflow, water/glycol/GLYCOOL, 105kW (30 ton), all compressor models

Drawing views are simplified with panels removed to show overall dimensions. See disassembly and handling instructions in installation manual. Blower & Electric Box Assembly

31-1/4" (794mm)

Compressor Assembly

Filter & Coil Assembly

76" (1930mm) Assembled Height

76" (1930mm) 45-13/16" (1164mm)

33" (838mm)

26" (660mm)

131" (3327mm Assembled Length

105" (2667mm)

DPN001256 REV 0

Table 46

Component weightsupflow, water/glycol/GLYCOOL, 105kW (30 ton), all compressor models

Dry Weight, Approximate, Including Panels, lb (kg) Semi-Hermetic Compressor Scroll or Digital Scroll Compressor Water/Glycol 1200 (544) 1080 (490) 970 (440) GLYCOOL/Dual-Cool 1200 (544) 1080 (490) 1300 (590)

Component Compressor Assembly Blower & Electric Box Assembly Filter & Coil Assembly

Water/Glycol 1320 (599) 1080 (490) 970 (440)

GLYCOOL/Dual-Cool 1320 (599) 1080 (490) 1300 (590)

75

Electrical Connections

8.0

ELECTRICAL CONNECTIONS
Three-phase electrical service is required for all models. Electrical service must conform to national and local electrical codes. Refer to equipment nameplate regarding wire size and circuit protection requirements. Refer to electrical schematic when making connections. Refer to Figure 61 for electrical service entrances into unit. A manual electrical disconnect switch should be installed in accordance with local codes and distribution system. Consult local codes for external disconnect requirements.

! WARNING Can cause injury or death. Risk of electric shock.

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 instructions, 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. NOTE Seal openings around piping and electrical connection to prevent air leakage. Failure to do so could reduce the units cooling performance.

NOTICE
Risk of improper electrical connection of three-phase input power. Can cause unit damage. Service technicians should use a gauge set on the Liebert DS system during the initial startup to verify that the three-phase power is connected properly. The EC fans are not a reliable indicator of proper connection. The blowers will rotate the same direction, regardless of the three-phase power input.

NOTICE
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.

NOTICE
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.

NOTICE
Risk of overheated terminals. Can cause wiring and component damage. Use copper wiring only. Make sure that all connections are tight.

76

Electrical Connections

Figure 61 Electrical field connections for upflow and downflow models

2 13

Liebert IntelliSlot Housing

4

A
5 14

B D

C
OVERCURRENT PROTECTION DEVICES

P64 P67
CONTACTORS

6 60 Hz 12

CONTACTORS & RELAYS AND OVERLOAD PROTECTORS Note: Typical orientation of components shown. Component location varies by option and unit size. 16 17 10 21 15 18 9

6 50 Hz

Downflow 3

DOWNFLOW LOW-VOLTAGE SECTION

UPFLOW
82 83 88 89 75 76 94 95 96 97 91 92 93 80 81 11 12 77 78

A
23 22 20 7

B
8 11 19

CAUTION: Risk of broken or shorted low-voltage wiring. Field-installed low-voltage wiring must be routed with loop as shown to allow electric box to swing.

58 59 84 85

37C38C37B38B 37 38 24 50 51 55 56 70 71 72 73

C
Refer to Table 47 on page 78 for keys to numbered items.

Point of Hinged Low-Voltage Electric Box

UPFLOW LOW-VOLTAGE SECTION DPN000806 Rev. 4

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Electrical Connections

Table 47

Electrical field connection descriptions

OPTIONAL ELECTRICAL CONNECTIONS 12.Factory-installed disconnect switch. 13.Secondary disconnect switch and earth ground. STANDARD ELECTRICAL CONNECTIONS 14.Three-phase electrical service - Terminals are on top of disconnect 1. Primary high voltage entrance - 2.50" switch. Three-phase service not by Emerson. (64mm); 1.75" (44mm); 1.375" (35mm) diameter concentric knockouts in bottom of box. 15.Smoke sensor alarm - Factory-wired dry contacts from smoke sensor are 91-common, 92-NO, and 93-NC. Supervised contacts, 80 2. Secondary high voltage entrance - 2.50" & 81, open on sensor trouble indication. This smoke sensor is not (64mm); 1.75" (44mm); 1.375" (35mm) intended to function as, or replace, any room smoke detection diameter concentric knockouts in top of box. system that may be required by local or national codes. 1A, 24VAC 3. Primary low voltage entrance - Quantity (3) max load. Use field-supplied Class 1 wiring. 1.125" (28mm) diameter knockouts in bottom of 16.Reheat and humidifier lockout - Remote 24VAC required at unit. Terminals 82 & 83 for lockout of reheat and humidifier. 4. Secondary low voltage entrance - Quantity 17.Condensate alarm (with condensate pump option) - On pump (3) 1.125" (28mm) diameter knockouts in top of high water indication, normally open dry contact is closed across box. Terminals 88 & 89 for remote indication. 1A, 24VAC max load. Use 5. Three-phase electrical service - Terminals field-supplied Class 1 wiring. are on high voltage terminal block (disregard if 18.Analog inputs - Terminals for up to two customer-supplied analog unit has optional disconnect switch). inputs. Device 1 wires to 41(-) and 42(+). Device 2 wires to 43(-) and Three-phase service not by Emerson. 44(+). 6. Earth ground - Terminal for field-supplied earth grounding wire. Earth grounding required for all 19.Remote humidifier - On any call for humidification, normally open dry contact is closed across Terminals 11 & 12 to signal field-supplied units. remote humidifier. 1A, 24VAC max load. Use field-supplied Class 1 7. Remote unit shutdown - Replace existing wiring. jumper between Terminals 37 & 38 with field20.Auxiliary cool contact - On any call for Econ-O-Coil operation, supplied normally closed switch having a normally open dry contact is closed across Terminals 72 & 73 on minimum 75VA, 24VAC rating. Use Dual-Cool units only. 1A, 24VAC max load. Use field-supplied field-supplied Class 1 wiring. Class 1 wiring. 8. Customer alarm inputs - Terminals for field-supplied, normally open contacts, having a OPTIONAL LOW VOLTAGE TERMINAL PACKAGE CONNECTIONS 21.Remote unit shutdown - Two additional contact pairs available for minimum 75VA, 24VAC rating, between unit shutdown (labeled as 37B & 38B, 37C & 38C). Replace jumpers Terminals 24 & 50, 51, 55, 56. Use with field-supplied normally closed switch having a minimum 75VA, field-supplied Class 1 wiring. Terminal 24VAC rating. Use field-supplied Class 1 wiring. availability varies by unit options. 9. Liebert SiteScan - Terminals 77(-) & 78(+) for 22.Common alarm - On any alarm, two additional normally open dry contacts are closed across Terminals 94 & 95 and 96 & 97 for remote a 2-wire, twisted-pair, communication cable indication. 1A, 24VAC max load. Use Class 1 field-supplied wiring. (available from Emerson) to optional Liebert 23.Main fan auxiliary switch - On closure of main fan contactor, SiteScan. The communication cable must be normally open dry contact is closed across Terminals 84 & 85 for shielded on units with VFD or EC fans. remote indication. 1A, 24VAC max load. Use field-supplied Class 1 10.Common alarm - On any alarm, normally open wiring. dry contact is closed across Terminals 75 & 76 for remote indication. 1A, 24VAC max load. Use 24.Liebert Liqui-tect shutdown and dry contact - On Liebert Liqui-tect activation, normally open dry contact is closed across field-supplied Class 1 wiring. Terminals 58 & 59 for remote indication (Liebert Liqui-tect sensor 11.Heat rejection interlock - On any call for ordered separately). 1AMP, 24VAC max load. Use field-supplied compressor operation, normally open dry Class 1 wiring. contact is closed across Terminals 70 & 71 to DPN000807 heat rejection equipment. 1A, 24VAC max load. Rev. 2 Use field-supplied Class 1 wiring. Refer to specification sheet for total unit full load amps, wire size amps and maximum overcurrent protective device size.

78

Electrical Connections

8.1

Variable Speed Drive

! WARNING from leakage current. Can cause injury or death. Risk of electric shock
Reconnect earth ground if servicing or replacing the variable speed drive (VSD). An optional Variable Speed Drive (VSD) is available on some Liebert DS models. The VSD reduces power consumption by reducing the blower speed to match the units load. This packaged unit is factory-set and should not require field-adjustment.

! WARNING Risk of contact with nearby high speed moving parts. Can cause injury or death.
Do not attempt to adjust or view variable frequency drive settings at the display on the face of the VSD. Instead, use a remote display (Liebert service item part number 196632P1) and connect to the VSD remote cable in the extra low voltage electric panel.

NOTICE
Risk of improper program adjustment. Can cause equipment damage and loss of warranty. The VSD is factory-programmed for proper operation. Altering the VSD program without authorization from the factory may void the warranty. NOTE Emerson requires the Liebert DS to have a grounded supply. The VSD may be damaged if it is operated on an ungrounded supply.

8.1.1

VSD Power SupplyField-Adjustment May Be Required

The installer/startup technician must determine the type of three-phase supply power (Wye-connected or Delta-connected) being used at the building power distribution panel for the VSD-controlled unit.

NOTICE
Risk of mismatched input power supply and VSD requirements. May cause equipment damage and failure. The EMC filter must be removed from the VSD if the power supply is Delta-connected.

8.1.2

Wye-Connected Power Supply

No control changes are required if the Liebert VSD Control unit will be operated with Wye-connected power.

Figure 62 Wye-connected power diagram

Phase A Phase B

Winding A Winding B

Neutral

Winding C Phase C DPN001944 Rev. 0

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Electrical Connections

8.1.3

Delta-Connected Power Supply

For Delta-connected power, the EMC filter must be removed from the VSD unit during installation. The size of the inverter (C, D, or 2) must be determined by Table 48, based on the units electrical requirements and horsepower. Failure to disconnect or remove EMC filter from VSD with delta connected power may result in failure of VSD and the fan motor to operate.

Figure 63 Delta-connected power diagram

Phase A

Winding C-A

Winding A-B

Phase B Winding B-C Phase C DPN001945 Rev. 0

Table 48
Motor hp 3hp 5hp 7.5hp 10hp

Inverter type
Unit Electrical Requirements, Voltage, Phase, Hz 208-3-60 Size C Size D Size 2 N/A 230-3-60 Size C Size D Size 2 Size 2 380-3-60 Size C Size C Size D Size 2 460-3-60 Size C Size C Size D Size D 575-3-60 N/A N/A N/A N/A 200-3-50 N/A N/A N/A N/A 380/415-3-50 Size C Size C Size D Size 2

Disconnect EMC Filter for Delta-Connected Power for Size C & D Inverters
The EMC filter on the VSD must be disconnected if the Liebert VSD control DS unit will be operated with Delta-connected power. 1. Disconnect the power supply before working on the unit. 2. Locate the VSD (refer to Figure 1 for the drives location on downflow units; see Figure 2 for the location on upflow units). 3. Remove electrical junction box cover. 4. Using Figure 64, locate the small black plastic tab immediately to the right of the wiring connection block of the VFD control. 5. Pull the tab to fully extend it, disconnecting the EMC filter from the circuit. 6. Reinstall the electrical junction box cover.

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Electrical Connections

Figure 64 Disconnecting EMC filter for operation with Delta-connected power size C & D inverters

Internal EMC filter

Tab fully inserted: EMC filter fitted

B
Internal EMC filter

Tab fully extended: EMC filter disconnected

DPN001946 Rev. 0

Remove EMC Filter for Delta-Connected Power for Type 2 inverters

The EMC filter on the VSD must be disconnected if the Liebert VSD control DS unit will be operated with Delta-connected power. NOTE This procedure requires substantial work. 1. Disconnect the power supply before working on the unit. 2. Locate the VSD (refer to Figure 1 for the drives location on downflow units; see Figure 2 for the location on upflow units). 3. Remove inverter assembly. Follow instructions in 13.2.4 - Electronic Variable Speed Drive Inverter. 4. Loosen and remove the screws as shown (#1 in Figure 65) and (#2 in Figure 65). 5. Remove filter (#3 in Figure 65). 6. Reinsert and tighten the screws removed in Step 4. Figure 65 Figure bb Disconnecting EMC filter for operation with Delta-connected power Type 2 inverters

4 1 2

3 DPN001947 Rev. 0
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9.0

PIPING
All fluid and refrigeration connections to the unit, with the exception of the condensate drain, are sweat copper. Factory-installed piping brackets must not be removed. Field-installed piping must be installed in accordance with local codes and must be properly assembled, supported, isolated and insulated. Avoid piping runs through noise-sensitive areas, such as office walls and conference rooms. Refer to specific text and detailed diagrams in this manual for other unit-specific piping requirements. 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 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.

9.1

Fluid Connections

NOTICE
Risk of clogged or leaking drain lines. Can cause equipment and building damage. This unit requires a water drain connection. Drain lines must be inspected regularly and maintenance must be performed to ensure that drain water runs freely through the drain system and that lines are clear and free of obstructions and in good condition with no visible sign of damage or leaks. This unit may also require an external water supply to operate. Improper installation, application and service practices 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. NOTE Seal openings around piping and electrical connection to prevent air leakage. Failure to do so could reduce the units cooling performance.

9.1.1

Condensate PipingField-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 DrainUnits Without Factory-Installed Condensate Pump

3/4" FPT drain connection is provided on units without optional factory-installed condensate pump with infrared humidifier or no humidifier; 1-1/4" FPT connection is provided on units with steam generating humidifier Pitch drain line toward drain a minimum of 1/8" (3mm) per 1 foot (305mm) of length Drain is trapped internally. Do not trap external to equipment Drain line must be sized for 2 gpm (7.6 l/m) flow

NOTICE
The drain line must not be trapped outside the unit or water may back up in the drain pan.

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Piping

Figure 66 Gravity drain for downflow and upflow units

DOWNFLOW DS UNIT
INTERNAL DRAIN UNIT

UPFLOW DS UNIT
EXTERNAL DRAIN INTERNAL DRAIN UNIT

EXTERNAL DRAIN CONTINUOUS DOWNWARD SLOPE CONTINUOUS DOWNWARD SLOPE

CORRECT
INTERNAL DRAIN

CORRECT
INTERNAL DRAIN UNIT EXTERNAL DRAIN

UNIT

EXTERNAL DRAIN

DO NOT EXTERNALLY TRAP THE UNIT

DO NOT EXTERNALLY TRAP THE UNIT

INCORRECT
INTERNAL DRAIN UNIT

INCORRECT
EXTERNAL DRAIN INTERNAL DRAIN UNIT

EXTERNAL DRAIN
THESE ARE EXTERNAL TRAPS ALSO, ALTHOUGH UNINTENTIONAL. LINES MUST BE RIGID ENOUGH NOT TO BOW OVER TOP OF OTHER OBJECTS. THESE ARE EXTERNAL TRAPS ALSO, ALTHOUGH UNINTENTIONAL. LINES MUST BE RIGID ENOUGH NOT TO BOW OVER TOP OF OTHER OBJECTS.

INCORRECT
Condensate Pump

INCORRECT

DPN001556 Rev. 0

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

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Piping

9.1.2

Humidifier Supply WaterOptional Infrared

1/4" supply line; maximum water pressure is 150 psi (1034kPa) Size humidifier supply line for 1 gpm (3.8 l/m), with a minimum water pressure of 20 psi (138kPa) Do not supply de-ionized water to the humidifier

9.1.3

Humidifier Supply WaterOptional Steam Generating

1/4" supply line; maximum water pressure is 145psi (1000kPa) Fill valve is sized for pressure range of 30 to 120psi (207-827kPa) Do not supply steam generating humidifier with softened water Do not use hot water source Water conductivity must be in the range of 330-750 micro-siemens

9.1.4

Requirements of Systems Using Water or Glycol

These guidelines apply to field leak checking and fluid requirements for field piping systems, including 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 checking, 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 protection 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.

NOTICE
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.

NOTICE
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 copper alloys that require appropriate corrosion protection. Contact a water consultant about 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 to prevent corrosion of system components. 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.

NOTICE
Risk of fluid leaks from tubing and piping corrosion. Can cause serious equipment and building 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.

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Piping

Leak Checking of Unit and Field Piping

Liebert unit fluid systems are factory-checked for leaks and may be shipped with a nitrogen holding charge. Liebert unit fluid circuits should be checked for leaks at installation as described below. NOTE During leak checking of field-installed piping, Emerson recommends that the unit be isolated using field-installed shutoff valves. When the Liebert units are included in a leak test, use of fluid for pressure testing is recommended. 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, (<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.

9.2

Refrigeration Piping

! WARNING from high-pressure refrigerant. Can cause injury or death. Risk of explosive discharge
This unit contains fluids and/or gases under high pressure. Relieve pressure before working with piping.

! WARNING rupture or explosion from over pressurization. Can cause Risk of refrigerant system
equipment damage, injury or death. For systems requiring EU CE-compliance (50Hz), 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. The pressure relief valve must be CE-certified to the EU Pressure Equipment Directive by an EU Notified Body. NOTE The Liebert indoor cooling unit has a factory-installed high-pressure safety switch in the high side refrigerant circuit. A pressure relief valve is provided with Liebert Lee-Temp condensers. Consult local building codes to determine whether the Liebert Fan Speed Control and VFD condensers will require field provided pressure relief devices.

NOTICE
Risk of oil contamination with water. Can cause equipment damage. Some Liebert DS Systems require the use of POE (polyolester) oil. See 13.10.1 - 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.

NOTICE
Risk of improper refrigerant charging. Can cause equipment damage. Refrigerant charge must be weighed into scroll and digital scroll compressors before they are started. Starting scroll and digital scroll compressors without proper refrigerant charging can cause the compressors to operate at less than 5F (-15C) evaporator temperature and at less than 20psig (138kPa). Operation for extended periods at less than 20psig (138kPa) can cause premature compressor failure.

85

Piping

9.2.1

Piping GuidelinesAir-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 49 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 13.10.1 - Compressor Oil) Refer to ASHRAE Refrigeration Handbook for general, good-practice refrigeration piping. Table 49
Model

Recommended refrigerant line sizes - OD copper (inches)*

028 035 042 053 070 077 105

Standard Scroll Models (Non-Digital Scroll) Hot Hot Hot Hot Hot Hot Hot 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) 100 ft (30m) 150 ft (45 m) Model 7/8 7/8 7/8 1/2 5/8 5/8 028 7/8 7/8 7/8 1/2 5/8 5/8 035 7/8 7/8 7/8 042 1/2 5/8 5/8 7/8 1-1/8 1-1/8 053 5/8 7/8 7/8 1-1/8 1-1/8 1-1/8 070 7/8 7/8 7/8 1-1/8 1-1/8 1-1/8 7/8 7/8 7/8 1-3/8 1-3/8 7/8 7/8

1-3/8 1-1/8 105

4-Step Semi-Hermetic and Digital Scroll Models 077 Hot Hot Hot Hot Hot Hot Hot 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) 100 ft (30m) 150 ft (45 m) 3/4 3/4 7/8 1/2 5/8 5/8 3/4 7/8 7/8 1/2 5/8 5/8 7/8 7/8 1-1/8* 5/8 5/8 5/8 7/8 1-1/8* 1-1/8 7/8 7/8 7/8 1-1/8* 1-1/8 1-1/8 7/8 7/8 7/8 1-1/8 1-1/8 1-1/8 7/8 7/8 7/8 1-3/8 1-3/8 7/8 7/8

1-3/8 1-1/8

* Downsize vertical riser one trade size (1-1/8" to 7/8")

Table 50

Indoor unit approximate refrigerant charge for R-22 or R-407C Model

028, 035, 042

System Type

R-22 Charge per Circuit, lb (kg)

6.5 (3.0) 9.5 (5.0) 11.0 (5.0) 13.0 (5.9) 18.5 (8.4) 24.0 (10.9)

R-407C Charge per Circuit, lb (kg)

5.5 (2.5) 8.0 (3.6) 9.5 (4.3) 12.2 (5.6) 17.0 (7.8) 22.5 (10.3)

Air-Cooled

053, 070, 077 105 028, 035, 042

Water, Glycol/GLYCOOL

053, 070, 077 105

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Piping

Table 51

Interconnecting piping refrigerant charge

R-22, lb/100 ft. (kg/30m) Liquid Line 7.3 (3.3) 11.7 (5.3) 16.6 (7.5) 24.4 (11.1) 41.4 (18.9) 63.3 (28.7) Hot Gas Line 2.1 (1.0) 3.0 (1.4) 4.4 (2.0) 7.8 (3.5) 11.8 (5.4) R-407C, lb/100 ft. (kg/30m) Liquid Line 6.9 (3.1) 11.0 (5.0 15.7 (7.1) 23.0 (10.4) 39.3 (17.8) 59.8 (27.1 Hot Gas Line 2.2 (1.0) 3.1 (1.3) 4.5 (1.9) 7.8 (3.5) 11.8 (5.4)

Line Size, O.D., in. 1/2 5/8 3/4 7/8 1-1/8 1-3/8

Table 52

R-22 and R-407C refrigerant required, approximate

Approximate R-22 Refrigerant Needed Approximate R-407C Refrigerant Needed Dual Circuit lb/circuit (kg/circuit) Dual Circuit lb/circuit (kg/circuit) FSC or VFD 5 (2.3) 7 (3.2) 10 (4.6) 11 (5.0) 24 (10.9) 29 (13.2) N/A N/A N/A N/A N/A Lee-Temp (includes receiver) 26 (11.8) 54 (24.4) 36 (16.3) 55 (24.9) 102 (46.2) 142 (64.4) 61 (27.7) 77 (34.9) 119 (54.0) 125 (55.8) 186 (84.4)

Standard Condenser Models 165 205 251 308 415 510 143 214 286 409 572

FSC or VFD 5 (2.3) 7 (3.2) 10 (4.6) 11 (5.0) 25 (11.3) 30 (13.6) N/A N/A N/A N/A N/A

Lee-Temp (includes receiver) 27 (12.3) 56 (25.3) 38 (17.2) 58 (26.3) 107 (48.4) 149 (67.6) 64 (29.0) 81 (36.7) 125 (56.7) 129 (58.5) 196 (88.9)

Quiet-Line Condenser Models

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Piping

9.2.2

Scroll and Digital ScrollAdditional Oil Requirements

System charges over 40 lb (18.1kg) per circuit may require additional oil charge to be added. See Table 53 for the amount required for various system charge levels. After the system has been fully charged with refrigerant, use a hand pump to add the additional oil at the suction side of the system while the system is running. The amount of oil added by field service must be recorded on the tag marked Oil Added Field Service Record, attached to each compressor. The date of oil addition must be included as well. Table 53 Additional oil required per refrigerant charge
System Charge Per Circuit - lb (kg) * 40lb (18.1kg) Model DS028 DS035 DS042 DS053-60Hz DS053-50Hz DS070 DS077 DS105
*

60lb (27.2kg)

80lb (36.3kg)

100lb (45.4kg)

120lb (54.4kg)

140lb (63.5kg)

160lb (72.6kg)

180lb (81.6kg)

200lb (90.7kg)

Additional Oil Required Per Circuit - Ounces (Grams) 0 7.5 (213) 5 (142) 4 (113) 15.5 (439) 13 (369) 7 (198) 23.5 (666) 21 (595) 10 (283) 31.5 (893) 29 (822) 13 (369) 39.5 (1120) 37 (1049) 16 (454) 47.5 (1347) 45 (1276) 20 (567) 55.5 (1573) 53 (1502) 23 (652) 63.5 (1800) 61 (1729) 26 (737) 71.5 (2027) 69 (1956)

For system charges over 200lb (90.7kg), consult your Emerson representative.

NOTICE
Risk of improper compressor lubrication. Can cause compressor and refrigerant system damage. Failure to use oil types, viscosities and quantities recommended by the compressor manufacturer may reduce compressor life and void the compressor warranty. See Table 64 for compressor oil types. Do not mix polyolester (POE) and mineral-based oils. Do not mix oils of different viscosities. Consult Emerson or the compressor manufacturer if questions arise.

88

Piping

9.3
9.3.1

Dehydration/Leak Test and Charging Procedures for R-407C and R-22

Air-Cooled Condenser with Variable Fan Speed Head Pressure Control Systems
The Variable Fan Speed Control systems (FSC & VFD) use pressure activated electronic fan speed control systems and remotely located thermostat(s) to ensure operation at ambient temperatures as low as 0F (-18C). For this ambient temperature range, the VFD Control Condenser must be used with digital scroll indoor units and can be used for energy savings with any Liebert DS indoor unit.

Variable Fan Speed Control Piping

Two discharge lines and two liquid lines must be field-installed between the indoor unit and the outdoor condenser. See Figures 67 and 69 for details.

Variable Fan Speed Control Materials Supplied

Built-in, pre-wired condenser control box Air-Cooled condenser Piping access cover to be reinstalled when piping is complete Boltsfour per leg (3/8" x 5/8") Terminal block for two-wire, 24V interlock connection between unit and condenser Condenser legsfour with 1-fan, 2-fan and 3-fan models; six with 4-fan models

Variable 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 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 67 and 69). 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 Liebert iCOM control (refer to the Liebert 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 system 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 Variable Fan Speed Charging.

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Piping

Variable Fan Speed Charging

1. Check unit nameplate for refrigerant type to be used. Unit control configurations differ depending on refrigerant type. 2. Refrigerant charging requires unit operation. Refer to 11.0 - Checklist for Completed Installation. 3. Calculate the amount of charge for the system. Refer to the unit, condenser and refrigerant line charge data in Tables 50, 51 and 52. 4. 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 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 Liebert iCOM control (see Liebert iCOM 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 54 Fan speed suction pressure transducer settings
R-22 Function Pump-Down Cutout Pump-Down Reset Minimum to Start-Cooling Low-Pressure Cutout Freeze Protection (DX w/Econ-O-Coil) Gauge (Sea Level) psiG (kPa) 35 (241) 65 (448) 35 (241) 20 (138) 48 (331) Absolute psiA (kPa) 50 (344) 80 (552) 50 (344) 35 (241) 63 (434) R-407C Gauge (Sea Level) psiG (kPa) 35 (241) 65 (448) 35 (241) 20 (138) 52 (358) Absolute psiA (kPa) 50 (345) 80 (552) 50 (344) 35 (241) 67 (461)

Due to control processing time, the pumpdown pressure at compressor shutoff will be approximately 20psiG (138kPa) / 35psiA (241 kPa) even though the setpoint is 35 psiG (241 kPa) / 50 psiA (344kPa).

6. Charge the unit until 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. When operating below 100%, the sight glass may show bubbles with each 15-second unloading cycle. 7. As head pressure builds, the variable fan speed controlled condenser fan begins rotating. The fan will run at full speed when sufficient head pressure is developedfan starts to rotate at 190 psig (1310 kPA) and is full speed at 250 psig (1724 kPA).

90

Piping

9.3.2

Air-Cooled Condenser with Liebert Lee-Temp Flooded Condenser Head Pressure Control System
The Liebert Lee-Temp system consists of a modulating type head pressure control valve and insulated receivers with heater pads to ensure operation at ambient temperatures as low as -30F (-34.4C). The Liebert Lee-Temp system can be used with any Liebert DS compressor choice.

Liebert Lee-Temp Piping

Two discharge lines and two liquid lines must be field-installed between the indoor unit and the outdoor condenser. See Figures 67 and 69 for details.

Liebert 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 (models with one to four fans only) Boltsfour per leg (3/8" x 5/8") Terminal block for two-wire, 24V interlock connection between unit and condenser Condenser legsfour with 1-fan, six on two-, three- and six-fan models and eight on four- and eight-fan models Boltssix per receiver (3/8" x 1") Lee-Temp system: Insulated storage receiverone per circuit Head pressure control valve with integral check valve - one per circuit Service valveone per circuit Pressure relief valveone per circuit Liquid level sight glasstwo per circuit Check valveone 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 69). 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 Liebert 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. 2. 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. 3. For semi-hermetic compressors, connect refrigeration gauges to the suction and discharge service valves of both compressors. 4. 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. 5. 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. 6. 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.

91

Piping

7. After completion of leak testing, release the test pressure (per local code) and pull an initial deep vacuum on the system with a suitable pump. 8. After four hours, check the pressure readings and, if they have not changed, break vacuum with dry nitrogen. Pull a second (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 Variable Fan Speed Charging on page 90. 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 depending on refrigerant type. 2. Refrigerant charging requires unit operation. Refer to 11.0 - Checklist for Completed Installation. 3. Calculate the amount of charge for the system. Refer to the unit, condenser and refrigerant line charge data in Tables 50, 51 and 52. 4. Weigh in as much of the system charge as possible before starting the unit.

NOTICE
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 Liebert 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 times as required to complete unit charging. Table 55 Lee-Temp suction pressure transducer settings
R-22 Function Pump-Down Cutout Pump-Down Reset Minimum to Start-Cooling Low-Pressure Cutout (DX only) Freeze Protection (DX w/Econ-O-Coil) Gauge (Sea Level) psiG (kPa) 35 (241) 65 (448) 50 (345) 20 (138) 48 (331) Absolute psiA (kPa) 50 (344) 80 (552) 65 (448) 35 (241) 63 (434) R-407C Gauge (Sea Level) psiG (kPa) 35 (241) 65 (448) 50 (345) 20 (138) 52 (358) Absolute psiA (kPa) 50 (344) 80 (552) 65 (448) 35 (241) 67 (461)

Due to control processing time, the pumpdown pressure at compressor shut off will be approximately 20psiG (138kPa) / 35psiA (241kPa) even though the setpoint is 35psiG (241kPa) / 50psiA (344kPa).

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.

92

Piping

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 40F (4.5C) and lowerbottom sight glass is 3/4 full 40 to 60F (4.5 to 15.5C)bottom sight glass is full 60F (15.5C) and highertop sight glass is 3/4 full.

9.3.3

Water/Glycol Cooled System

The water/glycol cooled system is factory-charged and includes and includes a Paradenser condenser and control valves. Table 56 Water/Glycol-cooled and GLYCOOL suction pressure transducer settings
R-22 Function Pump-Down Cutout Pump-Down Reset Minimum to Start-Cooling Low-Pressure Cutout (DX only) Freeze Protection (DX w/Econ-O-Coil) Gauge (Sea Level) psiG (kPa) 35 (241) 65 (448) 50 (345) 20 (138) 48 (331) Absolute psiA (kPa) 50 (344) 80 (552) 65 (448) 35 (241) 63 (434) R-407C Gauge (Sea Level) psiG (kPa) 35 (241) 65 (448) 50 (345) 20 (138) 52 (358) Absolute psiA (kPa) 50 (344) 80 (552) 65 (448) 35 (241) 67 (461)

Due to control processing time, the pumpdown pressure at compressor shut off will be approximately 20 psiG (138 kPa) / 35 psiA (241 kPa) even though the set point is 35 psiG (241 kPa) / 50 psiA (344kPa).

93

Piping Schematics

10.0 PIPING SCHEMATICS

Figure 67 Piping schematicair-cooled, semi-hermetic compressor models
Check Valve Relief Valve Service Valve

LIQUID RETURN

LIEBERT LEE-TEMP RECEIVER

Head Pressure Control Valve

Inverted Trap on discharge & liquid lines to extend above base of coil by a minimum of 7-1/2" (190mm)

CONDENSER COIL (LIEBERT LEE-TEMP) HOT GAS DISCHARGE

CONDENSER COIL (FAN SPEED or VFD)

OPTIONAL FIELD INSTALLED FUSIBLE PLUG

LIEBERT LEE-TEMP
LIQUID EVAPORATOR COIL * For rises over 25ft. (7.6m), trap every 20ft. (6m) or at evenly spaced points

Service Valve

Cylinder Unloader(s)

Sensing Bulb SUCTION

COMPRESSOR Muffler Service Valve

External Equilizer

Field installed relief valve(s) required for 50Hz EU CE units rated maximum 480 PSIG (33 Bar). *Isolation Valve

**Muffler

HOT GAS DISCHARGE

Expansion Solenoid Valve Valve

Sight Glass

Filter Drier

NOTES: Schematic representation shown. Do not use for specific connection locations. Two refrigeration circuits provided. Single refrigeration circuit shown for clarity. REFRIGERANT PIPING FIELD PIPING SERVICE / SCHRADER (ACCESS) CONNECTION, NO VALVE CORE SERVICE / SCHRADER (ACCESS) CONNECTION WITH VALVE CORE

*Isolation * Trap at base Valve of risers longer * Components are not supplied than 5ft. (1.5m) by Emerson but are recommended for proper circuit operation and maintenance ** Components supplied by Emerson and must be field-installed (70kW, 77kW & 105kW models only)

LIQUID RETURN

DPN000797 REV 5

94

Piping Schematics

Figure 68 Piping schematicair-cooled, scroll compressor models

Check Valve Inverted Trap on discharge and liquid lines to extend above base of coil by a minimum of 7-1/2" (190mm) Relief Valve Service Valve

LIQUID RETURN Head Pressure Control Valve

Liebert Lee-Temp Receiver

CONDENSER COIL (FAN SPEED or VFD)

Optional Field-Installed Fusible Plug

CONDENSER COIL (LIEBERT LEE-TEMP) HOT GAS DISCHARGE

HOT GAS DISCHARGE

FAN SPEED/VFD (Liebert Lee-Temp or VFD condenser is required with digital scroll) LIQUID
28-42kW Digital Solenoid Valve 53-70kW Digital Solenoid Valve Service Valve Check Valve Service COMPRESSOR Valve External Equalizer Sensing Bulb SUCTION

LIEBERT LEE-TEMP (Liebert Lee-Temp or VFD condenser is required with digital scroll)
* For rises over 25ft. (7.6m), trap every 20ft. (6m) or at evenly spaced points

EVAPORATOR COIL

Field-installed relief valve(s) required for 50Hz EU CE units rated maximum 480 PSIG (33 Bar). *Isolation Valve HOT GAS DISCHARGE

Expansion Solenoid Valve Valve

Sight Glass

Filter Drier

LIQUID RETURN

NOTES: Schematic representation shown. Do not use for specific connection locations. Two refrigeration circuits provided. Single refrigeration circuit shown for clarity. REFRIGERANT PIPING FIELD PIPING SERVICE / SCHRADER (ACCESS) CONNECTION, NO VALVE CORE

* Trap at base of risers longer than 5ft. (1.5m) * Components are not supplied by Emerson but are recommended for proper circuit operation and maintenance

*Isolation Valve

SERVICE / SCHRADER (ACCESS) CONNECTION WITH VALVE CORE

DPN000798 REV 5

95

Piping Schematics

Figure 69 Piping schematicwater/glycol, semi-hermetic compressor models

For systems with drycoolers, refer to 13.14.3 - Drycooler Settings.
Optional Dual Pump System Shown Expansion Tank** Glycol Pumps

Customer Heat Rejection

Liebert Heat Rejection

Cooling Tower and Pump System by Others

Drycooler (Glycol )

Aquastat Sensing Bulb Hose Bib *

Pressure Port *

Check Valves * (on Dual Pump Systems only) Gate Valves * Air Vents (typical) *** Pressure Port * Flow Switch Supplied with Dual Pump Systems Flow-Regulating Valve

Shutoff Valve *

Return Supply

Shutoff Valve * Return

Supply Supply
Shutoff Valve *

Liebert DS Unit
(and associated piping)

Return
Optional 3-Way Regulating Valve Shutoff Valve * Hose Bib *

Liquid
Service Valve
Cylinder Unloader (s) Sensing Bulb Suction

Evaporator Coil

Hose Bib *

Compressor
Muffler

Discharge

External Service Equalizer Valve

2-Way Regulating Valve

Paradenser Condenser
Expansion Valve Sight Glass Relief valve(s) supplied with 50Hz EU CE units rated maximum 480 PSIG (33 Bar). Sensor To Second Refrigeration Circuit

Bypass Valve

Solenoid Valve Filter Dryer

Factory Piping Field Piping Optional Factory Piping Service/Schrader (Access) Connection No Valve Core Service/Schrader (Access) Connection With Valve Core Note: 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

DPN00895 Rev. 2

96

Piping Schematics

Figure 70 Piping schematicwater/glycol with scroll compressor models

For systems with drycoolers, refer to 13.14.3 - Drycooler Settings.

CUSTOMER HEAT REJECTION

LIEBERT HEAT REJECTION

EXPANSION TANK**

Optional Dual Pump System shown GLYCOL PUMPS Check Valves* (on Dual Pump Systems only) Gate Valves*

COOLING TOWER AND PUMP SYSTEM BY OTHERS

DRYCOOLER (Glycol)

Aquastat Sensing Bulbs

Hose Bib*

Pressure Port*

Shutoff Valve*

Air Vents (typical)***

Pressure Port* Flow Switch Supplied with Dual Pump Systems

RETURN SUPPLY

Shutoff Valve*

Flow-Regulating Valve* RETURN SUPPLY

LIEBERT DS (and associated piping)

LIQUID
Sensing Bulb SUCTION Service Valve Service Check Valve Valve COMPRESSOR DISCHARGE Optional 3-Way Regulating Valve

RETURN

SUPPLY

Shutoff Valve* Hose Bib*

Shutoff Valve* Hose Bib*

EVAPORATOR COIL

External Equalizer

2-Way Regulating Valve

PARADENSER CONDENSER
Expansion Valve Solenoid Valve Sight Glass Filter Dryer Sensor Relief valve(s) supplied with 50Hz EU CE units rated maximum 480 PSIG (33 Bar) TO SECOND REFRIGERATION CIRCUIT

Bypass Valve

Factory Piping Field Piping Optional Factory Piping Service/Schrader (Access) Connection No Valve Core Service/Schrader (Access) Connections With Valve Core Note: 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 DPN000896 REV 3

97

Piping Schematics

Figure 71 Piping schematicGLYCOOL semi-hermetic compressor models

For systems with drycoolers, refer to 13.14.3 - Drycooler Settings.

LIEBERT HEAT REJECTION

EXPANSION TANK**

Optional Dual Pump System shown

GLYCOL PUMPS
Pressure Port* Check Valves* (on Dual Pump Systems only) Gate Valves*

DRYCOOLER (Glycol) Aquastat Sensing Bulbs Hose Bib* Shutoff Valve*

Air Vents (typical)***

Pressure Port* Flow Switch Supplied with Dual Pump Systems

Shutoff Valve*

Flow-Regulating Valve*

RETURN

SUPPLY

LIEBERT DS UNIT (and associated piping)

LIQUID
Sensing Bulb Service Valve Cylinder Unloader(s) SUCTION

ECON-O-COIL
3-Way Chilled Glycol Valve

RETURN
Shutoff Valve*

SUPPLY
Shutoff Valve*

EVAPORATOR COIL

Thermistor

Hose Bib*

Hose Bib*

Muffler

COMPRESSOR
Service Valve

External Equalizer

DISCHARGE PARADENSER CONDENSER

Expansion Solenoid Sight Valve Glass Valve Filter Dryer Relief valve(s) supplied TO SECOND with 50Hz EU CE units rated REFRIGERATION maximum 480 PSIG (33 Bar). CIRCUIT 3-Way Regulating Valve

Sensor

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

98

Piping Schematics

Figure 72 Piping schematicGLYCOOL with scroll compressor models

LIEBERT HEAT REJECTION

For systems with drycoolers, refer to 13.14.3 - Drycooler Settings.
DRYCOOLER (Glycol)

EXPANSION TANK**

Optional Dual Pump System shown GLYCOL PUMPS

Check Valves* (on Dual Pump Systems only)

Aquastat Sensing Bulbs Hose Bib*

Pressure Port*

Gate Valves*

Shutoff Valve*

Air Vents (typical)***

Pressure Port*
Flow Switch Supplied with Dual Pump Systems

Shutoff Valve*

Flow-Regulating Valve* RETURN SUPPLY

LIEBERT DS UNIT (and associated piping)

LIQUID Sensing Bulb
SUCTION

ECON-O-COIL 3-Way Chilled Glycol Valve

RETURN Shutoff Valve* Thermistor Hose Bib*

SUPPLY Shutoff Valve*

EVAPORATOR COIL

3-Way Chilled Glycol Valve

Hose Bib*

Service Check Valve COMPRESSOR Valve External Equalizer DISCHARGE Paradenser Condenser Expansion Solenoid Sight Valve Valve Glass Filter Dryer Sensor 3-Way Regulating Valve

Relief valve(s) supplied 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. FIELD PIPING FACTORY PIPING

SERVICE / SCHRADER (ACCESS) CONNECTION WITH VALVE CORE 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 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 DPN000898 REV 3

99

Piping Schematics

Figure 73 Piping schematicwater/glycol with digital scroll compressor models

CUSTOMER HEAT REJECTION

LIEBERT HEAT REJECTION

DRYCOOLER (Glycol) Aquastat Sensing Bulbs

EXPANSION TANK**

Optional Dual Pump System shown GLYCOL PUMPS

Check Valves* (on Dual Pump Systems only)

COOLING TOWER AND PUMP SYSTEM BY OTHERS

Pressure Port*

Gate Valves*

Hose Bib* Shut-Off Valve*

Air Vents (typical)***

Pressure Port* Flow Switch Supplied with Dual Pump Systems

RETURN SUPPLY

Shut-Off Valve*

Flow-Regulating Valve* RETURN SUPPLY

LIEBERT DS UNIT (and associated piping)

LIQUID 28-42kW Digital Solenoid Valve Sensing Bulb 53-70kW Digital Solenoid Valve SUCTION

HOT GAS REHEAT Optional 3-Way Motorized Ball Valve EVAPORATOR COIL

RETURN Shut-Off Valve* Hose Bib*

SUPPLY Shut-Off Valve* Hose Bib*

Service Valve Service Check Valve Valve COMPRESSOR DISCHARGE

Hot Gas Reheat Valve External Equalizer Check Valve 2-Way Motorized Ball Valve

From iCOM Control

PARADENSER CONDENSER Expansion Solenoid Sight Filter Drier Valve Valve Pressure Glass Relief valve(s) supplied Transducer with 50 Hz EU CE units rated maximum 480 PSIG (33 Bar). To iCOM Control TO SECOND REFRIGERATION CIRCUIT

NOTE: TWO REFRIGERATION CIRCUITS PROVIDED SINGLE REFRIGERATION CIRCUIT SHOWN FOR CLARITY. FACTORY PIPING FIELD PIPING OPTIONAL FACTORY PIPING SERVICE / SCHRADER (ACCESS) CONNECTION NO VALVE CORE SERVICE / SCHRADER (ACCESS) CONNECTION WITH VALVE CORE * 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 DPN001430 Rev. 0

NOTE: SCHEMATIC REPRESENTATION SHOWN. THIS SCHEMATIC DOES NOT IMPLY OR DEFINE ELEVATIONS AND COMPONENT LOCATION, UNLESS SPECIFICALLY NOTED.

100

Piping Schematics

Figure 74 GLYCOOL with digital scroll compressor models

LIEBERT HEAT REJECTION

EXPANSION TANK**

Optional Dual Pump System shown GLYCOL PUMPS Check Valves* (on Dual Pimp Systems only) Gate Valves*

DRYCOOLER (Glycol) Aquastat Sensing Bulb Hose Bib*

Pressure Port*

Shut-Off Valve*

Air Vents (typical)***

Pressure Port*

Flow Switch Supplied with Dual Pump Systems Shut-Off Valve* RETURN Flow-Regulating Valve* SUPPLY SUPPLY Shut-Off Valve*

LIEBERT DS UNIT (and associated piping)

LIQUID 28-42kW Digital Solenoid Valve 53-70kW Digital Solenoid Valve Sensing Bulb SUCTION

ECON-O-COIL 3-Way Chilled Glycol Valve Thermistor

RETURN Shut-Off Valve* Hose Bib*

EVAPORATOR COIL

Hose Bib*

Service Valve Check Valve COMPRESSOR DISCHARGE

External Equalizer

3-Way Motorized Ball Valve

From iCOM Control

PARADENSER CONDENSER Expansion Solenoid Sight Filter Drier Valve Valve Pressure Glass Relief valve(s) supplied Transducer with 50 Hz EU CE units rated maximum 480 PSIG (33 Bar). To iCOM Control TO SECOND REFRIGERATION CIRCUIT

NOTE: TWO REFRIGERATION CIRCUITS PROVIDED SINGLE REFRIGERATION CIRCUIT SHOWN FOR CLARITY. FACTORY PIPING FIELD PIPING SERVICE / SCHRADER (ACCESS) CONNECTION NO VALVE CORE SERVICE / SCHRADER (ACCESS) CONNECTION WITH VALVE CORE * 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

NOTE: SCHEMATIC REPRESENTATION SHOWN. THIS SCHEMATIC DOES NOT IMPLY OR DEFINE ELEVATIONS AND COMPONENT LOCATION, UNLESS SPECIFICALLY NOTED.

DPN001432 Rev. 0

101

Piping Schematics

Figure 75 Optional piping schematic for Econ-O-Coil

Return Supply
Thermistor *

Return Supply
Thermistor *

Actuator

Actuator

Return

Return

Supply

Econ-O-Coil

Supply

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 on field supply line . Field Piping

Note: 1. Place thermistor in location where flow is always present DPN000805 . 2. Thermistor must be located out of the supply air stream Rev. 1 .

102

Piping Schematics

Figure 76 Primary connection locationsdownflow, air-cooled, 28-42kW (8-12 ton), semi-hermetic compressor models

NOTE: Drawing not to scale. Tolerance on all piping dimensions is 1/2" (13mm).

A FRONT VIEW SECTION A-A

ALL DIMENSIONS FROM REAR CORNER OF UNIT INCLUDING PANELS

BLOWER OUTLET
L1 L2 G1 G2

16-1/16" (408mm) B

R 35" (889mm)

4" (102mm) 16-7/16" (418mm)

ECS HUM CD E1 E2 ECR LV1 LV2 LV3

FRONT OF UNIT
86" (2184mm)

DPN000803 Rev. 3
Y inches (mm) 13-13/16 (351) 16-3/4 (425) 16-3/4 (425) 16-3/4 (425) 16-3/4 (425) 29-1/2 (749) 29-1/2 (749) 29-1/2 (749) 29 (737) 22-9/16 (573) 30-3/4 (781) 31-1/4 (794) 31-1/4 (794) 27 (686) 29 (737) 31 (787) 18-1/16 (459) Connection Size / Opening inches (mm) 16-7/16 x 4 (418 x 102) 1/2 Cu Sweat 1/2 Cu Sweat 5/8 Cu Sweat 5/8 Cu Sweat 3/4 FPT 1-1/4 FPT 1/2 Cu Sweat 1/4 Cu Sweat 1-5/8 Cu Sweat 1-5/8 Cu Sweat 2-1/2 2-1/2 7/8 7/8 7/8 18-3/4 x 16-1/16 (476 x 408)

Point R L1 L2 G1 G2

Description Refrigerant Access Liquid Line System 1 Liquid Line System 2 Hot Gas Discharge 1 Hot Gas Discharge 2 Condensate Drain* (infrared humidifier or no humidifier)*

X inches (mm) 63 (1600) 79-3/16 (2011) 76-1/2 (1943) 73-7/8 (1876) 70-1/8 (1780) 46 (1168) 46 (1168) 46 (1168) 53-1/2 (1359) 54-7/8 (1394) 49-3/8 (1254) 55-1/2 (1410) 52-7/16 (1332) 2-1/4 (57) 2-1/4 (57) 2-1/4 (57) 21-15/16 (558)

CD

Condensate Drain* (steam generating humidifier)* W/ Optional Pump Humidifier Supply Line Econ-O-Coil Supply Econ-O-Coil Return Electrical Connection (High Volt) Electrical Connection (High Volt) Electrical Connection (Low Volt) Electrical Connection (Low Volt) Electrical Connection (Low Volt) Blower Outlet

HUM ECS ECR E1 E2 LV1 LV2 LV3 B

* 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.

103

Piping Schematics

Figure 77 Primary connection locationsdownflow, air-Cooled, 28-42kW (8-12 ton) with scroll compressor models
NOTE: Drawing not to scale. Tolerance on all piping dimensions is 1/2" (13mm).

A FRONT VIEW SECTION A-A

ALL DIMENSIONS FROM REAR CORNER OF UNIT INCLUDING PANELS

BLOWER OUTLET R
L1 L2 G1 G2

16-1/16" (408mm) B

4" (102mm) 11-3/16" (284mm)

35" (889mm)

ECS HUM CD E1 E2 ECR LV1 LV2 LV3

FRONT OF UNIT
73" (1854mm)

DPN000804 Rev. 3

Point R L1 L2 G1 G2

Description Refrigerant Access Liquid Line System 1 Liquid Line System 2 Hot Gas Discharge 1 Hot Gas Discharge 2 Condensate Drain* (infrared humidifier or no humidifier)

X inches (mm) 59-5/16 (1507) 69-15/16 (1776) 67-5/8 (1718) 65-1/2 (1664) 62-7/16 (1586) 46 (1168) 46 (1168) 46 (1168) 53-1/2 (1359) 54-7/8 (1394) 49-3/8 (1254) 55-1/2 (1410) 52-7/16 (1332) 2-1/4 (57) 2-1/4 (57) 2-1/4 (57) 21-15/16 (557)

Y inches (mm) 14-3/4 (375) 16-13/16 (411) 16-13/16 (411) 16-13/16 (411) 16-13/16 (411) 29-1/2 (749) 29-1/2 (749) 29-1/2 (749) 29 (737) 22-9/16 (573) 30-3/4 (781) 31-1/4 (794) 31-1/4 (794) 27 (686) 29 (737) 31 (787) 18-1/16 (459)

Connection Size / Opening inches (mm) 11-3/16 x 4 (284 x 102) 1/2 Cu Sweat 1/2 Cu Sweat 5/8 Cu Sweat 5/8 Cu Sweat 3/4 FPT 1-1/4 FPT 1/2 Cu Sweat 1/4 Cu Sweat 1-5/8 Cu Sweat 1-5/8 Cu Sweat 2-1/2 2-1/2 7/8 7/8 7/8 18-3/4 x 16-1/16 (476 x 408)

CD

Condensate Drain* (steam generating humidifier) W/ Optional Pump Humidifier Supply Line Econ-O-Coil Supply Econ-O-Coil Return Electrical Connection (High Volt) Electrical Connection (High Volt) Electrical Connection (Low Volt) Electrical Connection (Low Volt) Electrical Connection (Low Volt) Blower Outlet

HUM ECS ECR E1 E2 LV1 LV2 LV3 B

*

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.

104

Piping Schematics

Figure 78 Primary connection locationsdownflow water/glycol/GLYCOOL 28-42kW (8-12 ton), all compressor models
NOTE: Drawing not to scale. Tolerance on all piping dimensions is 1/2" (13mm).

A
FRONT VIEW SECTION A-A

ALL DIMENSIONS FROM REAR CORNER OF UNIT INCLUDING PANELS

W 8" (203mm) WS WR

BLOWER OUTLET

16-1/16" (408mm) B

35" (889mm)

3-1/2" (89mm)

ECS HUM CD E1 E2 ECR LV1 LV2 LV3

FRONT OF UNIT
86" (2184mm) DPN000900 Rev. 3

Point W WS WR

Description Water/Glycol/GLYCOOL Access Water/Glycol/GLYCOOL Supply Water/Glycol/GLYCOOL Return Condensate Drain (infrared humidifier or no humidifier) *

X in. (mm) 79-15/16 (2030) 82-15/16 (2107) 82-15/16 (2107) 46 (1168) 46 (1168) 46 (1168) 53-1/2 (1359) 54-7/8 (1394) 49-13/16 (1265) 55-1/2 (1410) 52-7/16 (1332) 2-1/4 (57) 2-1/4 (57) 2-1/4 (57) 21-15/16 (557)

Y in. (mm) 9-1/16 (230) 10-15/16 (278) 14-1/16 (357) 29-1/2 (749) 29-1/2 (749) 29-1/2 (749) 29 (737) 22-9/16 (573) 28-1/2 (724) 31-1/4 (794) 31-1/4 (794) 27 (686) 29 (737) 31 (787) 18-1/16 (459)

Connection Size / Opening in. (mm) 3-1/2 x 8 (89 x 203) 1-5/8" Cu Sweat 1-5/8" Cu Sweat 3/4" FPT 1-1/4" FPT 1/2" Cu Sweat 1/4" Cu Sweat 1-5/8" Cu Sweat 1-5/8" Cu Sweat 2-1/2" 2-1/2" 7/8" 7/8" 7/8" 18-3/4 x 16-1/16 (476 x 408)

CD

Condensate Drain (steam generating humidifier) * W/ Optional Pump Humidifier Supply Line Econ-O-Coil Supply Econ-O-Coil Return Electrical Conn. (High Volt) Electrical Conn. (High Volt) Electrical Conn. (Low Volt) Electrical Conn. (Low Volt) Electrical Conn. (Low Volt) Blower Outlet

HUM ECS ECR E1 E2 LV1 LV2 LV3 B

* 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 79 Primary connection locationsdownflow, air-Cooled, 53-77kW (15-22 ton), semi-hermetic compressor models
All dimensions from rear corner of unit including panels

A NOTE: Drawing not to scale. Tolerance on all piping dimensions is 1/2" (13mm).

FRONT VIEW SECTION A-A

A
X O

R
R

BLOWER OUTLET

16-1/16" (408mm) B2

BLOWER OUTLET
Y

4" (102mm)

L1 L2

G1 G2

B1

16-7/16" (418mm)

35" (889mm)

ECS HUM ECR CD E1 E2 FRONT OF UNIT 109" (2769mm)

LV1 LV2 LV3

DPN00928 Rev. 4
Connection Size / Opening in. (mm)
16-7/16 x 4 (418 x 102)
53kW (15 tons) / 70 & 77kW (20 & 22 tons)

Point
R

Description
Refrigerant Access

X in. (mm)
82-3/4 (2102)

Y in. (mm)
13-7/8 (352)

L1 L2 G1 G2

Liquid Line System 1 Liquid Line System 2 Hot Gas Discharge 1 Hot Gas Discharge 2 Condensate Drain (infrared humidifier or no humidifier) *

97 (2464) 93-5/16 (2370) 90-5/8 (2302) 88 (2235) 69-1/4 (1759) 69-1/4 (1759) 69-1/4 (1759) 76-1/2 (1943) 78-5/8 (1997) 72 (1829) 78-1/2 (1994) 75-3/8 (1915) 1-7/8 (48) 1-7/8 (48) 1-7/8 (48) 23-1/8 (587) 27-3/4 (705) 50-3/8 (1280) 54-3/8 (1381)

16-7/8 (428) 16-7/8 (428) 16-5/8 (422) 16-5/8 (422) 30 (762) 30 (762) 30 (762) 29 (736) 22-1/4 (565) 29 (737) 31-1/8 (790) 31-1/8 (790) 28-1/2 (724) 30-1/4 (768) 32 (813) 18-1/16 (459) 18-1/16 (459) 18-1/16 (459) 18-1/16 (459)

1/2" / 5/8" Cu Sweat 1/2" / 5/8" Cu Sweat 7/8" / 1-1/8" Cu Sweat 7/8" / 1-1/8" Cu Sweat 3/4" FPT 1-1/4" FPT 1/2" Cu Sweat 1/4" Cu Sweat 2-1/8" Cu Sweat 2-1/8" Cu Sweat 2-1/2" 2-1/2" 7/8" 7/8" 7/8" 18-3/4 x 16-1/16 (476 x 408) 14-3/4 x 16-1/16 (375 x 408) 18-3/4 x 16-1/16 (476 x 408) 14-3/4 x 16-1/16 (375 x 408)

CD

Condensate Drain (steam generating humidifier)* W/ Optional Pump Humidifier Supply Line

HUM

ECS** Econ-O-Coil Supply ECR** Econ-O-Coil Return E1 E2 LV1 LV2 LV3 B1 B2 Electrical Conn. (High Volt) Electrical Conn. (High Volt) Electrical Conn. (Low Volt) Electrical Conn. (Low Volt) Electrical Conn. (Low Volt) Blower Outlet (15 x 15) Blower Outlet (15 x 11) Blower Outlet (15 x 15) Blower Outlet (15 x 11)

* 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 (4 pipe system)

106

Piping Schematics

Figure 80 Primary connection locations downflow air cooled 53-77kW (15-22 tons) semi-hermetic compressor models, with EC fan
All dimensions from rear corner of unit including panels

A Note: Drawing not to scale. Tolerance on all piping dimensions is 1/2" (13mm).

A FRONT VIEW SECTION A-A

X O

Y BLOWER OUTLET 35" (889mm)

LV1 LV2 B1 LV3

4" (102mm)

L1 L2 G1 G2

16-7/16" (418mm) ECS ECR CD E1 E2 HUM

FRONT OF UNIT
109" (2769mm)

DPN002179 Rev. 0
Point R L1 L2 G1 G2 CD HUM ECS** ECR** HS HR E1 E2 LV1 LV2 LV3 Description Refrigerant Access Liquid Line System 1 Liquid Line System 2 Hot Gas Discharge 1 Hot Gas Discharge 2 Condensate Drain (infrared humidifier or no humidifier)* W/ Optional Pump Humidifier Supply Line Econ-O-Coil Supply Econ-O-Coil Return Hot Water Reheat Supply Hot Water Reheat Return Electrical Conn. (High Volt) Electrical Conn. (High Volt) Electrical Conn. (Low Volt) Electrical Conn. (Low Volt) Electrical Conn. (Low Volt) 78-1/2 (1994) 75-3/8 (1915) 2 (51) 2 (51) 2 (51) X in. (mm) 82-3/4 (2102) 97 (2464) 93-5/16 (2370) 90-5/8 (2302) 88 (2235) 68-3/8 (1737) 68-3/8 (1737) 76-1/2 (1943) 78-5/8 (1997) 73-15/16 (1862) Y in. (mm) 13-7/8 (352) 16-7/8 (428) 16-7/8 (428) 16-5/8 (422) 16-5/8 (422) 31-3/8 (797) 31-3/8 (797) 29 (736) 22-1/4 (565) 26-9/16 (675) CONSULT FACTORY CONSULT FACTORY 31-1/8 (790) 31-1/8 (790) 29 (737) 30-7/8 (784) 32 (813) 2-1/2" 2-1/ " 7/8" 7/8" 7/8" Connection Size / Opening in. (mm) 16-7/16 x 4 (4181 x 102mm) 53kW (15 Tons)/70 & 77kW (20 & 22 Tons) 1/2" / 5/8" Cu Sweat 1/2" / 5/8" Cu Sweat 7/8" / 1-1/8" Cu Sweat 7/8" / 1-1/8" Cu Sweat 3/4" FPT 1/2" Cu Sweat 1/4 Cu Sweat 2-1/8 Cu Sweat 2-1/8 Cu Sweat

* 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 (four-pipe system)

107

Piping Schematics

Figure 81 Primary connection locationsdownflow, air-Cooled, 53-77kW (15-22 ton) with scroll compressor models
All dimensions from rear corner of unit including panels

A NOTE: Drawing not to scale. Tolerance on all piping dimensions is 1/2" (13mm).

A
FRONT VIEW SECTION A-A
X O

BLOWER OUTLET

16-1/16" (408mm)

BLOWER OUTLET B1

4" (102mm)

L1 L2 G1 G2

B2 12-3/16" (310mm) ECS HUM ECR CD E1 E2 FRONT OF UNIT 98" (2489mm)

35" (889mm)

LV1 LV2 LV3

DPN00929 Rev. 4
Connection Size / Opening in. (mm) 12-3/16 x 4 (310 x 102) 53kW (15 tons) / 70 &77kW (20 &22 tons) 1/2" / 5/8" Cu Sweat 1/2" / 5/8" Cu Sweat 7/8" / 1-1/8" Cu Sweat 7/8" / 1-1/8" Cu Sweat 3/4" FPT 1-1/4" FPT 1/2" Cu Sweat 1/4" Cu Sweat 2-1/8" Cu Sweat 2-1/8" Cu Sweat 2-1/2" 2-1/2" 7/8" 7/8" 7/8" 18-3/4 x 16-1/16 (476 x 408) 14-3/4 x 16-1/16 (375 x 408) 18-3/4 x 16-1/16 (476 x 408) 14-3/4 x 16-1/16 (375 x 408)

Point R L1 L2 G1 G2

Description Refrigerant Access Liquid Line System 1 Liquid Line System 2 Hot Gas Discharge 1

X in. (mm) 81-3/4 (2076) 94-11/16 (2405) 91-7/8 (2334) 88-3/4 (2254) 85-9/16 (2173) 69-1/4 (1759) 69-1/4 (1759) 69-1/4 (1759) 76-1/2 (1943) 78-5/8 (1997) 72 (1829) 78-1/2 (1994) 75-3/8 (1915) 1-7/8 (48) 1-7/8 (48) 1-7/8 (48) 23-1/8 (587) 27-3/4 (705) 50-3/8 (1280) 54-3/8 (1381)

Y in. (mm) 14-3/4 (374) 16-3/4 (425) 16-3/4 (425) 16-3/8 (416) 16-3/8 (416) 30 (762) 30 (762) 30 (762) 29 (736) 22-1/4 (565) 29 (737) 31-1/8 (790) 31-1/8 (790) 28-1/2 (724) 30-1/4 (768) 32 (813) 18-1/16 (459) 18-1/16 (459) 18-1/16 (459) 18-1/16 (459)

Hot Gas Discharge 2 Condensate Drain (infrared humidifier or no humidifier)* CD Condensate Drain (steam generating humidifier)* W/ Optional Pump HUM Humidifier Supply Line ECS** Econ-O-Coil Supply ECR** Econ-O-Coil Return E1 Electrical Conn. (High Volt) E2 Electrical Conn. (High Volt) LV1 Electrical Conn. (Low Volt) LV2 Electrical Conn. (Low Volt) LV3 Electrical Conn. (Low Volt) Blower Outlet (15 x 15) B1 Blower Outlet (15 x 11) Blower Outlet (15 x 15) B2 Blower Outlet (15 x 11)

* 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 (4 pipe system)

108

Piping Schematics

Figure 82 Primary connection locationsdownflow, air-Cooled, 53-77kW (15-22 ton) with scroll compressor models, with EC fan

All dimensions from rear corner of unit including panels Note: Drawing not to scale. A Tolerance on all piping dimensions is 1/2" (13mm).

A
FRONT VIEW SECTION A-A
X O

4" (102mm)

L1 L2 G1 G2

BLOWER OUTLET

12-3/16" (310mm) ECS ECR CD E1 E2 HUM

LV1 LV2 B1 LV3

35" (889mm)

FRONT OF UNIT
98" (2489mm)

DPN002182 Rev. 0
Point R L1 L2 G1 G2 CD HUM ECS** ECR** HS HR E1 E2 LV1 LV2 LV3 B1 Description Refrigerant Access Liquid Line System Liquid Line System 2 Hot Gas Discharge 1 Hot Gas Discharge 2 Condensate Drain (Infrared Humidifier or No Humidifier)* W/ Optional Pump Humidifier Supply Line Econ-O-Coil Supply Econ-O-Coil Return Hot Water Reheat Supply Hot Water Reheat Return Electrical Conn. (High Volt) Electrical Conn. (High Volt) Electrical Conn. (Low Volt) Electrical Conn. (Low Volt) Electrical Conn. (Low Volt) Blower Outlet 78-1/2 (1994) 75-3/8 (1915) 2 (51) 2 (51) 2 (51) 4-1/2 (114) X in. (mm) 81-3/4 (2076) 94-11/16 (2405) 91-7/8 (2334) 88-3/4 (2254) 85-9/16 (2173) 68-3/8 (1737) 68-3/8 (1737) 76-1/2 (1943) 78-5/8 (1997) 73-15/16 (1862) Y in. (mm) 14-3/4 (374) 16-3/4 (425) 16-3/4 (425) 16-3/8 (416) 16-3/8 (416) 31-3/8 (797) 31-3/8 (797) 29 (736) 22-1/4 (565) 26-9/16 (675) Connection Size / Opening in. (mm) 12-3/16 (310) X 4" (102) 53kW (15 Tons) / 70 & 77kW (20 & 22 Tons) 1/2 / 5/8" Cu Sweat 1/2 / 5/8" Cu Sweat 7/8 / 1-1/8" Cu Sweat 7/8 / 1-1/8" Cu Sweat 3/4 FPT 1/2 Cu Sweat 1/4 Cu Sweat 2-1/8 Cu Sweat 2-1/8 Cu Sweat

CONSULT FACTORY CONSULT FACTORY 31-1/8 (790) 31-1/8 (790) 29 (737) 30-7/8 (784) 32 (813) 33 (838) 2-1/2" 2-1/2" 7/8" 7/8" 7/8" 58-3/8 x 30 (1483x762)

* 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 (four-pipe system)

109

Piping Schematics

Figure 83 Primary connection locationsdownflow, water/glycol/GLYCOOL, 53-77kW (15-22 ton), all compressor models

NOTE: Drawing not to scale. A Tolerance on all piping dimensions is 1/2" (13mm).

FRONT VIEW SECTION A-A

All dimensions from rear corner of unit including panels

X O

8" (203mm)

W WS WR

3-1/2" (89mm)

BLOWER OUTLET

16-1/16" (408mm) B2

BLOWER OUTLET
Y

B1

35" (889mm)

ECS HUM E1 E2 ECR CD FRONT OF UNIT 109" (2769mm)

LV1 LV2 LV3

DPN00933 Rev. 4
Y in. (mm) 9 (229) 11 (279) 15 (381) 30 (762) 30 (762) 30 (762) 29 (736) 22-1/4 (565) 29 (737) 31-1/8 (790) 31-1/8 (790) 28-1/2 (724) 30-1/4 (768) 32 (813) 18-1/16 (459) 18-1/16 (459) 18-1/16 (459) 18-1/16 (459) Connection Size / Opening in. (mm) 3-1/2 x 8 (89 x 203) 2-1/8" Cu Sweat 2-1/8" Cu Sweat 3/4" FPT 1-1/4" FPT 1/2" Cu Sweat 1/4" Cu Sweat 2-1/8" Cu Sweat 2-1/8" Cu Sweat 2-1/2" 2-1/2" 7/8" 7/8" 7/8" 18-3/4 x 16-1/16 (476 x 408) 14-3/4 x 16-1/16 (375 x 408) 18-3/4 x 16-1/16 (476 x 408) 14-3/4 x 16-1/16 (375 x 408)

Point W WS WR

Description Water/Glycol/GLYCOOL Access Water/Glycol/GLYCOOL Supply Water/Glycol/GLYCOOL Return Condensate Drain (infrared humidifier or no humidifier)*

X in. (mm) 103 (2616) 104-3/4 (2661) 104-3/4 (2661) 69-1/4 (1759) 69-1/4 (1759) 69-1/4 (1759) 76-1/2 (1943) 78-5/8 (1997) 72 (1829) 78-1/2 (1994) 75-3/8 (1915) 1-7/8 (48) 1-7/8 (48) 1-7/8 (48) 23-1/8 (587) 27-3/4 (705) 50-3/8 (1280) 54-3/8 (1381)

CD

Condensate Drain (steam generating humidifier)* W/ Optional Pump Humidifier Supply Line Econ-O-Coil Supply Econ-O-Coil Return Electrical Conn. (High Volt) Electrical Conn. (High Volt) Electrical Conn. (Low Volt) Electrical Conn. (Low Volt) Electrical Conn. (Low Volt) Blower Outlet (15 x 15) Blower Outlet (15 x 11) Blower Outlet (15 x 15) Blower Outlet (15 x 11)

HUM ECS** ECR** E1 E2 LV1 LV2 LV3 B1 B2

* 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 (4 pipe system)

110

Piping Schematics

Figure 84 Primary connection locationsdownflow, water/glycol/GLYCOOL, 53-77kW (15-22 ton), all compressor models, with EC fan

A Note: Drawing not to scale. Tolerance on all piping dimensions is 1/2" (13mm).

All dimensions from rear corner of unit including panels X

FRONT VIEW SECTION A-A

3-1/2" (89mm) 8" (203mm) W WS WR Y BLOWER OUTLET 35" (889mm)

LV1

ECS ECR CD E1 E2 HUM

B1 LV2

LV3

FRONT OF UNIT
109" (2769mm)

DPN002183 Rev. 0
Point W WS WR CD HUM ECS** ECR** HS HR E1 E2 LV1 LV2 LV3 B1 Description Water/Glycol/GLYCOOL Access Water/Glycol/GLYCOOLSupply Water/Glycol/GLYCOOL Return Condensate Drain (Infrared Humidifier or No Humidifier)* W/Optional Pump Humidifier Supply Line Econ-O-Coil Supply Econ-O-Coil Return Hot Water Reheat Supply Hot Water Reheat Return Electrical Conn. (High Volt) Electrical Conn. (High Volt) Electrical Conn. (Low Volt) Electrical Conn. (Low Volt) Electrical Conn. (Low Volt) Blower Outlet 78-1/2 (1994) 75-3/8 (1915) 2 (51) 2 (51) 2 (51) 4-1/2 (114) X in. (mm) 103 (2616) 104-3/4 (2661) 104-3/4 (2661) 68-3/8 (1737) 68-3/8 (1737mm) " 76-1/2 (1943) 78-5/8 (1997) 73-15/16 (1862) Y in. (mm) 9 (229) 11 (279) 15 (381) 31-3/8 (797) 31-3/8 (797) 29 (736) 22-1/4 (565) 26-9/16 (675) CONSULT FACTORY CONSULT FACTORY 31-1/8 (790) 31-1/8 (790) 29 (737) 30-7/8 (784) 32 (813) 33 (838) 2-1/2" 2-1/2" 7/8" 7/8" 7/8" 58-3/8 x 30 (1483 x 762) Connection Size / Opening in. (mm) 3-1/2 x 8 (89 x 203) 2-1/8 Cu Sweat 2-1/8 Cu Sweat 3/4 FPT 1/2 Cu Sweat 1/4 Cu Sweat 2-1/8 Cu Sweat 2-1/8 Cu Sweat

* 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 (four- pipe system)

111

Piping Schematics

Figure 85 Primary connection locationsdownflow, air-cooled, 105kW (30 ton), all compressor models

A
NOTE: Drawing not to scale. Tolerance on all piping dimensions is 1/2" (13mm).

A FRONT VIEW SECTION A-A

ALL DIMENSIONS FROM REAR CORNER OF UNIT INCLUDING PANELS

G1 G2 R 4" (102mm) L1 L2 16-7/16" (418mm)

15-11/16" (398mm)

BLOWER OUTLET B3

BLOWER OUTLET B2

BLOWER OUTLET B1

Y 35" (889mm)

ECS

ECR CD

LV1 LV2 LV3

HUM E1

E2

FRONT OF UNIT
131" (3327mm)

DPN001014 Rev. 3

Point R L1 L2 G1 G2

Description Refrigerant Access Liquid Line System 1 Liquid Line System 2 Hot Gas Discharge 1 Hot Gas Discharge 2 Condensate Drain (infrared humidifier or no humidifier)*

X in. (mm) 109 (2769) 121-3/4 (3092) 118-1/8 (3000) 118-1/4 (3004) 115-5/8 (2937) 83-13/16 (2129) 83-13/16 (2129) 83-13/16 (2129) 102-3/4 (2610) 101-7/8 (2588) 94-9/16 (2402) 98-1/8 (2492) 91 (2311) 2 (51) 2 (51) 2 (51) 27-7/8 (708) 52-1/16 (1322) 76-1/4 (1937)

Y in. (mm) 15-3/4 (400) 16-3/4 (425) 16-3/4 (425) 14-1/4 (362) 14-1/4 (362) 30 (762) 30 (762) 30 (762) 31-3/4 (806) 29 (737) 29 (737) 31-1/4 (794) 31-1/4 (794) 28-1/4 (718) 30-1/4 (768) 32 (813) 18 (457) 18 (457) 18 (457)

Connection Size / Opening in. (mm) 16-7/16" x 4 (418 x 102) 5/8" Cu Sweat 5/8" Cu Sweat 1-1/8" Cu Sweat 1-1/8" Cu Sweat 3/4" FPT 1-1/4" FPT 1/2" Cu Sweat 1/4" Cu Sweat 2-5/8" Cu Sweat 2-5/8" Cu Sweat 2-1/2" 2-1/2" 7/8" 7/8" 7/8" 14-1/2 x 15-11/16 (368 x 398) 14-1/2 x 15-11/16 (368 x 398) 14-1/2 x 15-11/16 (368 x 398)

CD

Condensate Drain (steam generating humidifier)* W/ Optional Pump Humidifier Supply Line Econ-O-Coil Supply Econ-O-Coil Return Electrical Conn. (High Volt) Electrical Conn. (High Volt) Electrical Conn. (Low Volt) Electrical Conn. (Low Volt) Electrical Conn. (Low Volt) Blower Outlet Blower Outlet Blower Outlet

HUM ECS** ECR** E1 E2 LV1 LV2 LV3 B1 B2 B3

* 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 (4 pipe system)

112

Piping Schematics

Figure 86 Primary connection locationsdownflow, air-cooled, 105kW (30 ton), all compressor models, with EC fan

A Note: Drawing not to scale. Tolerance on all piping dimensions is 1/2" (13mm).

FRONT VIEW SECTION A-A

All dimensions from rear corner of unit including panels X O

Y G1G2 R 4" (102mm) L1 L2 ECS ECR 16-7/16" (418mm) E1 E2 CD HUM B1 BLOWER OUTLET 35" (889mm)

LV1 LV2 LV3

FRONT OF UNIT
132" (3353mm)

DPN002154 Rev. 0
Point R L1 L2 G1 G2 CD HUM ECS ** ECR ** HS HR E1 E2 LV1 LV2 LV3 B1
*

Description Refrigerant Access Liquid Line System 1 Liquid Line System 2 Hot Gas Discharge 1 Hot Gas Discharge 2 Condensate Drain (Infrared Humidifier Or No Humidifier)* W/ Optional Pump Humidifier Supply Line Econ-O-Coil Supply Econ-O-Coil Return Hot Water Reheat Supply Hot Water Reheat Return Electrical Conn. (High Volt) Electrical Conn. (High Volt) Electrical Conn. (Low Volt) Electrical Conn. (Low Volt) Electrical Conn. (Low Volt) Blower Outlet

X in. (mm) 109 (2769) 121-3/4 (3092) 118-1/8 (3000) 118-1/4 (3004) 115-5/8 (2937) 87-3/8 (2220) 83-13/16 (2129) 85-5/16 (2167) 101-7/8 (2588) 94-9/16 (2402)

Y in. (mm) 15-3/4 (400) 16-3/4 (425) 16-3/4 (425) 14-1/4 (362) 14-1/4 (362) 31 (787) 30 (762) 32-1/2 (825) 29 (737) 29 (737)

Connection Size / Opening in. (mm) 16-7/16 (418) x 4 (102) 5/8 Cu Sweat 5/8 Cu Sweat 1-1/8 Cu Sweat 1-1/8 Cu Sweat 3/4 FPT 1/2 Cu Sweat 1/4 Cu Sweat 2-5/8 Cu Sweat 2-5/8 Cu Sweat

CONSULT FACTORY CONSULT FACTORY 98-1/8 (2492) 91 (2311) 2 (51) 2 (51) 2 (51) 4-1/2 (114) 31 (788) 31 (788) 29 (737) 30-7/8 (784) 32 (813) 33 (838) 2-1/2 2-1/2 7/8 7/8 7/8 77-3/8 x 30 (1965 x 762)

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 (four-pipe system)

113

Piping Schematics

Figure 87 Primary connection locationsdownflow, water/glycol/GLYCOOL, 105kW (30 ton), all compressor models

A
NOTE: Drawing not to scale. Tolerance on all piping dimensions is 1/2" (13mm).

FRONT VIEW SECTION A-A

ALL DIMENSIONS FROM REAR CORNER OF UNIT INCLUDING PANELS

8" (203mm)

W WS WR

15-7/8" (403mm) TYP

BLOWER OUTLET B3

BLOWER OUTLET B2

BLOWER OUTLET B1

Y
35" (889mm)

3-1/2" (89mm) ECS ECR

14-1/2" (368mm) TYP CD

LV1 LV2 LV3

HUM E1

E2

FRONT OF UNIT
131" (3327mm)

DPN001015 Rev. 3

Point W WS WR

Description Water/Glycol/GLYCOOL Access Water/Glycol/GLYCOOL Supply Water/Glycol/GLYCOOL Return Condensate Drain (infrared humidifier or no humidifier)*

X in. (mm) 125-15/16 (3199) 127-7/8 (3248) 127-7/8 (3248) 83-13/16 (2129) 83-13/16 (2129) 83-13/16 (2129) 102-3/4 (2610) 101-7/8 (2588) 94-9/16 (2402) 98-1/4 (2496) 88-7/16 (2246) 2 (51) 2 (51) 2 (51) 28-1/4 (718) 52 (1321) 75-11/16 (1922)

Y in. (mm) 9 (229) 10-1/16 (256) 13-1/4 (337) 30 (762) 30 (762) 30 (762) 31-3/4 (806) 29 (737) 29 (737) 30 (762) 30 (762) 27-1/2 (796) 30-1/4 (768) 32 (813) 18 (457) 18 (457) 18 (457)

Connection Size / Opening in. (mm) 3-1/2 x 8 (89 x 203) 2-1/8" Cu Sweat 2-1/8" Cu Sweat 3/4" FPT 1-1/4" FPT 1/2" Cu Sweat 1/4" Cu Sweat 2-5/8" Cu Sweat 2-5/8" Cu Sweat 2-1/2" 2-1/2" 7/8" 7/8" 7/8" 14-1/2 x 15-7/8 (368 x 403) 14-1/2 x 15-7/8 (368 x 403) 14-1/2 x 15-7/8 (368 x 403)

CD

Condensate Drain (steam generating humidifier)* W/ Optional Pump Humidifier Supply Line Econ-O-Coil Supply Econ-O-Coil Return Electrical Conn. (High Volt) Electrical Conn. (High Volt) Electrical Conn. (Low Volt) Electrical Conn. (Low Volt) Electrical Conn. (Low Volt) Blower Outlet Blower Outlet Blower Outlet

HUM ECS** ECR** E1 E2 LV1 LV2 LV3 B1 B2 B3

* 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 (4 piping system).

114

Piping Schematics

Figure 88 Primary connection locations downflow water/glycol/GLYCOOL 105kW (30 tons) all compressor models, with EC fan

A Note: Drawing not to scale. Tolerance on all piping dimensions is 1/2" (13mm).

FRONT VIEW
All dimensions from rear corner of unit including panels X

SECTION A-A
W WS WR

8" (203mm)

3-1/2" (89mm) ECS ECR CD HUM

BLOWER OUTLET

35" (889mm)
LV1 LV2 LV3

B1

E1

E2

FRONT OF UNIT
132" (3353mm)

DPN002153 Rev. 0
Point W WS WR CD Description Water/Glycol/GLYCOOL Access Water/Glycol/GLYCOOL Supply Water/Glycol/GLYCOOL Return Condensate Drain (Infrared Humidifier or No Humidifier)* W/Optional Pump HUM Humidifier Supply Line ECS HS HR E1 E2 LV1 LV2 LV3 B1 Econ-O-Coil Supply Hot Water Reheat Supply Hot Water Reheat Return Electrical Conn. (High Volt) Electrical Conn. (High Volt) Electrical Conn. (Low Volt) Electrical Conn. (Low Volt) Electrical Conn. (Low Volt) Blower Outlet 98-1/8 (2492) 91 (2311) 2 (51) 2 (51) 2 (51) 4-1/2 (114) ECR Econ-O-Coil Return X in. (mm) 125-15/16 (3199) 127-7/8 (3248) 127-7/8 (3248) 87-3/8 (2220) 83-13/16 (2129) " 85-5/16 (2167) 101-7/8 (2588) 94-9/16 (2402) Y in. (mm) 9 (229) 10-1/16 (256) 13-1/4 (337) 31 (787) 30 (762) 32-1/2 (825) 29 (737) 29 (737) CONSULT FACTORY CONSULT FACTORY 31 (788) 31 (788) 29 (737) 30-7/8 (784) 32 (813) 33 (838) 2-1/2" 2-1/2" 7/8" 7/8" 7/8" 77-3/8 x 30 (1965 x 762) Connection Size / Opening in. (mm) 3-1/2 (89) X 8" (203) 2-1/8 Cu Sweat 2-1/8 Cu Sweat 3/4 FPT" 1/2 Cu Sweat 1/4" Cu Sweat 2-5/8" Cu Sweat 2-5/8" Cu Sweat

* 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 (4 piping system).

115

Piping Schematics

Figure 89 Primary connection locationsupflow, air-cooled, 28-42kw (8-12 ton), semi-hermetic compressor models
NOTES: 1. Drawing not to scale. 2. Tolerance on all piping dimensions is 1/2" (13mm). 15-3/16" Field-routed alternatives for refrigerant 35" (386mm) gas and liquid line connection points. (889mm) See submittal page DPN001120 for 4" blower outlet and deck dimensional data. (102mm) 22-1/2" (572mm) All dimensions from rear corner of unit including panels Blower Outlet

16-7/16" (418mm)

86" (2184mm) Top View 6" (152mm) 17-3/16" (437mm) 14-1/4" (362mm) 15-7/8" (403mm) Left Side Section View 20-1/16" (509mm) Front of Unit

3-7/8" (98mm)

Factory Location Front Section View (Left Front Panel Not Shown) DPN001114 Rev. 02

Point R1 R2 L1 L2 G1 G2 R3
3

Description Refrigerant Access (Top) Refrigerant Access (Bottom) Liquid Line System 1 Liquid Line System 2 Hot Gas Discharge 1 Hot Gas Discharge 2 Refrigerant Access (Side) Condensate Gravity Drain Condensate Pump Discharge (Opt) Humidifier Supply Line Econ-O-Coil Supply Econ-O-Coil Return Electrical Connection (High Voltage) Electrical Connection (High Voltage) Electrical Connection (Low Voltage) Electrical Connection (Low Voltage) Electrical Connection (Low Voltage)

X inches (mm) 60-11/16 (1542) 63 (1600) 79-3/16 (2011) 76-1/2 (1943) 73-7/8 (1876) 70-1/8 (1780) 56-1/4 (1429) 56-1/4 (1429) 56 (1423) 56 (1423) 52-3/8 (1330) 46-7/8 (1191) 19-1/2 (495) 19-1/2 (495) 19-1/2 (495)

Y inches (mm) 1-7/8 (48) 13-13/16 (351) 16-3/4 (425) 16-3/4 (425) 16-3/4 (425) 16-3/4 (425) 11-1/8 (283) 9-1/8 (233) 7-5/16 (186) 4-1/2 (114) 30 (762) 30 (762) 29-1/16 (738) 30-1/2 (775) 31-15/16 (811)

Connection Size / Opening inches (mm) 22-1/2 x 15-3/16 (572 x 386) 16-7/16 x 4 (418 x 102) 1/2 Cu Sweat 1/2 Cu Sweat 5/8 Cu Sweat 5/8 Cu Sweat 6 x 17-3/16 (152 x 437) 3/4 FPT 1/2 Cu Sweat 1/4 Cu Sweat 1-5/8 Cu Sweat 1-5/8 Cu Sweat 2-1/2 2-1/2 7/8 7/8 7/8

3 3

CGD* CPD HUM ECS** ECR** E1 E2 LV1 LV2 LV3

* 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)

116

Piping Schematics

Figure 90 Primary connection locationsupflow, air-Cooled, 28-42kW (8-12 ton), semi-hermetic compressor models
NOTES: 1. Drawing not to scale. 2. Tolerance on all piping dimensions is 1/2" (13mm). 3 Field routed alternatives for refrigerant gas and liquid line connection points. 4 See submittal page DPN001120 for blower outlet and deck dimensional data.
10-1/8" (257mm) 4-1/8" (105mm) 3. R1
ECR ECS HUM CPD

All dimensions from rear corner of unit including panels X

BL OWER OU T TLE 4. Y

R2 4" (102mm)
L1 L2 G1 G2

35" (889mm)

3.

11-1/8" (283mm) E1 E2 73" (1854mm)

LV 1 LV 2 LV 3

6" (152mm)

TOP VIEW
R3 3.

Front of Unit

17-3/16" (437mm)

CGD*
3-7/8" (98mm) 14-1/4" (362mm) 15-7/8" (403mm)

17-1/16" (434mm)

L1L2G1 G2

CGD*

Factory Location

FRONT SECTION
(Left Front Panel Not Shown)

LEFT SIDE SECTION

DPN001119 Rev. 2

Point R1 R2 L1 L2 G1 G2 R3
3 3 3

Description Refrigerant Access (Top) Refrigerant Access (Bottom) Liquid Line System 1 Liquid Line System 2 Hot Gas Discharge 1 Hot Gas Discharge 2 Refrigerant Access (Side) Condensate Gravity Drain Condensate Pump Discharge (Opt) Humidifier Supply Line Econ-O-Coil Supply Econ-O-Coil Return Electrical Conn. (High Volt) Electrical Conn. (High Volt) Electrical Conn. (Low Volt) Electrical Conn. (Low Volt) Electrical Conn. (Low Volt)

X in. (mm) 60-1/2 (1537) 59-3/8" (1508mm) 70" (1778mm) 67-5/8" (1718mm) 65-3/8" (1661mm) 63" (1600mm) 56-1/4 (1429) 56-1/4 (1429) 56 (1423) 56 (1423) 52-3/8 (1330) 46-7/8 (1191) 19-1/2 (495) 19-1/2 (495) 19-1/2 (495)

Y in. (mm) 1-7/8" (48mm) 14-3/4" (375mm) 16-3/4 (425) 16-3/4 (425) 16-5/8 (422) 16-5/8 (422) 11-1/8 (283) 9-1/8 (233) 7-5/16 (186) 4-1/2 (114) 30 (762) 30 (762) 29-1/16 (738) 30-1/2 (775) 31-15/16 (811)

Connection Size / Opening in. (mm) 10-1/8 x 4-1/8 (257 x 105) 11-1/8 x 4 (283 x 102) 1/2" Cu Sweat 1/2" Cu Sweat 5/8" Cu Sweat 5/8" Cu Sweat 6 x 17-3/16 (152 x 437) 3/4" FPT 1/2" Cu Sweat 1/4" Cu Sweat 1-5/8" Cu Sweat 1-5/8" Cu Sweat 2-1/2" 2-1/2" 7/8" 7/8" 7/8"

CGD* CPD HUM ECS** ECR** E1 E2 LV1 LV2 LV3

*

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

117

Piping Schematics

Figure 91 Primary connection locationsupflow, 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). 3. Field-routed alternatives for water/glycol connections. 4. See submittal page DPN001120 for blower outlet and deck dimensional data. W1,W2 8" 35" (203mm) (889mm) 3 2-7/8" (73mm) 3-1/2" (89mm)
E1 E2

All dimensions from rear corner of unit including X panels ECS ECR HUM CPD Blower Outlet 4

Y LV1 LV2 LV3

6" (152mm) 17-3/16" (437mm) 3-7/8" (98mm)

86" (2184mm) Top View of Unit W3 WS WR

3

Front

CGD* 14-1/4" (362mm)

15-7/8" (403mm)
Left Side Section View

CGD*

Front Section View (Left Front Panel Not Shown)

DPN001179 Rev. 2

Point W1 W2 W3 WS WR CPD HUM ECS** ECR** E1 E2 LV1 LV2 LV3

3 3 3 3 3

Description Water/Glycol/GLYCOOL Access (Bottom) Water/Glycol/GLYCOOL Access (Top) Water/Glycol/GLYCOOL Access (Side) Water/Glycol/GLYCOOL Supply Water/Glycol/GLYCOOL Return Condensate Gravity Drain Condensate Pump Discharge (Opt) Humidifier Supply Line Econ-O-Coil Supply Econ-O-Coil Return Electrical Connection (High Voltage) Electrical Connection (High Voltage) Electrical Connection (Low Voltage) Electrical Connection (Low Voltage) Electrical Connection (Low Voltage)

X in. (mm) 79-15/16 (2030) 79-15/16 (2030) 56-1/4 (1429) 56-1/4 (1429) 56 (1423) 56 (1423) 52-3/8 (1330) 46-7/8 (1191) 19-1/2 (495) 19-1/2 (495) 19-1/2 (495)

Y in. (mm) 9 (229) 9 (229) 11-1/8 (282) 9-1/8 (232) 7-5/16 (186) 4-1/2 (114) 30 (762) 30 (762) 29-1/16 (738) 30-1/2 (775) 31-15/16 (811)

Connection Size / Opening in. (mm) 3-1/2 x 8 (89 x 203) 3-1/2 x 8 (89 x 203) 6 x 17-3/16 (152 x 437) 1-5/8 Cu Sweat 1-5/8 Cu Sweat 3/4 FPT 1/2 Cu Sweat 1/4 Cu Sweat 1-5/8 Cu Sweat 1-5/8 Cu Sweat 2-1/2 2-1/2 7/8 7/8 7/8

CGD

* 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)

118

Piping Schematics

Figure 92 Primary connection locationsupflow, air-cooled, 53-77kW (15-22 ton), semi-hermetic compressor models
22-1/2" (572mm) All dimensions from rear corner of unit including panels Blower Outlet Blower Outlet X

NOTES: 15-3/16" 1. Drawing not to scale. 35" (386mm) 2. Tolerance on all piping dimensions (889mm) is 1/2" (13mm). 4" 3. Field routed alternatives for refrigerant (102mm) gas and liquid line connection points. 4. See submittal page DPN001191 for blower outlet and deck dimensional data.

16-7/16" (418mm)

109" (2769mm) 6" (152mm)

Front of Unit

TOP VIEW OF UNIT

17-3/16" (437mm)
14-1/4" (362mm) 15-7/8" (403mm)

20-1/16" (509mm)

3-7/8" (98mm)

Factory Location

LEFT SIDE SECTION VIEW OF UNIT

FRONT SECTION VIEW OF UNIT (Left Front Panel Not Shown)

* 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. DPN001212 ** Supplied on Dual Cooling Systems only

Rev. 2

Point R1 R2 L1 L2 G1 G2 R3
3 3 3

Description Refrigerant Access (Top) Refrigerant Access (Bottom) Liquid Line System 1 Liquid Line System 2 Hot Gas Discharge 1 Hot Gas Discharge 2 Refrigerant Access (Side) Condensate Pump Discharge (Opt) Humidifier Supply Line

X inches (mm) 83-3/4 (2127) 86 (2184) 97 (2464) 93-5/16 (2370) 90-5/8 (2302) 88 (2235) 79-5/16 (2015) 79-5-16 (2015) 78-5/8 (1998) 78-5/8 (1998) 75-3/8 (1915) 69-7/8 (1775) 19-1/2 (495) 19-1/2 (495) 19-1/2 (495)

Y inches (mm) 1-7/8 (48) 13-7/8 (352) 16-3/4 (425) 16-3/4 (425) 16-5/8 (422) 16-5/8 (422) 11-7/8 (302) 9-7/8 (251) 7-7/8 (200) 4-5/8 (117) 30 (762) 30 (762) 29-1/16 (738) 30-1/2 (775) 31-15/16 (811)

Connection Size / Opening inches (mm) 22-1/2 x 15-3/16 (572 x 386) 16-7/16 x 4 (418 x 102)

53kW (15 ton)/ 70 & 77kW (20 & 22 ton) 1/2 / 5/8 Cu Sweat 1/2 / 5/8 Cu Sweat 7/8 / 1-1/8 Cu Sweat 7/8 / 1-1/8 Cu Sweat 6 x 17-3/16 (152 x 437) 3/4 FPT 1/2 Cu Sweat 1/4 Cu Sweat 2-1/8 Cu Sweat 2-1/8 Cu Sweat 2-1/2 2-1/2 7/8 7/8 7/8

CGD* Condensate Gravity Drain CPD HUM

ECS** Econ-O-Coil Supply ECR** Econ-O-Coil Return E1 E2 LV1 LV2 LV3 Electrical Connection (High Voltage) Electrical Connection (High Voltage) Electrical Connection (Low Voltage) Electrical Connection (Low Voltage) Electrical Connection (Low Voltage)

* 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)

119

Piping Schematics

Figure 93 Primary connection locationsupflow, air-cooled, 53-77kW (15-22 ton), scroll compressor models
All dimensions from rear corner of unit including panels NOTE 4" 1. Drawing not to scale. (102mm) 2. Tolerance on all piping dimensions 35" is 1/2" (13mm). 4" (102mm) 3. Field-routed alternatives for refrigerant (889mm) gas and liquid line connection points. 12-13/16" 4. See submittal page DPN001191 for (325mm) blower outlet and deck dimensional data. Blower Outlet
4

Blower Outlet
4

Y
Lv1 LV2 LV3

98" (2489mm)

Front

Top View
6" (152mm)

17-3/16" (437mm) 3-7/8" (98mm) 14-1/4" (362mm) 15-7/8" (403mm)

CGD*

17-1/16" (433mm)

Factory Location CGD*

Left Side Section View

Point R1 R2
3 3

Front Section View

(Left Front Panel Not Shown)

DPN001213 Rev. 1

Description Refrigerant Access (Top) Refrigerant Access (Bottom)

X inches (mm) 83-5/8 (2124) 82-3/4 (2102)

Y inches (mm) 2 (51) 14-3/4 (374)

Connection Size / Opening inches (mm) 12 x 4 (305 x 102) 12-3/16 x 4 (310 x 102) 53kW (15 tons )/ 70 & 77kW (20 & 22 ton)

L1 L2 G1 G2 R3
3

Liquid Line System 1 Liquid Line System 2 Hot Gas Discharge 1 Hot Gas Discharge 2 Refrigerant Access (Side) Condensate Gravity Drain Condensate Pump Discharge (Opt) Humidifier Supply Line

94-11/16 (2405) 91-7/8 (2334) 88-3/4 (2254) 85-9/16 (2173) 79-5/16 (2015) 79-5/16 (2015) 78-5/8 (1998) 78-5/8 (1998) 75-3/8 (1915) 69-7/8 (1775) 19-1/2 (495) 19-1/2 (495) 19-1/2 (495)

16-3/4 (425) 16-3/4 (425) 16-3/8 (416) 16-3/8 (416) 11-7/8 (302) 9-7/8 (251) 7-7/8 (200) 4-5/8 (117) 30 (762) 30 (762) 29-1/16 (738) 30-1/2 (775) 31-15/16 (811)

1/2 / 5/8 Cu Sweat 1/2 / 5/8 Cu Sweat 7/8 / 1-1/8 Cu Sweat 7/8 / 1-1/8 Cu Sweat 6 x 17-3/16 (152 x 437) 3/4 FPT 1/2 Cu Sweat 1/4 Cu Sweat 2-1/8 Cu Sweat 2-1/8 Cu Sweat 2-1/2 2-1/2 7/8 7/8 7/8

CGD* CPD HUM

ECS** Econ-O-Coil Supply ECR** Econ-O-Coil Return E1 E2 LV1 LV2 LV3 Electrical Connection (High Voltage) Electrical Connection (High Voltage) Electrical Connection (Low Voltage) Electrical Connection (Low Voltage) Electrical Connection (Low Voltage)

* 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 (four-pipe system)

120

Piping Schematics

Figure 94 Primary connection locationsupflow, water/glycol/GLYCOOL, 53-77kW (15-22 ton), all compressor models
All dimensions from rear corner of unit including panels Blower Outlet Blower Outlet

NOTES: 1. Drawing not to scale. 2. Tolerance on all piping dimensions 8" is 1/2" (13mm). (203mm) 3. Field routed alternatives for water/glycol 35" connections. (889mm) 2-7/8" (73mm) 4. See submittal page DPN001191 for 3-1/2" blower outlet and deck dimensional data.
(89mm)

109" (2769mm) 6" (152mm) 17-3/16" (437mm) 3-7/8" (98mm)

TOP VIEW OF UNIT

Front of Unit

14-1/4" (362mm) 15-7/8" (403mm)

LEFT SIDE SECTION VIEW OF UNIT

FRONT SECTION VIEW OF UNIT (Left Front Panel Not Shown)

X inches (mm) Y inches (mm) 9 (229) 9 (229) 11-7/8 (302) 9-7/8 (251) 7-7/8 (200) 4-5/8 (117) 30 (762) 30 (762) 29-1/16 (738) 30-1/2 (775) 31-15/16 (811)

DPN001214 Rev. 1

Point W1 W2 W3 WS WR CPD HUM

3 3 3 3

Description Water/Glycol/GLYCOOL Access (Bottom) Water/Glycol/GLYCOOL Access (Top) Water/Glycol/GLYCOOL Access (Side) Water/Glycol/GLYCOOL Supply Water/Glycol/GLYCOOL Return Condensate Gravity Drain Condensate Pump Discharge (Option) Humidifier Supply Line

Connection Size / Opening inches (mm) 3-1/2 x 8 (89 x 203) 3-1/2 x 8 (89 x 203) 6 x 17-3/16 (152 x 437) 2-1/8 Cu Sweat 2-1/8 Cu Sweat 3/4 FPT 1/2 Cu Sweat 1/4 Cu Sweat 2-1/8 Cu Sweat 2-1/8 Cu Sweat 2-1/2 2-1/2 7/8 7/8 7/8

102-15/16 (2615) 102-15/16 (2615) 79-5/16 (2015) 79-5/16 (2015) 78-5/8 (1998) 78-5/8 (1998) 75-3/8 (1915) 69-7/8 (1775) 19-1/2 (495) 19-1/2 (495) 19-1/2 (495)

CGD*

ECS** Econ-O-Coil Supply ECR** Econ-O-Coil Return E1 E2 LV1 LV2 LV3

*

Electrical Connection (High Voltage) Electrical Connection (High Voltage) Electrical Connection (Low Voltage) Electrical Connection (Low Voltage) Electrical Connection (Low Voltage)

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 (four-pipe system)

121

Piping Schematics

Figure 95 Primary connection locationsupflow, air-cooled, 105kW (30 ton), all

22-1/2" (572mm) 15-3/16" (386mm)
ECR ECS HUM CPD

All dimensions from rear corner of unit including panels Blower Outlet Blower Outlet Blower Outlet

R2

35" (889mm)

4" (102mm) NOTES: 1. Drawing not to scale. 2. Tolerance on all piping dimensions is 1/2" (13mm). 3. Field routed alternatives for refrigerant gas and liquid line connection points. 4. See submittal page DPN001192 for blower outlet and deck dimensional data. 6" (152mm) R3 17-3/16" (437mm) 3-7/8" (98mm) 14-1/4" (362mm) 15-7/8" (403mm) 20-1/16" (509mm) CGD*

16-7/16" (418mm)
E1 E2

LV1 LV3 LV2 132" (3353mm) LV4

Front Of Unit

TOP VIEW OF UNIT

G1 G2 L1 L2

CGD* Factory Location

LEFT SIDE SECTION VIEW OF UNIT

Table 57
Point R1 R2 L1 L2 G1 G2 R3
3 3 3

FRONT SECTION VIEW OF UNIT

(Left Front Panel Not Shown)

DPN001257 Rev. 0

Piping dataupflow, air-cooled 105kW (30 ton), all

X 106-7/8 (2715) 109-1/8 (2772) 121-3/4 (3092) 118-1/8 (3000) 118-1/4 (3004) 115-5/8 (2937) 102-3/8 (2600) 101-1/8 (2569) 101-1/8 (2569) 101-1/8 (2569) 98-1/2 (2502) 93 (2362) 41-1/8 (1045) 38-7/8 (987) 35-1/8 (892) 31-5/8 (803) Y 1-7/8 (48) 13-7/8 (352) 16-3/4 (425) 16-3/4 (425) 14-1/4 (362) 14-1/4 (362) 13-5/8 (346) 13-1/8 (333) 10-1/4 (260) 5-1/4 (133) 30 (762) 30 (762) 30-3/8 (772) 30-3/8 (772) 30-3/8 (772) 30-3/8 (772) Connection Size / Opening 22-1/2 x 15-3/16 (572 x 386) 16-7/16 x 4 (418 x 102) 5/8 Cu Sweat 5/8 Cu Sweat 1-1/8 Cu Sweat 1-1/8 Cu Sweat 6 x 17-3/16 (152 x 437) 3/4 FPT 1/2 Cu Sweat 1/4 Cu Sweat 2-5/8 Cu Sweat 2-5/8 Cu Sweat 2-1/2 2-1/2 7/8 7/8 7/8 7/8

Description Refrigerant Access (Top) Refrigerant Access (Bottom) Liquid Line System 1 Liquid Line System 2 Hot Gas Discharge 1 Hot Gas Discharge 2 Refrigerant Access (Side) Condensate Gravity Drain Condensate Pump Discharge (Opt) Humidifier Supply Line Econ-O-Coil Supply Econ-O-Coil Return Electrical Conn. (High Volt) Electrical Conn. (High Volt) Electrical Conn. (Low Volt) Electrical Conn. (Low Volt) Electrical Conn. (Low Volt) Electrical Conn. (Low Volt)

CGD* CPD HUM ECS ECR E1 E2 LV1 LV2 LV3 LV4

*

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.

122

Piping Schematics

Figure 96 Primary connection locationsupflow, water/glycol/GLYCOOL, 105kW (30 ton), all

All dimensions from rear corner of unit including panels Blower Outlet Blower Outlet Blower Outlet

35" (889mm)

8" (203mm)

NOTES: 1. Drawing not to scale. 2. Tolerance on all piping dimensions is 1/2" (13mm). 3. Field routed alternatives for water/glycol connections. 4. See submittal page DPN001192 for blower outlet and deck dimensional data. 6" (152mm)

2-7/8" (73mm) 3-1/2" (89mm) 132" (3353mm)

LV1 LV3 LV2 LV4

Front Of Unit

TOP VIEW OF UNIT

17-3/16" (437mm) 3-7/8" (98mm)

W3 WS WR CGD* CGD*

14-1/4" (362mm) 15-7/8" (403mm)

FRONT SECTION VIEW OF UNIT

(Left Front Panel Not Shown)

LEFT SIDE SECTION VIEW OF UNIT

Table 58
Point W1 W2 W3 WS WR CPD HUM ECS ECR E1 E2 LV1 LV2 LV3 LV4
3 3 3 3 3

DPN001258 Rev. 0

Piping dataupflow, upflow, water/glycol/GLYCOOL, 105kW (30 ton), all

Description Water/Glycol/GLYCOOL Access (Bottom) Water/Glycol/GLYCOOL Access (Top) Water/Glycol/GLYCOOL Access (Side) Water/Glycol/GLYCOOL Supply Water/Glycol/GLYCOOL Return Condensate Gravity Drain Condensate Pump Discharge (Opt) Humidifier Supply Line Econ-O-Coil Supply Econ-O-Coil Return Electrical Conn. (High Volt) Electrical Conn. (High Volt) Electrical Conn. (Low Volt) Electrical Conn. (Low Volt) Electrical Conn. (Low Volt) Electrical Conn. (Low Volt) X inches (mm) 126-1/8 (3204) 126-1/8 (3204) 102-3/8 (2600) 101-1/8 (2569) 101-1/8 (2569) 101-1/8 (2569) 98-1/2 (2502) 93 (2362) 41-1/8 (1045) 38-7/8 (987) 35-1/8 (892) 31-5/8 (803) Y inches (mm) 9 (229) 9 (229) 13-5/8 (346) 13-1/8 (333) 10-1/4 (260) 5-1/4 (133) 30 (762) 30 (762) 30-3/8 (772) 30-3/8 (772) 30-3/8 (772) 30-3/8 (772) Connection Size / Opening, inches (mm) 3-1/2 x 8 (89 x 203) 3-1/2 x 8 (89 x 203) 6 x 17-3/16 (152 x 437) 2-1/8 Cu Sweat 2-1/8 Cu Sweat 3/4 FPT 1/2 Cu Sweat 1/4 Cu Sweat 2-5/8 Cu Sweat 2-5/8 Cu Sweat 2-1/2 2-1/2 7/8 7/8 7/8 7/8

CGD*

* 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.

123

Checklist for Completed Installation

11.0 CHECKLIST FOR COMPLETED INSTALLATION

11.1 Moving and Placing Equipment
___ 1. Unpack and check received material. ___ 2. Proper clearance for service access has been maintained around the equipment. ___ 3. Equipment is level and mounting fasteners are tight. ___ 4. If the equipment has been disassembled for installation, unit must be reassembled per instructions.

11.2

Electrical
___ 1. Supply voltage and phase matches equipment nameplate. ___ 2. 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 equipment. ___ 5. All internal 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. ___ 11. For units with variable speed drive (VSD) operating on Delta-connected power, ensure that the EMC filter has been disconnected; see 8.1 - Variable Speed Drive for details. ___ 12. Check for loose electrical connections on steam generating humidifier. Confirm that electrode plugs are pressed firmly onto the electrode pins.

11.3

Piping
___ 1. Piping completed to refrigerant or coolant loop (if required). ___ 2. Piping has been leak-checked, evacuated and charged (if required). ___ 3. Additional oil has been added for system charges over 40 pounds (18.1kg) per circuit (see 9.2.2 - Scroll and Digital ScrollAdditional Oil Requirements. ___ 4. Piping is properly sized, sloped and trapped as shown in the piping schematics ___ 5. Check piping inside and outside of equipment for proper supportand adequate spacing to prevent rub-through. ___ 6. Ensure TXV equalizer lines and sensing bulb lines have sufficient clearance and do not rub against other refrigerant lines. ___ 7. Ensure that factory clamps have been reinstalled. ___ 8. Drain line connected and pitched per local code. ___ 9. Water supply line connected to humidifier.

124

Checklist for Completed Installation

11.4

Other
___ 1. Ducting complete (if required), maintain access to filters. ___ 2. Filters installed. ___ 3. Check fasteners that secure compressors, reheats, humidifier and motorssome 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-Hermetic Compressor Spring Isolation System). ___ 8. Remove rubber band from float in optional infrared humidifier. ___ 9. Seal openings around piping and electrical connections. ___ 10. Installation materials and tools have been removed from equipment (literature, shipping materials, construction materials, tools, etc.). ___ 11. Locate blank startup sheet, ready for completion by installer or startup technician.

125

Initial Startup Checks and Commissioning Procedure for Warranty Inspection

12.0 INITIAL STARTUP CHECKS AND COMMISSIONING PROCEDURE FOR WARRANTY INSPECTION

! WARNING Can cause injury or death Risk of electric shock.

Disconnect local and remote power supplies before working within. Before proceeding with installation, read all instructions, verify that all the parts are included and check the nameplate to be sure the voltage matches available utility power. Follow all local codes.

! WARNING piping, moving, lifting and/or handling. Can cause equipment Risk of improper wiring,
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 in this manual.

! WARNING and alarm system activation. Can cause injury during building Risk of fire suppression
evacuation and mobilization of emergency fire and rescue services. Startup operation of optional electric reheat elements may activate facility alarm and fire suppression system. Prepare and take appropriate steps to manage this possibility. Activating reheat during initial startup may burn off particulates from electric reheat elements. Check the steam generating humidifier electrode plugs to ensure that they are pressed firmly onto the pins. Loose connections will cause the cylinder and plugs to overheat. 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.

NOTICE
Risk of improper electrical connection of three-phase input power. Can cause unit damage. Service technicians should use a gauge set on the Liebert DS system during the initial startup to verify that the three-phase power is connected properly. The EC fans are not a reliable indicator of proper connection. The blowers will rotate the same direction, regardless of the three-phase power input. Confirm that all items on 11.0 - 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). Forward the completed Liebert DS Warranty Inspection Check Sheet to your local Emerson sales office. This information must be completed and forwarded to Emerson to validate warranty. 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 procedures includes the following steps. These steps must be completed to validate warranty.

126

Initial Startup Checks and Commissioning Procedure for Warranty Inspection

12.1

Information for Warranty InspectionRemove Power From Unit Disconnect

Complete the following items on the warranty inspection form: Installer name and address Owner name and address Site contact name and phone number Installation date Indoor unit model number and serial number Outdoor unit (condenser or drycooler) model number and serial number Condition of unit when received Is there a freight damage claim in process? If so, have all relevant parties been notified? Have manuals been kept with unit? Is the Liebert Precision Cooling unit connected to site monitoring or switchover controls? Provide model and serial of connected controls for switchover controls.

12.2

Startup Checks With Panels Removed and Main Disconnect Off

___ 1. Check all internal piping clamps and tighten or secure if needed. ___ 2. Check field piping for proper support and proper connection. ___ 3. Check unit belts for correct tension and alignment. ___ 4. Check unit electrical connections, including and Mate N Loc connections to the control boards, and tighten or secure if needed. ___ 5. Remove all debris, tools and documents from unit area.

12.2.1 Inspect and Record

Main Fan hp: _________________________ Voltage: _________________________ Proper Belt Tension and Alignment: _________________________ Belt Size: _________________________ Motor Sheave: _________________________ Fan Pulley: _________________________ EC Plug Fan: Assemblies Tight and Secured (check one) ___ Fan secured in UP position ___ Fan secured in Down position Filter Size: _________________________ Quantity: _________________________ Piping Size (Air Cooled Only) Discharge: _________________________ Liquid: _________________________ ___ Piping trapped according to installation manual (air cooled) Total Equivalent Length for Discharge and Liquid Piping: _________________________ #1 Compressor Model #: _________________________ #1 Compressor Serial #: _________________________ #2 Compressor Model #: _________________________ #2 Compressor Serial #: _________________________

127

Initial Startup Checks and Commissioning Procedure for Warranty Inspection

12.3

Startup
1. Turn On the Main Disconnect. 2. Check voltage at disconnect and record. L1-L2 _________________ L2-L3 _________________ L1-L3 _________________ 3. Check control voltage transformers for proper output. Secondary voltage(s) should not exceed 27VAC under load. Change tap if necessary. T1 __________ Volts. 4. Check fan rotation for proper direction. Change wiring at contactor if necessary. 5. Service technicians should use a gauge set on the Liebert DS system during the initial startup to verify that the three-phase power is connected properly. The rotation direction of EC blowers is not a reliable indicator of proper connection. The blowers will rotate the same direction, regardless of the three-phase power input. 6. Check Main Fan amps and record. L1 _____________ L2 _____________ L3 _____________ Fuse _____________ 7. Increase temperature setpoint to energize reheats. Check and record amperage. #1 _____________ #2 _____________ #3 _____________ Fuse _____________ 8. Increase humidity setpoint to energize humidifier. Check and record amperage L1-L2 _________________ L2-L3 _________________ L1-L3 _________________ 9. Infrared: Check water level and adjust high limit float for proper operation. 10. If condensate pump has been supplied, check for proper operation. 11. Chilled water and Econ-O-Coil (GLYCOOL) only: a. Decrease temperature setpoint to energize valve motor. Check for full valve travel in cooling mode. b. Adjust controls out of cooling mode. Check for valve closure. 12. Decrease humidity setpoint to call for dehumidification. Check for valve travel in dehumidification mode. 13. Decrease temperature setpoint to energize compressor(s). Check and record compressor amps. #1 L1 _____________ L2 _____________ L3 _____________ Fuse _____________ #2 L1 _____________ L2 _____________ L3 _____________ 14. Check compressor operating pressure and record. (Check digital compressors fully loaded position.) Suction Pressure 1 ___________________ 2 ___________________ Discharge Pressure 1 ___________________ 2 ___________________ 15. Sight Glass clear? 1 ___________________ 2 ___________________ some flashing may occur with system fluctuations and/or R-407c blend refrigerants 16. Sight Glass dry? 1 ___________________ 2 ___________________ 17. Check compressor oil sight glass , should be 1/2 to 3/4 full while running. Adjust accordingly. 18. Check superheat on each circuit. Should be approximately 10-25. Circuit 1 _____________ Circuit 2 _____________ 19. Check low pressure settings. Low pressure cutout 1 _____________ 2 _____________ Low pressure cut in 1 _____________ 2 _____________ 20. Winter Control System (air-cooled only) Liebert Lee-Temp liquid level correct ___________________ Record voltage to heater pads _______________Volts 21. If the head pressures recorded above equal 105F condensing temperature, no adjustment of the glycol/water regulating valves is required If the system has balancing valves in it, these valves also should be adjusted. After the condensing temperature has been set up properly, the system should be allowed to run for 10 to 15 minutes to obtain stable conditions. Entering condenser water/glycol temperature ____________________ Leaving condenser water/glycol temperature _____________________

128

Initial Startup Checks and Commissioning Procedure for Warranty Inspection

12.4

Commissioning Procedure With Panels On

1. Disconnect all power to the environmental control unit and check. 2. Remove all line voltage fuses except the main fan fuses and the control voltage fuses in the electric panel. (Use Liebert iCOM to activate loads.) 3. Turn On power to the unit and check line voltage on main unit disconnect switch. Line voltage must be within 10% of nameplate voltage. 4. 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 the On lamp will light. 6. Check fan rotation if not correct make necessary changes to the line side of the unit disconnect with power Off. (The unit is phased at the factory.) 7. 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 and the deadband. The user menu may be used to set alarms and other control functions. Refer to the Liebert iCOM user manual, SL-18835, for large or small display operation and settings.

NOTICE
Risk of improper operation. Can cause damage to equipment. Do not change Advanced Menu parameter settings in the Liebert iCom without first getting permission from Emerson Network Power Liebert Services. Lowering this parameter to less than 100% will cause the coil to freeze on DX units, will overheat the reheat components on any unit and cause condensation problems on any unit equipped with a humidifier. 8. 9. 10. 11. 12. 13. 14. Turn Off the unit with the On/Off button. Remove power from main unit disconnect and main breaker and check with a meter. Replace all fuses removed in Step 2. Restore power to the unit. Turn On the main unit disconnect switch. Press the On button. Check and record the current draw on all line voltage components and match with serial tag. NOTE Electric Reheat. See Warning on page 126. Activate for a minimum of five (5) minutes. 15. Check for unusual noises and vibration. Note observations on the warranty inspection forms comments section. 16. Check all refrigerant and water lines for leaks. Note observations on warranty inspection form. 17. 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 subcooling. NOTE Unit superheat should be in the range of 10 to 20F (-12 to -6C). 18. Test all control sequences and functions of your unit for proper operation. Use Liebert iCOM user manual as a guide to system control operations. 19. 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 Precision Cooling product support.

129

Maintenance

13.0 MAINTENANCE

! WARNING Can cause injury or death. Risk of electric shock.

Disconnect local and remote power supplies before working within. Before proceeding with installation, read all instructions, verify that all the parts are included and check the nameplate to be sure the voltage matches available utility power. Follow all local codes.

! WARNING piping, moving, lifting and handling. Can cause equipment damage, Risk of improper wiring,
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

NOTICE
Risk of improper operation. Can cause damage to equipment. Do not change Advanced Menu parameter settings in the Liebert iCom without first getting permission from Emerson Network Power Liebert Service. Lowering this parameter to less than 100% will cause the coil to freeze on DX units, will overheat the reheat components on any unit and cause condensation problems on any unit equipped with a humidifier. 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, drycoolers, cooling towers, piping, heat rejection fluid, ambient temperature, etc.) and indoor cooling and humidity loads (equipment load, location, outside air infiltration). Proper application and maintenance 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 based on site-specific conditions. See the Liebert iCOM user manual, SL-18835, for instructions on how to utilize the unit controller to predict some service maintenance intervals. Emerson recommends the use of trained and authorized service personnel, extended service contracts and factory-specified replacement parts. Contact your local Emerson representative.

130

Maintenance

13.1

Filters

NOTICE
Risk of improper filter installation and filter collapse. Can cause equipment damage. Pleat direction is non-standard. Use only short-pleat filters (see Figure 97). Long-pleat filters are subject to collapse at high airflows. To maximize the performance and reliability of Liebert DS equipment, use only Liebert filters. Contact your local Emerson representative to order replacement filters. Table 59 Filter quantities, downflow units
Filter Quantities Unit Size DS 028, 035, 042 DS 053, 070, 077 DS 105 16 x 25 Filter Size Width x Length 4" Filter Option Merv 8 or Merv 11 5 7 9 2" Primary / 2" Pre-Filter Option Merv 11 Primary Filter / Merv 7 Pre-Filter 5/5 7/7 9/9

Table 60

Filter quantities, upflow units

Filter Quantities Filter Size Width x Length 25 x 20" 2" Primary/2" Pre-Filter Option Merv 11 Primary/Merv 7 Pre-Filter 4/4 6/6 8/8

Upflow Models VS025, 035, 042 VS053, 070, 077 VS105

4" Filter Option Merv 8 or Merv 11 4 6 8

131

Maintenance

13.1.1 Filter Replacement ProcedureDownflow Units

1. Disconnect power from the Liebert DS. 2. Using a stepladder, remove filters from the top of the unit. The optional downflow return air plenum includes a filter access door. 3. Replace with new filtersinstall the filters in the proper direction of the airflow (see Figure 97). 4. Test the operation of the filter clog switch. The unit panels must be in place and closed to find this point. 5. Start the blower and turn the switch counterclockwise until the alarm is energized. 6. Turn the adjusting knob one turn clockwise or to the desired filter change point.

13.1.2 Filter Replacement ProcedureUpflow Units

1. Disconnect power from the Liebert DS. 2. 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 filter rack and tilt forward for removal. For upflow rear return units, remove filters using filter access door in rear return filter box. 3. Replace with new filtersinstall the filters in the proper direction of the airflow (see Figure 97). 4. Test the operation of the filter clog switch. The unit panels must be in place and closed to find this point. 5. Start the blower and turn the switch counterclockwise until the alarm is energized. 6. Turn the adjusting knob one turn clockwise or to the desired filter change point. Figure 97 Proper filter pleat direction
16" (406mm)

Do Not Use

25" (635mm)

Short Pleat Construction

The filter pleat direction should run parallel to the direction of the short side of the filter , as shown above . Do NOT use long pleat filter construction , as shown at right above , because it can result in filter collapse .

Long Pleat Construction DPN000994 Rev. 0

13.2

Blower Drive SystemCentrifugal Fans

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 150.

! WARNINGpinching action from spring-loaded motor base. Can cause serious injury Risk of crushing and
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.
132

Maintenance

13.2.1 Upflow Motor Access

1. Remove the lateral support (sheet metal channel) under electric box by removing two screws at each end. 2. Removed the hinged deadfront panel (30-ton units have open access to the motor). 3. Remove two screws on the right side of the low-voltage electric box that secure the low volt electric box to the sheet metal shoulder. 4. Swing open low-voltage electric box to gain access to the motor. Figure 98 Upflow motor access
Hinge

Deadfront Low Voltage Electric Box Screws Lateral Support DPN001221 Rev. 0

Screws

13.2.2 Belt Removal

1. Disconnect power to unit. Do not pry the belts off sheave or pulley. 2. Refer to instruction labels on unit near motor base. 3. Turn adjustment nut (see Figure 99) counterclockwise (left) to loosen belts and bring motor base internal spring out of compression. 4. Remove belts.

133

Maintenance

13.2.3 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. 2. Ensure pulley grooves are properly aligned. If adjustment is required, loosen (do not remove) four nuts in adjustment slots (see Figure 99) holding motor base to unit frame and slide motor base assembly into alignment. 3. Tension belts by turning adjustment nut clockwise (right) until motor base carriage stops moving downward. 4. Ensure minimum 1/2" (12.7mm) clearance exists from motor base carriage to base front flange (see Figure 99). If the clearance is less than 1/2" (12.7mm), select shorter belts. 5. Mark the adjustment nut and rotate clockwise (right) five additional full turns. This sets internal spring for proper belt tension, no readjustments necessary. Figure 99 Auto-belt tensioning motor base

Spring Housing

Motor Base Carriage

Minimum 1/2 (13mm) Gap

Motor Plate Adjustment Slot

Adjustment Nut

DPN000995 Rev. 0

Blower Bearing Maintenance

Field lubrication is NOT required for the life of the bearing. Bearings are permanently sealed and self-lubricating and cannot be greased.

Blower Bearing Inspection

1. 2. 3. 4. 5. Disconnect power to unit. Remove drive belts (see 13.2.2 - Belt Removal). Inspect bearing for tightness of set screws and mounting bolts. Rotate fan wheel by hand. Listen for unusual noise and look for signs of unusual play.

Blower Bearing Replacement

1. 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 manufacturers instructions.

134

Maintenance

Blower Motor
Inspect motor at regular intervals. Keep motor clean and ventilation openings clear of dust, dirt and other debris.

Blower Motor Lubrication

Motor 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.

13.2.4 Electronic Variable Speed Drive - Inverter

On Liebert DS models with digital scroll, an optional, variable speed drive is available. This packaged unit is factory-set and should not require field adjustment.

Removing VSD from Liebert DS

1. Turn off power at the unit disconnect. 2. Remove the front right panel. 3. Remove the VSD subassembly from the unit shoulder (downflow) or from the unit floor (upflow). To find the inverter in downflow units, see Figure 1; refer to Figure 2 for the inverters location in upflow units. 4. Remove the VSD sheet metal cover from the VSD subassembly. 5. Label the wires from the VSD, then disconnect the wires from the VSD junction box. 6. Remove the VSD from the sheet metal bracket. 7. Install the new VSD on the sheet metal bracket. 8. Reconnect wires to the VSD. 9. Reinstall the VSD sheet metal cover. 10. Re-mount the VSD on the unit shoulder or on the unit floor. 11. Reinstall the right panel. 12. Engage power to the unit disconnect.

13.3

Blower Drive SystemEC Fans

Fan impellers should be periodically inspected and any debris removed. Check to ensure that the impellers can rotate freely and that the fan guards are still properly mounted for sufficient protection against accidentally contacting the impeller. Bearings used on the units are maintenance-free. Consult the factory for more information.

13.3.1 Fan Impellers and Bearings

13.3.2 Protective Features

Monitoring functions protect the motor against overtemperature of electronics, overtemperature of motor and incorrect rotor position detection. With any of these failures, an alarm will display through the Liebert iCOM and the motor stops electronically. There is no automatic restart. The power must be switched off for a minimum of 20 seconds once the motor is at a standstill. The motor also provides locked rotor protection, undervoltage/phase failure detection and motor current limitation. These conditions will display an alarm through the Liebert iCOM.

! WARNING Can cause injury or death. Risk of electric shock.

Disconnect all local and remote electrical power supplies before working within the unit. When connecting the motor to input power, dangerous voltages occur. Do not open the motor within the first 5 minutes after disconnection of all phases.

135

Maintenance

! WARNING Can cause injury or death. Risk of electric shock.

Dangerous external voltages can be present at main fan terminal KL2 even after the motor has been turned off.

! WARNING Can cause injury. Risk of improper handling.

Use proper skin protection when touching the electronics housing or allow time for the housing to cool before replacing parts. The electronics housing can get hot and can cause severe burns

! CAUTION lifting and handling. Can cause equipment damage or injury. Risk of improper moving,
Only properly trained and qualified personnel should work on this equipment. Fan modules weigh in excess of 100lb. (45kg) each. Take precautions to avoid back injury and dropping during removal.

NOTICE
Risk of improper installation. Can cause equipment damage. Only a properly trained and qualified technician should install or open this motor. Use 60/75C copper wire only. Use Class 1 wires only.

13.4

HumidifierInfrared
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 maintenance (see Liebert iCOM user manual SL-18835 for autoflush setup). To help reduce excessive scaling in locations with difficult water quality, the use of Vapure is recommended (contact your local Emerson representative).

13.4.1 Cleaning Humidifier Pan and Float Switch

Before turning off unit: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. With unit operating, remove call for humidification at the Liebert iCOM control. Let the blower operate 5 minutes to allow the humidifier and water to cool. If unit has a condensate pump, turn unit OFF at Liebert iCOM control. Pull out the humidifier standpipe in pan. Inspect the O-ring (replace if necessary). Let the pan drain and condensate pump operate (if applicable). Disconnect power from the unit. Disconnect the drain coupling from the bottom of the pan. Remove the thermostat from the bottom of the pan and the retaining screws from the sides of the pan. Slide the pan out. Loosen scale on side and bottom of pan with a stiff nylon brush or plastic scraper. Flush with water. Carefully clean scale off float switch (make sure to reinstall correctly (see Figure 100). Reinstall the pan, thermostat, standpipe, drain coupling and screws into the humidifier. Operate the humidifier and check for leaks.

136

Maintenance

Figure 100Correct orientation of float switch

Correct Switch Orientation

Incorrect Switch Orientation

DPN000996 Rev. 0

13.4.2 Changing Humidifier Lamps

NOTE Touching quartz lamps with bare hands will severely shorten bulb life. Skin oils create hot spots on lamp surface. Wear clean cotton gloves when handling lamps. 1. Remove humidifier pan (see 13.4.1 - Cleaning Humidifier Pan and Float Switch, Steps 1 through 10). 2. Disconnect power from unit. 3. At humidifier, remove screws and cover from high-voltage compartment. 4. Disconnect one end of purple jumper wires. 5. Using a continuity meter, locate burned out lamp. 6. Remove lamp brackets under lamps. 7. Loosen two screws securing lamp lead wires to junction block. 8. Pull bulb straight down and discard. 9. Wrap lead wires once around new lamps metal ends. This will support lamp and allow for thermal expansion. Insert lead wires into junction block and torque screws to 30 in-lb. 10. Reassemble by reversing Steps 1 through 9. Figure 101Infrared humidifier lamps
Infrared Bulbs

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Maintenance

13.5

HumidifierSteam Generating
The humidifier drains and refills to maintain a current setpoint and alert the operator when the humidifier canister needs to be replaced.

Figure 102Steam generating humidifier canister

13.5.1 Replacing the Steam Generating Humidifier Canister

! WARNING Can cause injury or death. Risk of electric shock.

Disconnect local and remote power supplies before working within. Before proceeding with installation, read all instructions, verify that all the parts are included and check the nameplate to be sure the voltage matches available utility power. Follow all local codes.

! WARNING piping, moving, lifting and handling. Can cause equipment damage, Risk of improper wiring,
injury or death. Only properly trained and 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.

! WARNING equipment damage, injury or death. Risk of fire. Can cause

Do not ignore humidifier problem alarms. Resetting humidifier without addressing cause may result in fire or damage due to leaking water. See Table 62, for alarm corrective actions. After an extended period of operation, in accordance with life expectancy information, the cylinder is completely used as indicated by the amber high water sensor light illuminated on the cabinet. When this condition is reached, a new replacement cylinder is to be installed. NOTE The amber high water sensor light may come on during initial startup but this instance does not indicate that the cylinder should be replaced.

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Maintenance

The steam cylinder is disposable and must be replaced at the end of the cylinders life. Cylinder life will vary according to water supply conditions and humidifier usage.

! WARNING meltdown, smoke and fire. Can cause fire suppression system Risk of humidifier canister

activation, fire and smoke alarm activation, serious equipment and building damage, injury and death. Using a humidifier canister that has reached the end of its service life can be extremely hazardous. If the canister cannot be replaced immediately at the end of life condition, turn Off the power and water supply to the humidifier and remove the canister until a replacement canister can be installed.

Table 61
Unit Model DS 028-042 DS 053-105

Humidifier canister part numbers

200V, 208V, 230V 163814P1 163814P1 380/415V, 460V, 575V 163814P4 163814P2 Humidifier Model MES 10 MES 20

Removing the Old Canister

To replace a used-up humidifier cylinder, refer to Figure 103 and perform these steps: 1. Turn off the water supply to unit. 2. The old cylinder must be drained completely before removing. This is done by pushing the auto on/off/drain switch to the Drain position. 3. When completely drained, push the auto on/off/drain switch to the Off position. 4. Open the main electrical disconnect during the entire cylinder change operation. 5. The power wires to the cylinder are attached by cylinder plugs to the electrode pins on top of the cylinder. Pull up to remove the plugs from the pins. 6. Use slotted screwdriver to loosen the steam hose clamp(s) 7. Disconnect the steam hose by pulling it straight up. 8. Loosen reversible cylinder zip tie. 9. The cylinder is now ready to be lifted out of the unit. Figure 103Removing the old canister

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Maintenance

Mandatory Cleaning of the Drain Valve

Always clean the drain valve before installing a new cylinder. Figure 104 shows an exploded view of the drain valve for reference to clean it. 1. Remove old cylinder as previously described. 2. Note that the ring terminal for the drain valve green ground wire is sandwiched between the drain valve and the drain pan. 3. Remove the two screws securing the drain valve body to the drain pan. 4. Remove the hose clip and hose connection from the drain valve body. 5. Drain valve assembly is now free to be taken to a sink for disassembly and cleaning. 6. Remove the snap fit red cap from the coil assembly and slide the coil off the actuator. 7. Loosen actuator using a wrench and unscrew from the plastic body. 8. Clean the exposed core, spring and plastic drain valve pot 9. Reinstall in the reverse order. NOTE Be cautious when putting the spring back into the plunger, the taper end of the spring must be installed toward the solenoid. 10. Hand tighten the actuator back into place, then secure it by using a wrench to turn it a quarter of a turn. 11. Clean out the end of the hose, then reconnect it to the drain valve body with the clamp. 12. Fit mounting screws back through the drain valve body, one through ring terminal on the green wire. Figure 104Drain valve assembly

Actuator Plunger Spring Sleeve Male Slip-On Connection Tabs Holding Coil

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Maintenance

Installing the New Canister

1. The reverse procedure should be followed to install a new cylinder. The main electrical disconnect is to be left open until the cylinder is completely installed and reconnected. 2. The blue sensor plug on all units is for the high water sensor pin, which always goes on the single pin with collar offset from the others. See Figure 105. 3. Ensure that cylinder plugs are snug on the pins. Replace any loose fitting plugs as these may result in hazardous operation. Figure 105Canister plugs

High Water Sensor Pin Cylinder Pin

3O Cylinder Pin

Cylinder Pin

! WARNING meltdown, smoke and fire. Can cause fire suppression system Risk of humidifier canister

activation, fire and smoke alarm activation, equipment or serious building damage, injury and death. Check steam generating humidifier electrode plugs to ensure that they are pressed firmly onto pins. Loose connections will cause overheating of cylinder and plugs..

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Maintenance

Table 62
Yellow

Steam generating humidifier status lamps: causes, corrective action

Green Symptom Maximum water level inside cylinder. Corrective Actions This usually happens on initial startup after replacing the cylinder (normal). Water is concentrated with minerals inside the cylinder. Let unit run, yellow light will disappear when the unit is at full output. This may take a day or two. Check for main power supply fault. Turn power switch to DRAIN position. If drain valve is activated (sound of solenoid), check connection to the board or board itself. When no sound present, check fuse (replace with 3A, if needed), transformer (voltage should be present between fuse holder and ground screw). Check drain valve operation, drain time, possible drain restrictions. Check if fill valve leaks (not holding supply water). Back-pressure may also cause very conductive water conditions. Check for short cycling. Water conductivity too high. Check water level in the cylinder - should be more than one-quarter full. If it is not, check the fill rate, 24VAC voltage on fill valve terminals (unit must be on with call for humidity - green light steady on). Verify fresh water supply to the humidifier. Leaking drain valve can be at fault (minerals blocking the plunger). If cylinder is more than full, check primary power, connections to the cylinder, continuity of wires to cylinder. Are power wires connected to proper terminals on the cylinder? (Color coding) Low water conductivity. Check L1 to ensure that power is properly connected. Check that L1 wire runs through CT of main PCB. Cylinder may be defective, check for conductivity between powered pins and H.W.S. (should be an opened circuit). Ensure all legs are drawing similar current. Low water conductivity. Are power wires connected to proper terminals on the cylinder? (Color coding). Foaming. Check water level in the cylinder; it should be about three-fourths full. Check for foaming if water level lower or cylinder life shorter than expected. Change cylinder, clean drain valve.

Unit Status Lamp

On

On

Off

Off

No power to the board.

One flash sequence

Off

Excess current. Operating amperage exceeded 130% of rated amps. Water is drained from the cylinder (drain valve on for 10 min.).

Two flashes in sequence

Off

No current detection for 30 minutes with continuous call for humidity.

Three flashes in sequence

Off

No current detected with high water sensor activated.

Four flashes in sequence

Off

End of cylinder life; change cylinder.

Table 63

Steam generating humidifier troubleshooting guide

Symptom Possible Cause Humidifier not receiving power No water available to unit Clogged fill line strainer Drain valve clogged or defective Improper water supply Check or Remedy Verify ON/OFF/DRAIN switch is in ON position. Check fuses or CB's and replace or reset if necessary. Check external water shut-off valves. Clean or replaced fill line strainer Verify that drain valve operates freely when activated. Clean valve and replace if defective. Flush canister several times and replace if arcing persists. If water is commercially softened, reconnect humidifier to raw water supply, drain canister and restart. If connected to hot water supply, reconnect to cold water. Verify that drain valve operates freely when activated. Clean valve and replace if defective. Flush canister several times and replace if arcing persists. Analyze mineral content of water. If mineral content is excessive contact Liebert service. 142

Unit in call for humidification, humidifier will not operate Humidifier Contactor pulled in, but no water enters canister

Excessive arcing in canister Insufficient drain rate Excessive mineral content in water

Maintenance

Figure 106Circuit board diagram

PCB is configured for: MES-L

To configure the PCB to the proper voltage, the jumpers should be set as follows: (* = Factory setting; do not adjust)
200V/208V: 230V: 380V/415V: 460V: 575V: J6, J9, J15*, J17*, J19*, J10*, J23*, P11 pin (2-3)* J5, J9, J15*, J17*, J19*, J10*, J23*, P11 pin (2-3)* J3, J8, J15*, J17*, J19*, J10*, J23*, P11 pin (2-3)* J2, J8, J15*, J17*, J19*, J10*, J23*, P11 pin (2-3)* J1, J8, J15*, J17*, J19*, J10*, J23*, P11 pin (2-3)*

J8 J9

J19 J20 J21 J22

Current Transformer

HW Sensor Jumpers J9: Low Voltage 200-240V J8: High Voltage 380-600V P11
J24
P12 1

Capacity adjust (Default at 100%) Sealed, do not adjust CURRENT TRANSFORMER For MES-L 10, loop current-sensing wire twice through current-sensing coil.

1
J1 J2 J3 J4 J5 J6 J7 J18 J17 J16 J15 J14 J13 J12 J11

J25

J26

Mains Voltage Select Jumpers J6: 200-208 J5: 230V J3: 380-415 J2: 460V J1: 575V
J10

Green LED For MES-L 20, loop current-sensing wire once Yellow through current-sensing coil. LED

J23

13.6

Condensate Drain and Condensate Pump Systems

Check and clear obstructions in tubing during routine maintenance.

13.6.1 Condensate Drain 13.6.2 Condensate Pump

Disconnect power to unit using disconnect switch.

! WARNING Can cause injury or death. Risk of electric shock.

The Liebert 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 the Liebert 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.

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Maintenance

13.7

Air-Cooled Condenser and Drycoolers

Clear coil surface of all debris that will inhibit airflow. Check for bent or damaged coil fins and correct. Do not permit snow to accumulate around or under outdoor unit. Periodically consider commercial cleaning of coil surface Inspect fans, motors and controls for proper operation. Check all piping and capillaries for proper support. Inspect for leaks.

13.8

ReheatElectric Reheat (Three-Stage and SCR)

Inspect and clean reheat elements. Inspect and tighten support hardware.

13.9

Thermostatic Expansion Valve

The Thermostatic Expansion Valve (TEV) performs one function: It keeps the evaporator supplied with enough refrigerant to satisfy load conditions. It does not effect compressor operation. Proper valve operation can be determined by measuring superheat. The correct superheat setting is between 10 and 20F (-12 and -6C). If too little refrigerant is being fed to the evaporator, the superheat will be high; if too much refrigerant is being supplied, the superheat will be low.

13.9.1 Determine Suction Superheat

To determine superheat: 1. 2. 3. 4. 5. Measure the temperature of the suction line at the point the TEV bulb is clamped. Obtain the gauge pressure at the compressor suction valve. Add the estimated pressure drop between the bulbs location and the suction valve. Convert the sum of the two pressures to the equivalent temperature. Subtract this temperature from the actual suction line temperature. The difference is superheat.

13.9.2 Adjust Superheat Setting with the TEV

To adjust the superheat setting: 1. Remove the valve cap at the bottom of the valve. 2. Turn the adjusting stem counterclockwise to lower the superheat. 3. Turn the adjusting stem clockwise to increase the superheat. NOTE Make no more than one turn of the stem at a time. As long as thirty minutes may be required for the new balance to take place.

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Maintenance

13.10 Compressor
13.10.1Compressor Oil

NOTICE
Risk of improper compressor lubrication. Can cause compressor and refrigerant system damage. Failure to use oil types, viscosities and quantities recommended by the compressor manufacturer may reduce compressor life and void the compressor warranty. See oil types specified in Table 64. 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 64 Compressor oil types
Refrigerant Type Compressor Type Carlyle Semi-Hermetic Copeland Scroll and Digital Scroll R-22 Mineral Oil 1 R-407c POE Oil - ISO 68 Viscosity 2

POE Oil - ISO 32 Viscosity 3

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 32-3MAF or other Copeland-approved oils.

13.10.2Semi-Hermetic Compressors
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.

13.10.3Scroll and Digital Scroll Compressors

Hermetic scroll and digital scroll compressors do not have an oil sight glass. NOTE Refer to 9.2.2 - Scroll and Digital ScrollAdditional Oil Requirements for approved oil types and additional oil required based on the systems refrigerant charge.

13.11 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 Application (LSCA) with the compressor that is being returned. The original compressor should be returned in the same packaging.

13.11.1Compressor 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.

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Maintenance

13.11.2Digital Compressor Unloading Solenoid(s) Models 028, 035 and 042

When replacing a digital scroll compressor, digital solenoid valve and coil must be replaced. Compressor and valve kit are shipped separately. Valve kit must be field-brazed to top of compressor in proper orientation and supported with original factory bracket.

Models 053, 070 and 077

When replacing a digital scroll compressor, digital solenoid coil must be replaced. Compressor and coil kit are shipped separately.

13.11.3Compressor Replacement Procedure

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 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. Remove marked pressure transducer and discharge pressure switch. Disconnect all electrical connections. Detach service valves from compressor. Remove failed compressor. If required, follow compressor manufacturers suggested clean-out procedures. Install replacement compressor and make all connections. Replace gaskets or seals on service valves. Replace unloading solenoid. Evacuate, charge and operate per 9.3 - Dehydration/Leak Test and Charging Procedures for R-407C and R-22. Semi-hermetic only: see 5.3 - Semi-Hermetic Compressor Spring Isolation System for compressor spring adjustment.

NOTICE
Risk of improper component reinstallation. Can cause equipment damage. Identify and mark location of suction pressure transducer and discharge pressure switch. These devices look similar and they must be reinstalled in their original location.

13.12 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 maintenance 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 9.1.4 Requirements of Systems Using Water or Glycol.

13.13 ParadenserWater-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 13.12 - Facility Fluid and Piping Maintenance.

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Maintenance

13.13.1 Cleaning Instructions

Refer to Figure 1 - Downflow model component locations. 1. Disconnect power to unit. 2. Close field-installed isolation valves to isolate this units 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 out 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: 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 85). 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.

13.14 Water/Glycol Control Valves

13.14.1Regulating 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, balance spring, valve seat, valve disc holders, capillary tube to discharge pressure, and adjusting screw.

AdjustmentJohnson Controls/Penn Johnson Valves

The valves may be adjusted with a standard refrigeration service valve wrench or screwdriver. Table 65 Recommended refrigerant pressures
PSIG (kPa) System Design Water-Cooled 65 to 75F water (18 to 24C) 85F water (29C) Glycol-Cooled Maximum High Pressure Cut-out 210 (1450) 225 (1550) 295 (2035) 330 (2275) 400 (2859)

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 counterclockwise until the desired setting is obtained. Consult the factory if your unit is equipped with valves from other manufacturers.

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Maintenance

Testing Function of Valve

First, turn off the refrigeration system. When the refrigeration system has been off for approximately 10 to 15 minutes, the water flow should stop. If the water continues to flow, the valve is either improperly adjusted (with head pressure too low) or the pressure-sensing capillary is not connected properly to the condenser.

Location
The water regulating valves are located in the condenser fluid supply line.

13.14.2Motor Ball ValveDigital Scroll Compressors

On digital scroll units discharge pressure is controlled by a motorized ball 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 signal. 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 similar to the pressure adjustment on a water regulating valve. Changing the setpoint offset will adjust the pressure thresholds 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 10oF (5.6oC) (see 13.14.3 - 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 MBVs through the Service menu using manual mode to override the normal control.

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Maintenance

13.14.3Drycooler Settings
Applications with the Optional Stat Setting require field piping to be insulated to prevent condensation. Table 66 shows acceptable applications where stats must be adjusted to Optional Setting. Aquastats must be field-adjusted to Optional Setting for: GLYCOOL/Dual Cool applications Single Drycooler loops with motor ball valve flow controls (motor ball valves are used on all Liebert DS units with digital compressors). These units have a D or G in the seventh character: DS/VS/xxxxD or DS/VS/xxxxG. Table 66 Water/glycol system conditions requiring optional settings for aquastats
Glycool MBV 1 Optional Yes Multiple Optional Yes 1 Optional Yes WRV Multiple Optional Yes 1 Optional Yes MBV Multiple Factory No 1 Factory No Glycol WRV Multiple Factory No Cooling Type Flow Control Drycoolers in Loop Stat Setting* Insulate Field Piping

* See Tables 67 through 69 MBV=motor ball valve; WRV=water regulating valve

Table 67

Aquastat settingstwo-fan through four-fan drycoolers

Dial Setting (Stat Open Temp) Set for Mid Differential 8F (4.4C) Rise to Close Factory Setting (Glycol) (see Notes 1 and 2) 65F (18.3C) 75F (23.9C) 70F (21.1C) Optional Setting (GLYCOOL) (see Note 3) 35F (1.7C) 45F (7.2C) 40F (4.4C)

Aquastat # AQ1 AQ2 AQ3

Fans F1 F2 & F3 F4

Table 68

Aquastat settingssix-fan drycoolers

Dial Setting (Stat Open Temp) Set for Mid Differential 8F (4.4C) Rise to Close Stat Location Cabinet Main Main Auxiliary Auxiliary Factory Setting (Glycol) (see Notes 1 and 2) 65F (18.3C) 70F (21.1C) 73F (22.8C) 75F (23.9C) Optional Setting (GLYCOOL) (see Note 3) 35F (1.7C) 40F (4.4C) 43F (6.1C) 45F (7.2C)

Aquastat # AQ1 AQ2 AQ3 AQ4

Fans F1 F2 F3 & F4 F5 & F6

Table 69

Aquastat settingseight-fan drycoolers

Dial Setting (Stat Open Temp) Set for Mid Differential 8F (4.4C) Rise to Close Stat Location Cabinet Main Main Auxiliary Auxiliary Main Factory Setting (Glycol) (see Notes 1 and 2) 65F (18.3C) 70F (21.1C) 73F (22.8C) 75F (23.9C) 78F (25.6C) Optional Setting (GLYCOOL) (see Note 3) 35F (1.7C) 40F (4.4C) 43F (6.1C) 45F (7.2C) 48F (8.9C)

Aquastat # AQ1 AQ2 AQ3 AQ4 AQ5

Fans F1 F2 F3 & F4 F5 & F6 F7 & F8

NOTE 1. 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.
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HVAC Maintenance Checklist

14.0 HVAC MAINTENANCE CHECKLIST

Inspection Date Indoor Unit Model # Condenser/Drycooler Model # Room Temperature/Humidity Job Name Indoor Unit Serial Number # Condenser/Drycooler Serial # % Ambient Temperature

Filters
___ 1. Check/replace filters ___ 2. Grille area unrestricted ___ 3. Wipe section clean ___ 4. Coil clean

Blower Section
___ 1. Blower wheels free of debris ___ 2. Check belt tension and condition (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. #3

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 the fill 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 ___ 2. Check/clean pan for mineral deposits ___ 3. Clean reflector ___ 4. Check water make-up valve for leaks ___ 5. Check humidifier lamps (replace if burnt out) ___ 6. Check wire connections (inside humidifier box) ___ 7. Humidifier amp draw L1 ______________ L2 _______________L3 __________________

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HVAC Maintenance Checklist

Condensate Pump
___ 1. Check for debris in sump ___ 2. Check operation of float(s) (free movement)

Refrigeration Piping
___ 1. Check refrigerant lines (clamps secure/no rubbing/no leaks) ___ 2. Check for moisture (sight glass)

Water-Cooled Condensers
___ 1. Check water regulating valve operation ___ 2. Cap tubes (not rubbing) ___ 3. Check for water/glycol leaks ___ 4. Entering water temperature ______________ ___ 5. Leaving water

Drain Piping
___ 1. Check for free running drain system ___ 2. Clear out obstructions and material buildup on tubing walls ___ 3. Check for leaks ___ 4. Check for tubing kinks or damage

Compressor Section
___ 1. Check oil level ___ 2. Check for oil leaks ___ 3. Check compressor mounts (springs/bushings) ___ 4. Cap tubes (not rubbing) ___ 5. Check wire connections (inside compressor box) ___ 6. Compressor operation (vibration/noise) ___ 7. Suction Pressure ___ 9. Superheat ___ 11. Low pressure cut in ___ 12. High pressure cut out ___ 13. Amp draw ____ Circuit #1 ___ a. L1 L2 L3 ____ Circuit #2 ___ a. L1 L2 L3 Circuit #1 __________________ Circuit #2 ______________________ Circuit #1 __________________ Circuit #2 ______________________ Circuit #1 ______________Circuit #2__________________ Circuit #1 ______________Circuit #2__________________ Circuit #1 ______________Circuit #2__________________ ___ 8. Discharge Pressure Circuit #1 __________________ Circuit #2 ______________________ ___ 10. Low pressure switch cut out

Electrical Panel
___ 1. Check fuses ___ 2. Check contactors for pitting ___ 3. Check wire connections

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HVAC Maintenance Checklist

Controls
___ 1. Check/Verify Control Operation (Sequence) ___ 2. Check humidifier high water alarm operation ___ 3. Check operation of the air safety switch ___ 4. Check setting/operation of the filter clog switch ___ 5. Check/test changeover device(s) ___ 6. Check/test water detection device(s)

Air-Cooled Condenser / Drycooler

___ 1. Coil surfaces and fans free of debris (clean, wash and straighten fins as needed) ___ 2. Fan motors securely mounted ___ 3. Motor bearings in good condition ___ 4. Check all piping and capillaries for vibration isolation; support and secure as necessary ___ 5. Check fuses ___ 6. Check contactors for pitting ___ 7. Check wire connections ___ 8. Fan speed control operation ___ 9. Check operational sequence/thermostat setpoints ___ 10. Check refrigerant/glycol lines for signs of leaks/repair leaks as found ___ 11. Check refrigerant level in each Liebert Lee-Temp receiver ___ 12. Glycol level ___ 13. Glycol solution___________________________ % ___ 14. Motor amp draw
#1 #2 #3 #4 #5 #6 #7 #8 L1 L1 L1 L1 L1 L1 L1 L1 L2 L2 L2 L2 L2 L2 L2 L2 L3 L3 L3 L3 L3 L3 L3 L3

(L1 and L2 on Fan Speed Control Motor)

Glycol Pump
___ 1. Check pump rotation ___ 2. Check for glycol leaks ___ 3. Pump pressures
#1 #2 Suction Suction Discharge Discharge

___ 4. Amp Draw

#1 #2 L1 L1 L2 L2 L3 L3

___ 5. Pump changeover (if multiple pumps)

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HVAC Maintenance Checklist

Maintenance Notes___________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ ____________________________________________________________________________________________ Signature ___________________________________________________________________________________ Company ____________________________________________________________________________________ Make photocopies for your records. Compare readings / information to previous maintenance worksheet. To locate your local Emerson representative for Liebert-engineered parts, check the Liebert Web site: www.liebert.com or call 1-800-LIEBERT.
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HVAC Maintenance Checklist

NOTES

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HVAC Maintenance Checklist

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HVAC Maintenance Checklist

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COMPLIANCE WITH EUROPEAN UNION DIRECTIVES

Liebert Corporation 1050 Dearborn Drive P.O. Box 29186 Columbus, OH 43229 USA

IlProduttoredichiarache,semunitodimarchioCE,ilprodottoconformealledirettivedell'Unione europea: TheManufacturerherebydeclaresthatthisproduct,whenbearingtheCEmark,conformstothe EuropeanUniondirectives: DerHerstellererklrthiermit,dassdasvorliegendeProdukt,sollteesdieCEKennzeichnungtragen,den folgendenRichtlinienderEuropischenUnionentspricht: Lefabricantdclareparlaprsentequeceproduit,portantlamarqueCE,estconformeauxdirectives del'Unioneuropenne: ElfabricantedeclaraporlapresentequesiesteproductollevaelmarcadoCEesconformeconlas directivasdelaUninEuropea: Ofabricantedeclaraporestemeioqueesteproduto,quandoostentaamarcaCE,estem conformidadecomasdirectivasdaUnioEuropeia: Tillverkarentillknnagerhrmedattdenhrprodukten,nrdenrCEmrkt,verensstmmermed EU:sdirektiv: Defabrikantverklaarthierbijdatditproduct,indienhetvandeCEmarkeringisvoorzien,conformde EUrichtlijnenis: Valmistajavakuuttaatten,ettmiklituotteessaonCEmerkint,setyttseuraavienEUdirektiivien vaatimukset: Produsentenerklrerhervedatdetteproduktet,nrdeterCEmerket,erisamsvarmedEUdirektiver: Producentenerklrerhermed,atdetteproduktoverholderEU'sdirektiver,nrdetbrerCEmrket: ,CE, ..:
2006/42/EC; 2004/108/EC; 2006/95/EC; 97/23/EC

Ensuring The High Availability Of Mission-Critical Data And Applications.

Emerson Network Power, a business of Emerson (NYSE:EMR), is the global leader in enabling Business-Critical Continuity from grid to chip for telecommunication networks, data centers, health care and industrial facilities. Emerson Network Power provides innovative solutions and expertise in areas including AC and DC power and precision cooling systems, embedded computing and power, integrated racks and enclosures, power switching and controls, infrastructure management, and connectivity. All solutions are supported globally by local Emerson Network Power service technicians. Liebert AC power, precision cooling and monitoring products and services from Emerson Network Power deliver Efficiency Without Compromise by helping customers optimize their data center infrastructure to reduce costs and deliver high availability.

Technical Support / Service

Web Site www.liebert.com Monitoring liebert.monitoring@emerson.com 800-222-5877 Outside North America: +00800 1155 4499 Single-Phase UPS & Server Cabinets liebert.upstech@emerson.com 800-222-5877 Outside North America: +00800 1155 4499 Three-Phase UPS & Power Systems 800-543-2378 Outside North America: 614-841-6598 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 9719 111 Fax: +39 049 5841 257 Asia 29/F, The Orient Square Building F. Ortigas Jr. Road, Ortigas Center Pasig City 1605 Philippines +63 2 687 6615 Fax: +63 2 730 9572

While every precaution has been taken to ensure the accuracy and completeness of this literature, Liebert Corporation assumes no responsibility and disclaims all liability for damages resulting from use of this information or for any errors or omissions. 2008 Liebert Corporation All rights reserved throughout the world. Specifications subject to change without notice. Liebert is a registered trademark of Liebert Corporation. All names referred to are trademarks or registered trademarks of their respective owners.

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Emerson, Business-Critical Continuity, Emerson Network Power and the Emerson Network Power logo are trademarks of Emerson Electric Co. or one of its affiliated companies. 2008 Emerson Electric Co.