ENVIRONMENTAL PROTECTION

10 Fan Drycooler/Fluid Cooler

INCLUDING QUIET-LINE MODELS USER MANUAL

120 to 150 Tons 50 & 60 Hz

PRODUCT MODEL INFORMATION

Table i Model Number Designation
D 0 H X 1 5 0 D = Drycooler 0 = Standard 10 Fan Motor Type No. of Pumps Controlled Unit Control Nominal Capacity (Tons of Heat Rejection Capacity) G = Quiet-Line 10 Fan T = TEAO 10 Fan H = 0 Pumps T = Fan Cycling X = Fan Cycling w/Current Sensing 150 = 150 Tons, 60 & 50 Hz 120 = 120 Tons, 60 Hz Quiet-Line A = 460-3-60 B = 575-3-60 Voltage-Phase-Hz A C = 208-3-60 D = 230-3-60 M = 380/415-3-50 N = None Coil Guard G G = Wire A = Aluminum Coil Circuiting 1 3 6 068 = Number of Coil Circuits (Half) 136 = Number of Coil Circuits (Full) 272 = Number of Coil Circuits (Double) A = Aluminum Coil Type A C = Phenolic Coated P = Polycoated Fin U = Cu/Cu Model Type

NOTE To ensure optimum performance and safe operation of this system, each person responsible for the installation, operation and maintenance of this unit must read and carefully follow the instructions in this manual.

TABLE OF CONTENTS
PRODUCT MODEL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSIDE FRONT COVER 1.0
1.1 1.2

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
System Description and Standard Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Optional Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2.0
2.1 2.2 2.3 2.4

PRODUCT PERFORMANCE DATA & SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Standard Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Typical Application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Engineering Data, Calculations and Selection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Selection Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

3.0
3.1 3.2 3.3 3.4 3.5 3.6

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Location Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Site Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Equipment Inspection (Upon Receipt) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Handling, Lifting the Drycooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.4.1 3.5.1 3.6.1 3.6.2 3.6.3 Unit Weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Expansion Tanks, Fluid Relief Valves and Other Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Preparing the System for Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Glycol Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Filling the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Line Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Low Voltage Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Piping Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Filling Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.7

Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.7.1 3.7.2

3.8

Checklist for Completing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

4.0
4.1

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Initial Startup Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.1.1 4.1.2 4.1.3 Control Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Current Sensing Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Cold Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

5.0
5.1 5.2

SYSTEM MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
General Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Special Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.2.1 5.2.2 Drycooler Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Maintenance Inspection Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

6.0

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

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 Typical application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Capacity correction factor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Pressure drop correction factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Clearance considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Unit dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Rigging instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Typical piping diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Piping Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Electrical Field Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Typical low volt wiring diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Fluid temperature controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Current sensing relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

TABLES
Table 1 Table 2 Table 3 Table 4 Table 5 Table 6 Table 7 Table 8 Table 9 Table 10 Table 11 Drycooler performance data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Drycooler performance data per circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Drycooler performance data per circuitmetric. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Maximum Liebert evaporator units per every 10 Fan Drycooler. . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Specific heats for aqueous ethylene glycol solutions (Cv) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Altitude correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Electrical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Piping specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Volume in standard Type L copper piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Ethylene glycol concentrations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Control settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

ii

Introduction

1.0
1.1

INTRODUCTION
System Description and Standard Features
The 10 Fan Drycooler/Fluid Cooler is designed for maximum heat rejection with minimum footprint and to be used with glycol solutions for large site installations. It has a nominal range of 150 tons of heat rejection and is ideal for rejecting the heat of multiple evaporator units. Standard features include: Three different coil circuits: 068 (half), 136 (full), 272 (double). Each coil circuit is designed for a range of specific flow rates based on the particular application. Coil constructed of copper tubes in a staggered pattern expanded into continuous corrugated aluminum fins. The fins have full depth fin collars completely covering the copper tubes which are connected to heavy-wall type L headers. Inlet coil connector tubes pass through relieved holes in the tube sheet for maximum resistance to piping strain and vibration. Coil maximum operating pressure is 150 PSIG (1035 kPa). Wire guards constructed of coated wire, in 1" x 4" pattern, mounted to protect the exposed vertical coil surface. Current sensing relays are provided with customer connection to monitor change in motor current to detect possible motor/fan failure. Choice of either 60 or 50 Hz models as well as a Quiet-Line 60 Hz; comes from the factory completely assembled and pre-wired. Units are available in 208, 230, 460 and 575 Volts, 3-phase, 60 Hz, and 380/415 Volts, 3-phase, 50 Hz. Locking disconnect switch and fan cycling control. Unit frame of heavy galvanized steel for strength and corrosion resistance, divided internally into individual fan sections by full-width baffles to prevent fan reverse windmilling when not energized.

1.2

Optional Features
Quiet-Line
The Quiet-Line 10 Fan Drycooler includes the same features as the standard 10 Fan Drycooler, except that it has 8 pole motors in lieu of 6 pole motors for lower sound levels as well as reduced airflow and capacity. This option is not available on 50 Hz units.

Aluminum Grilles
Aluminum grilles are used for unit aesthetic and general mechanical security purposes. The aluminum grilles extend from the base of the unit and protect the exposed coil sides.

Coil Fin Options

Pre-Coated Fin Stock provides pre-coated coil fins for added protection in corrosive environments. Phenolic Coated Coil provides a baked phenolic coated coil for added protection in corrosive environments. Copper Fin/Copper Tube Coil provides coil constructed of copper fins and copper tubes.

Enclosed Motor Option

TEAO motors are totally enclosed and are used in industrial applications. They are not available for Quiet-Line, or 575 Volt models.

Ancillary Items
Tanks for fluid expansion, pumps, pump control panels, flow switches, shut off valves and relief valves should also be considered for the site/installation. Since these items are custom-sized per application, please consult with your sales representative for selection.

Introduction

Figure 1

Typical application

Refer to Figure 7 for a detailed installation diagram.

Product Performance Data & Selection

2.0
2.1
Table 1

PRODUCT PERFORMANCE DATA & SELECTION

Standard Data
Drycooler performance data
Total Heat Rejection* @25F (13.9C) ITD No. & No. & Size of Size of Air Flow No. of Connec- Connec- No. Ft of of tions Internal tions kW gpm lps Water kPa Circuits (inlet) (outlet) Fans cfm cmh Flow Rate Pressure Drop
136 8.6 27.2 81.2 68 136 272 68 136 272 68 136 272 2@2.625 2@2.625 2@4.125 2@4.125 2@4.125 2@4.125 2@2.625 2@2.625 2@4.125 2@4.125 2@4.125 2@4.125 2@2.625 2@2.625 2@4.125 2@4.125 2@4.125 2@4.125 10 10 10 10 10 10 10 10 10 74160 126000 74160 126000 74160 126000 99030 168250 99030 168250 99030 168250 82450 140080 82450 140080 82450 140080

Internal Shipping Sound Volume Weight dBA** Gal

65 65 65 72 72 72 68 68 68

Model No. Hz
120 60

Btu/h
1,172,000 1,447,000 1,579,000

Lbs

Kg

343 424 463 377 499 564 357 452 499

92.8 351 5100 2313 92.8 351 5100 2313 92.8 351 5100 2313 92.8 351 5100 2313 92.8 351 5100 2313 92.8 351 5100 2313 92.8 351 5100 2313 92.8 351 5100 2313 92.8 351 5100 2313

272 17.2 15.8 47.1 544 34.3 15.1 45.1 136 8.6 27.3 81.5

150

60

1,287,000 1,703,000 1,924,000

272 17.2 15.8 47.1 544 34.3 15.1 45.1 136 8.6 27.3 81.5

150

50

1,218,000 1,541,000 1,703,000

272 17.2 15.8 47.1 544 34.3 15.1 45.1

* Ratings based on using 40% ethylene glycol @ 95F (35C) entering air, 120F (48.9C) entering glycol; 2 gpm (.13 l/s) circ. ** Sound data is for sound pressure measured @ 5 ft. (1.5m) height, 30 ft.(9.1 m) from the unit.

Table 2

Drycooler performance data per circuit

Heat Rejection per ITD* (Btu/h/F) Flow Rate per Circuit (gpm/circuit) 1 29,507 45,829 56,201 30,144 50,346 65,785 29,791 47,617 59,756 1.5 39,991 53,713 60,785 42,440 61,660 73,118 41,011 56,724 65,257 2 46,972 57,917 63,153 51,621 68,219 77,019 48,823 61,728 68,146 Pressure Drop* (ft of water) Flow Rate per Circuit (gpm/circuit) 1 8.2 5 4 8.2 5 4 8.2 5 4 1.5 16.1 9.2 8.7 16.1 9.2 8.7 16.1 9.2 8.7 2 27.3 23.7 15.1 27.3 23.7 15.1 27.3 23.7 15.1

No. of Flow Rate Range Model Internal min-max No. Hz Circuits gpm 120 60 68 136 272 68 136 272 68 136 272 68-136 136-340 272-544 68-136 136-340 272-544 68-136 136-340 272-544

150

60

150

50

* Data is based on 40% ethylene glycol solution at 115F (46.1C) average solution temperature expressed in Btu/h.

Table 3

Drycooler performance data per circuitmetric

Heat Rejection per ITD* (kW/C) Pressure Drop* (kPa) Flow Rate per Circuit (lps/circuit) 0.06 24.5 14.9 11.9 24.5 14.9 11.9 24.5 14.9 11.9 0.09 48.0 27.5 26.0 48.0 27.5 26.0 48.0 27.5 26.0 0.13 81.5 70.7 45.1 81.5 70.7 45.1 81.5 70.7 45.1 No. of Internal Circuits 68 136 272 Flow Rate Range min-max lps 6-13 13-26 26-38 6-13 13-26 26-38 6-13 13-26 26-38 Flow Rate per Circuit (lps/circuit) 0.06 23.9 30.8 30.7 24.9 36.0 37.9 24.4 32.8 33.3 0.09 29.8 31.9 30.6 33.1 39.1 38.4 31.1 34.6 33.4 0.13 32.1 32.0 30.5 37.5 39.8 39.0 34.2 34.7 33.3

Model No. 120

Hz 60

150

60

68 136 272

150

50

68 136 272

* Data is based on 40% ethylene glycol solution at 46.1C (115F) average solution temperature expressed in kW.

Product Performance Data & Selection

2.2

Typical Application
The most popular use for the 10 Fan Drycooler is at sites with large cooling loads, such as data center/ telecom sites where multiple indoor air conditioners are used. See Table 4 for general outline of suggested quantity of indoor units for each 10 Fan Drycooler or contact your Liebert representative for custom match up. Figure 1 illustrates typical application. Table 4 Maximum Liebert evaporator units per every 10 Fan Drycooler
Liebert Deluxe Unit Capacity 8 tons (28.1 kW) Maximum Deluxe Units/10 Fan Drycooler 12 110 G (111 G) 9 6 10 116 G (121 G) 10 tons (35.2 kW) 7 5 7 192 G 15 tons (52.7 kW) 5 4 6 240 G 20 tons (70.3 kW) 4 3 4 363 G 30 tons (105 kW) 3 2 Total System Outdoor Ambient Rating 95F (35C) 100F (37.8C) 105F (40.6C) 95F (35C) 100F (37.8C) 105F (40.6C) 95F (35C) 100F (37.8C) 105F (40.6C) 95F (35C) 100F (37.8C) 105F (40.6C) 95F (35C) 100F (37.8C) 105F (40.6C) Drycooler1 Model # D*N*150**272 D*N*150**136 D*N*150**272 D*N*150**136 D*N*150**272 D*N*150**136 D*N*150**272 D*N*150**136 D*N*150**272 D*N*150**136

Liebert Deluxe Model 60 Hz (50 Hz)

gpm 384 288 192 380 266 190 378 270 216 402 268 201 312 234 156

(lps) (24.2) (18.2) (12.1) (24.0) (16.8) (12.0) (23.8) (17.0) (13.6) (25.4) (16.9) (12.7) (19.7) (14.8) (9.8)

1. Ratings based on using 40% ethylene glycol @ listed outdoor ambient rating temperature, 120F (48.9C) entering glycol. Selections are valid for standard or TEAO motors. Consult your local Liebert representative for Quiet-Line selections.

2.3

Engineering Data, Calculations and Selection Procedure

An alternate, detailed procedure is available to calculate values and select the correct the 10 Fan Drycooler(s) for the application. This can be used to assist in selecting drycoolers for applications for ambient conditions that are not standard. Use the following steps. 1. Determine the following items to begin this procedure: Design outdoor ambient air temperature, Toa (F or C) Fluid Flow Rate, VT (gpm or lps) % ethylene glycol concentration Fluid temperatures at drycooler: Entering, Tef and leaving Tlf (F or C), or Total Required Heat Rejection, QRT (Btu/h or kW) and one of the fluid temperatures above 2. Find the following values using these equations and known values above: Initial Temperature Difference (ITD) of entering fluid to outdoor design air, ITD = Tef - Toa Total Required Heat Rejection, QRT = VT * cv * (Tef - Tlf), where cv is found in Table 5, or Leaving fluid temperature, Tlf = Tef - QRT / (VT * cv) where cv is found in Table 5. 3. Find the Average Fluid Temperature, Tf,avg = (Tef + Tlf) / 2 4. Find Required Heat Rejection per ITD, QRITD = QRT / (ITD * f), where f is the capacity correction factor found in Figure 2.

Product Performance Data & Selection

5. Using Table 2 columns titled Flow Rate Range and Heat Rejection per ITD, choose the Drycooler Model matching application fluid flow rate and meeting/exceeding the required Heat Rejection per ITD, QRITD from Step 4. 6. Find the Flow Rate per Circuit, VC = VT / circuits for the drycooler selected in Table 2. This should be in the range of 1.0 to 2.0 gpm/circuit (0.06 to 0.13 lps/circuit) for proper long-term performance. 7. In Table 2, for the selected Model Number, find the Actual Heat Rejection per ITD using the gpm/circuit from Step 6. You may interpolate between columns as required. The Actual Heat Rejection should be equal to or greater than per ITD, QRITD (higher altitude application sites should use Table 6 correction factors to reduce Actual Heat Rejection results). If it is less, repeat process from Step 5 using a larger model. If 10 Fan Drycooler solution is oversized, lower capacity drycoolers are available and may be considered as an alternative solution. 8. Calculate the Total Actual Heat Rejection, QA, for the drycooler, using the Actual Heat Rejection per ITD (Step 7) and actual ITD and correcting for % glycol and AFT (see Figure 2). QA = QAITD * ITD * f 9. After selecting a model, look up the units Pressure Drop in Table 2. Multiply this pressure drop by the correction factor found in Figure 3. If the resulting pressure drop is higher than your system design, go back to Step 5 and select a model with more circuits or consider multiple units. Contact your sales representative for additional design assistance. 10. Electrical data for model selected is found in Table 7. Table 5 Specific heats for aqueous ethylene glycol solutions (Cv)
0% 500 4.18 10% 490 4.09 20% 480 4.01 30% 470 3.93 40% 450 3.76 50% 433 3.62

% Ethylene Glycol Btu/h/gpmF kW/lpsC

Table 6

Altitude correction
0 (0) 1.000 1000 (305) 0.979 2000 (610) 0.960 5000 (1525) 0.900 8000 (2440) 0.841 12000 (3660) 0.762 15000 (4575) 0.703

Altitude - Feet (M) Correction Factor

Figure 2

Capacity correction factor

Glycol % and Average Temperature

Correction Factor 80 (26.7)

100 (37.8)

120 (48.9)

140 (60)

160 F (71.1) C

Average Fluid Temperature

Product Performance Data & Selection

Figure 3

Pressure drop correction factor

Glycol % and Fluid Temperature

Correction Factor 80 (26.7)

100 (37.8)

120 (48.9)

140 (60)

160 F (71.1) C

Average Fluid Temperature

Table 7

Electrical specifications
VoltagePhase 60 Hz 50 Hz

208-3 230-3 460-3 575-3 380/415-3 Drycooler Model Motor Type FLA MCA OPD FLA MCA OPD FLA MCA OPD FLA MCA OPD FLA MCA OPD D0N*150 DTN*150 DGN*120 STANDARD 70 TEAO QuietLine 70 48 72 72 50 90 90 60 70 70 48 72 72 50 90 90 60 35 35 24 36 36 25 45 45 30 28 n/a 28 30 n/a 30 35 n/a 35 35 n/a 24 36 32 25 40 35 30

Product Performance Data & Selection

2.4

Selection Example
For the following example, English (I-P) units will be used. Metric units are also provided in the tables and figures. Find a drycooler to cool 340 gpm of 20% ethylene glycol/water solution from 125F to 115F. Application is located near sea level and has an outdoor design air temperature of 95F. 1. Assume the following values: Toa = 95F VT = 340 gpm 20% ethylene glycol Tef = 125F Tlf = 115F 2. Initial temperature difference, ITD = Tef - Toa = 125 - 95 = 30F Since Tef is known, calculate Total Required Heat Rejection, QRT = VT * cv * (Tef - Tlf) Using Table 5, cv = 480 for 20% ethylene glycol. QRT = 340 gpm * 480 Btu/h / gpmF * (125F - 115F) = 1,632,000 Btu/h 3. Average Fluid Temperature, Tf,avg = (Tef + Tlf) / 2 = 125F + 115F) / 2 = 120F 4. Required Heat Rejection per ITD, QRITD = QRT / (ITD * f), where f is found from Figure 2. Using Figure 2, f = 1.04 for 120F and 20% EG concentration. QRITD = 1,632,000 Btu/h / (30F * 1.04) = 52,300 Btu/h / F 5. Locate Model Number(s) in Table 2, matching flow rate of 340 gpm and meeting or exceeding 52,300 Btu/h / F. Either Model 120 with 272 circuits or the Model 150 with 272 circuits matches the flow rate requirements and meets or exceeds the Required Heat Rejection per ITD. For this example, Model 150 will be chosen to complete the procedure. 6. Flow rate per circuit, VC = VT / circuits = 340 gpm / 272 circuits = 1.25 gpm/circuit. This is within the 1.0 to 2.0 gpm/circuit range. 7. Using Table 2, the actual Heat Rejection per ITD, QAITD for Model 150 with 272 circuits @ 1.25 gpm/circuit is 69,526 Btu/h / F, which exceeds our Required Heat Rejection per ITD of 52,300 Btu/h / F. No correction for altitude is required. 8. Total Actual Heat Rejection for the drycooler, QA = QAITD * ITD * f, where f is found in Figure 2. QA = 69,526 Btu/h / F * 30F * 1.04 = 2,169,211 Btu/h 9. Pressure drop for 1.25 gpm/circuit is 6.25 ft., water using Table 2 for 40% ethylene glycol and Tf,avg = 115F. Use Figure 3 to find correction factor for the pressure drop for 20% ethylene glycol and Tf,avg = 120 F. Therefore, the pressure drop will be 6.259 * 0.93 = 5.8 ft., water. 10. Using Table 7 and Drycooler Model D0N*150 with a 460 VAC, 3-phase, 60 Hz motor, the electrical requirements will be FLA = 31 amps, WSA = 32 amps and OPD = 35 amps.

Installation

3.0

INSTALLATION
!

CAUTION

Follow all unit dimensional drawings carefully. Determine whether any building alterations are required to run piping and wiring. Also refer to the submittal engineering dimensional drawings.

3.1

Location Considerations
The drycooler should be located for maximum security and maintenance accessibility. Avoid ground level sites with public access or areas which contribute to heavy snow or ice accumulations. To assure an adequate air supply, it is recommended that drycoolers be located in a clean air area, away from loose dirt and foreign matter that may clog the coil. In addition, drycoolers must not be located in the vicinity of steam, hot air, or fume exhausts. The unit may be mounted either at ground level or on a roof, given proper structural support and following a review of local codes. Pit installations are not recommended. Air re-circulation will severely affect unit and/or system performance. For these same reasons, units should not be installed closer than 72" (1829 mm) from a wall. This clearance should be increased to 96" (2438 mm) in corner wall situations. In multiple unit installations, units should not be installed closer than 72" (1829 mm) end to end or 96" (2438 mm) side to side. For further details, see Figure 4.

Installation

Figure 4

Clearance considerations

Single Pit See Note 2

Double Pit See Note 2

Installation

3.2

Site Preparation
Drycoolers should be installed in a level position to assure proper venting and drainage. This space should have all services (electrical, drain, water) in close proximity. Also, the space should be level and free of loose gravel, sand, flooring or roofing. For roof installation, mount drycoolers on steel supports in accordance with local codes. To minimize sound and vibration transmission, mount steel supports across load-bearing walls. For ground installations, a concrete pad is sufficient to carry the load. The base should be at least 2 inches (51 mm) higher than the surrounding grade and 2 inches (51 mm) larger than the dimensions of the unit base. The drycooler base has mounting holes for securing the drycooler once installed. See Figure 5.

Figure 5

Unit dimensions

Air Flow Side and Bottom

183.94

93.11 88.07

93.11

6.0

85.7 20.50

Lifting Holes 94.0 216.0

Lifting Holes 94.0

Unit Anchor 85.75 Plan

82.75

0.69 Mounting Hole 6 places 1.50

20.50

86.0

103.5

6.0

10

Installation

3.3

Equipment Inspection (Upon Receipt)

When the 10 Fan Drycooler arrives, inspect it for any visible or concealed damage. Do not accept a damaged unit from the shipper! NOTE Any damage caused in transit must be reported immediately to the carrier and a damage claim filed with a copy sent to your sales representative. Failure to do so may result in an inability to recover costs for damage. Before removing the drycooler from the truck/container, review the previous section, 3.2 - Site Preparation.

CAUTION

If the drycooler is not installed immediately upon receipt, special storage precautions should be taken. It is recommended that the unit be stored in a dry, heated place. Do not store the unit at temperatures less that 36F (2.2C). If the storage temperature is below 36F (2.2C), water vapor can condense in the coil, freeze and cause permanent damage. Failure to store unit properly will void the warranty.

3.4

Handling, Lifting the Drycooler

!

WARNING

Do not unload the drycooler with a forklift. The drycoolers high center of gravity makes it a tip hazard. Further, tilted forks may damage the drycooler. When removing the unit from the truck and when moving the unit between areas of equal height, use chains and hooks.

Riggers are required to lift the unit into place. Refer to Figure 6 for lift locations. Any time the unit is lifted, use slings or chains (with spreader bars) attached to the three lifting eyes on either side of the unit base. Do not allow any part of the lifting apparatus to bear against the coil fins. All lifting apparatus must also clear the fan guards on the top of the unit.

3.4.1

Unit Weight
Dry weight of the unit is 5100 pounds (2313 kg).

WARNING

To avoid a tilt hazard, adjustment may be necessary to locate the center of gravity prior to lifting the UNIT.

11

Installation

Figure 6

Rigging instructions
LIFT LIFT SPREADER BAR MUST CLEAR TOP OF FAN GRILLES

2 7/8" REMOVABLE CHAIN PULLS (73 mm) (2 PLACES)

5 29/32" (150 mm)

94 3/32" (2390 mm)

94 3/32" (2390 mm)

3" (76 mm) DIAMETER LIFTING HOLES

MUST USE 2" NOMINAL PIPE THRU UNIT FOR SLINGS TO AVOID BASE DAMAGE. (DO NOT USE SMALL HOLES IN LEGS FOR RIGGING THESE UNITS.)

3.5

Piping Connections
See Figure 7 for a typical piping diagram. See Figure 8 piping locations.

CAUTION

To avoid the possibility of burst pipes, it is necessary to install a relief valve in the system. This valve may be obtained from your supplier as an option or may be sourced from another vendor. Galvanized pipe must not be used in glycol systems. To help prevent piping failures, supply and return lines must be supported such that their weight does not bear on the piping of the unit or pumps. NOTE Units are shipped pressurized with a 30 psig dry air holding charge.

It is recommended that manual service shut-off valves be installed at the supply and return connections to each unit. This enables routine service and/or emergency isolation of the unit. In addition, multiple pump packages require a check valve at the discharge of each pump to prevent back flow through the standby pump(s). It is further recommended that filters/strainers (that can be easily replaced or cleaned, with 16-20 mesh screen) be placed in the supply line. These filters extend the service life of the drycooler and the systems pumps. To facilitate filling, installation of hose bibs at the lowest point of the system is recommended. Consideration of the minimum glycol temperature to be supplied from the drycooler will determine if the need exists to insulate the glycol supply and return lines. Insulation will prevent condensation on the glycol lines in low ambient conditions. All fluid piping must comply with local codes. Care in sizing pipes will help reduce pumping power and operating costs.

12

Installation

3.5.1

Expansion Tanks, Fluid Relief Valves and Other Devices

An expansion tank must be provided for expansion and contraction of the fluid due to temperature change in this closed system. Vents are required at system high points to vent trapped air when filling the system. A relief valve is also a necessary piping component. Depending on the complexity of the system, various other devices may be specified. Pressure gauges, flow switches, automatic air separator, tempering valves, standby pumps and sensors for electrical controls are just a few of these devices.

Immediately following the use of water for leak testing or system cleaning, charge the tested system with the proper percentage of glycol and water for your coldest design ambient. Complete system drain-down cannot be assured and damage to the system could result from freezing of residual water.

CAUTION

13

Installation

Figure 7

Typical piping diagram

14

Installation

Figure 8

Piping dimensions

B A
69" (1753 mm) OUTLET 52" 51" TYP. (1295mm) (1321 mm) INLET TYP.

B A

15 1/4" (387 mm) OUTLET

22-1/4" 24 3/4" (566mm) (629 mm) INLET

61 1/4" (1556 mm) INLET 70 3/4" (1797 mm) OUTLET

Drycoolers
Table 8
Model D0N*150** DTN*150** DGN*120**

Piping specifications
No. of Internal Circuits 68 136 272 2 2 No. of Inlets (A) No. of Outlets (B) Connection Sizes, Inlet and Outlet OD (in.) * 2.625 4.125 92.8 (351) Coil Internal Volume, Gal. (l)

*Cut off closed end of connection tube; connect couplings and elbows as required.

Table 9
Outside 1-3/8 1-5/8 2-1/8 2-5/8 3-1/8 3-5/8 4-1/8

Volume in standard Type L copper piping

Volume gal/ft 0.065 0.092 0.161 0.248 0.354 0.479 0.622 l/m 0.81 1.15 2.00 3.08 4.40 5.95 7.73 Inside 1.265 1.505 1.985 2.465 2.945 3.425 3.905

Diameter (in.)

15

Installation

3.6
3.6.1

Filling Instructions
Preparing the System for Filling
It is important to remove any dirt, oil or metal filings that may contaminate the cooling system piping in order to prevent contamination of the fresh glycol solution and fouling of the drycooler piping. The system should be flushed thoroughly using a mild cleaning solution or high-quality water and then completely drained before charging with glycol. Cleaning new systems is just as important as cleaning old ones. New systems can be coated with oil or a protective film; dirt and scale are also common. Any residual contaminants could adversely affect the heat transfer stability and performance of your system. In many cases, in both old and new systems, special cleaners are needed to remove scale, rust and hydrocarbon foulants from pipes, manifolds and passages. Clean heat transfer surfaces are important in maintaining the integrity of the heating/cooling system. For more information on cleaners and degreasers, contact your sales representative. Follow the manufacturers instructions when using these products. Calculate the internal volume of the system as closely as possible. The 10 Fan Drycooler volume, not including the load or field-supplied piping, is 92.8 gallons (351 l). Use Table 9 for field-installed piping volumes.

3.6.2

Glycol Solutions
NOTE Glycol solutions should be considered for the protection of the coil. When glycol solutions are not used, damage can occur either from freezing or from corrosion from water. When considering the use of any glycol products in a particular application, you should review the latest Material Safety Data Sheets and ensure that the use you intend can be accomplished safely. For Material Safety Data Sheets and other product safety information, contact the supplier nearest you. Before handling any other products mentioned in the text, you should obtain available product safety information and take necessary steps to ensure safety of use.

Not

When mishandled, glycol products pose a threat to the environment. Before using any glycol products, review the latest Material Safety Data Sheets and ensure that you can use the product safely. Glycol manufacturers request that the customer read, understand and comply with the information on the product packaging and in the current Material Safety Data Sheets. Make this information available to anyone responsible for operation, maintenance and repair of the drycooler and related equipment.

CAUTION

No chemical should be used as or in a food, drug, medical device, or cosmetic, or in a product or process in which it may contact a food, drug, medical device, or cosmetic until the user has determined the suitability and legality of the use. Since government regulations and use conditions are subject to change, it is the user's responsibility to determine that this information is appropriate and suitable under current, applicable laws and regulations.

CAUTION

Automotive antifreeze is unacceptable and must NOT be used.

Typical inhibited formula ethylene glycol and propylene glycol manufacturers and suppliers are Union Carbide (Ucartherm) and Dow Chemical (Dowtherm SR-1, Dowfrost). These glycols are supplied with corrosion inhibitors and do not contain a silicone anti-leak formula. Commercial ethylene glycol, when pure, is generally less corrosive to the common metals of construction than water itself. Aqueous solutions of these glycols, however, assume the corrosivity of the water from which they are prepared and may become increasingly corrosive with use when not properly inhibited.

16

Installation

There are two basic types of additives: Corrosion inhibitors and Environmental stabilizers The corrosion inhibitors function by forming a surface barrier that protects the metals from attack. Environmental stabilizers, while not corrosion inhibitors in the strictest sense of the word, decrease corrosion by stabilizing or favorably altering the overall environment. An alkaline buffer, such as borax, is a simple example of an environmental stabilizer, since its prime purpose is to maintain an alkaline condition (pH above 7). The percentage of glycol to water must be determined by using the lowest design outdoor temperature in which the system is operating. Table 10 indicates the solution freeze point at several c concentration levels of ethylene glycol. Propylene glycol concentrations should be 1% higher than ethylene glycol table values to find the freeze point. For example, 41% propylene glycol freezes at -10F. Table 10 Ethylene glycol concentrations
0* 32 (0) 1 10 25 (-3.9) 1.014 20 16 (-8.9) 1.028 30 5 (-15.0) 1.042 40 -10 (-23.3) 1.057 50 -32 (-35.5) 1.071

% Glycol by Volume Freezing Point F (C) Apparent Specific Gravity @ 50F (10C)

* A minimal amount of glycol should be considered for inhibitive coil protection.

CAUTION

The quality of water used for dilution must be considered because water may contain corrosive elements that reduce the effectiveness of the inhibited formulation. Surface water that is classified as soft (low in chloride and sulfate ion contentless than 100 ppm each) should be used.

3.6.3

Filling the System

Installation of hose bibs at the lowest point of the system is recommended. When filling a glycol system keep air to a minimum. Air in glycol turns to foam and is difficult and time-consuming to remove. (Anti-foam additives are available and may be considered.) Open all operating systems to the loop. With the top vent(s) open, fill the system from the bottom of the loop. This will allow the glycol to push the air out of the top of the system, minimizing trapped air. Fill to approximately 80% of calculated capacity. Fill slowly from this point, checking fluid levels until full. NOTE For glycol solution preparation and periodic testing, follow manufacturers recommendations. Do not mix products of different manufacturers.

17

Installation

3.7

Electrical Connections
Each unit is shipped from the factory with all internal unit wiring completed. Refer to the electrical schematic when making connections. All wiring must be done in accordance with the National Electric Code and all local and state codes.

WARNING

UNIT CONTAINS POTENTIALLY LETHAL VOLTAGE. The fans may start unexpectedly. Disconnect power supply before working on unit. line side of factory disconnect remains energized when disconnect is off. Use a voltmeter to make sure power is turned off before making any electrical connections.

3.7.1

Line Voltage
Drycooler rated voltage should be verified with available power supply upon receipt of unit but before installation. Refer to the unit electrical schematic and serial tag for specific electrical requirements. All wiring must be done in accordance with the National Electric Code as well as all local and state codes.

CAUTION

Size the system electrical service for the total of all drycoolers and ancillary components FLA/WSA/OPD. Unit-specific wiring diagrams are provided on each unit. Use copper wiring only. Make sure that all connections are tight.

Line voltage electrical service is required for all drycoolers at the location of the drycooler. The power supply does not necessarily have to be the same voltage supply as required by the indoor unit for which the drycooler operates. This power source may be 208, 230, 460 or 575 Volt 60 Hz; or 380/415 Volt 50 Hz. A unit disconnect is standard. However, a site disconnect may be required per local code to isolate the unit for maintenance. Route the supply power to the site disconnect switch and then to the unit. Route the conduit through the hole provided in the cabinet. Connect earth ground to lug provided near terminal board. For units with multi-voltage transformer, the transformer connections should match (change if necessary) the local power supply. See Figure 9.

18

Installation

Figure 9

Electrical field connections

CONTROL FUSE AND FUSE BLOCK CURRENT SENSING RELAY OPTION HI-VOLTAGE FUSES AND FUSE BLOCKS

REMOTE START CONTACT/ REMOTE ALARM CONTACTS ON LOSS OF CURRENT CONTROL TRANSFORMER

FACTORY INSTALLED DISCONNECT SWITCH

70 71 80 81 83 84 85 86 1 01 1 02 1 03 1 04 1 05
POWER CONTROL SWITCH

GROUND LUG

L1 L2 L3

THERMOSTAT 1ST & 2ND STAGE AND DISPLAY MODULES CONTACTOR ENTRANCE FIELD SUPPLIED LOW VOLTAGE CLASS 2 WIRING ELECTRIC SERVICE NOT BY LIEBERT. THREE PHASE FOR ALL MODELS. PROVIDE IN ACCORDANCE WITH LOCAL AND NATIONAL ELECTRIC CODE. 7/8" KNOCKOUT (22 mm) (3 PLACES)

19

Installation

3.7.2

Low Voltage Control Wiring

A control interlock between the drycooler and the heat load(s) will require 24V Class 2 copper wiring for remote on/off sequencing of the drycooler with the load. Refer to the electrical schematic for wiring to terminals 70 & 71. See Figure 10 for typical low-volt system wiring. If the current sensing relay option is provided, 24V Class 2 wiring will be necessary to make the connections to monitor motor operation.

CAUTION

Make sure all electrical connections are tight.

Figure 10 Typical low volt wiring diagram

70 71 80 81 83 84 85 86 Flow Switch 101 102 103 104 105 Remote Alarm Optional Remote Alarms Contact on Loss of Current 70 71 80 81 83 84 85 86 101 102 103 104 105 Optional Remote Alarms Contact on Loss of Current Cooling Unit # __ 70 71 70 Cooling Unit # __ 70 71 70 Cooling Unit # __ 70 71 70 71 71 Cooling Unit # __ 71 Cooling Unit # __ Remote Start Contact Remote Start Contact Cooling Unit # __ 70 71 70 Cooling Unit # __ 70 71 70 Cooling Unit # __ 70 71 70 71 Cooling Unit # __ 71 Cooling Unit # __ 71 Cooling Unit # __ Cooling Unit # __

24 50 Standby Pump On Alarm (Dry Contact)

74 77 Flow Switch Connection

80 81

82 83

70 71 Heat Rejection Interlock

Drycooler Interlock

NOTES: 1. All 24 volt control wiring is shown in dashed linesby others. 2. Refer to individual wiring schematics for power wiring.

TYPICAL PUMP CONTROL PANEL

20

Installation

3.8

Checklist for Completing Installation

NOTE After installation, proceed with the following list to verify that the installation is complete. Complete and return the Warranty Inspection Check Sheet which is shipped with the unit and return to the address indicated on the check sheet. ___ 1. Proper clearances for service access have been maintained around the equipment. ___ 2. Equipment is level and mounting fasteners are tight. ___ 3. Piping completed to coolant loop. ___ 4. All piping connections are tight as well as secured and isolated for vibration reduction. ___ 5. All piping connections inspected for leaks during initial operation. ___ 6. Line voltage to power wiring matches equipment nameplate. ___ 7. Power wiring connections completed to disconnect switch, including earth ground. ___ 8. Power line circuit breakers or fuses have proper ratings for equipment installed. ___ 9. Control wiring connections completed to heat loads/evaporator(s), including wiring to optional controls. ___ 10. All wiring connections are tight. ___ 11. Foreign materials have been removed from in and around all equipment installed (shipping materials, construction materials, tools, etc.). ___ 12. Fans rotate freely and in correct direction without unusual noise and discharge the air upwards. ___ 13. Glycol has been added to the drycooler to prevent freeze damage.

21

Operation

4.0

OPERATION
!

WARNING

UNIT CONTAINS POTENTIALLY LETHAL VOLTAGE. The fans may start unexpectedly. Disconnect power supply before working on unit. Line side of factory disconnect remains energized when disconnect is off. Use a voltmeter to make sure power is turned off before checking any electrical connections or functions.

4.1

Initial Startup Procedure

Refer to 3.8 - Checklist for Completing Installation and verify that all installation items have been completed prior to proceeding. Turn the unit ON. Check the fans for proper rotation (air discharging up). Check the pumps for proper rotation.

CAUTION

Do not run pumps without fluid in the system. Pump seals require fluid to keep them cool; running them for any amount of time will damage the seals, which may cause a failure.

4.1.1

Control Setpoints
The fluid temperature controls should be set according to Table 11 for standard cooling only or freecooling GLYCOOL applications. See Figure 11. Table 11 Control settings
Fluid Temperature Control 1TAS Standard 1STG 2STG 1TAS Free-Cooling (GLYCOOL) 1STG 2STG

Heat Rejection Method

Setpoint 68F (20C) 42F (5.6C) -

Offset 5F (2.8C) 10F (5.6C) 2F (1.1C) 4F (2.2C)

Differential

Open 68F (20C)

Close 80F (26.7C) 85F (29.4C) 90F (32.2C) 50F (10C) 52F (11.1C) 54F (12.2C)

12F (6.7C)

73F (22.8C) 78F (25.6C) 42F (5.6C)

8F (4.4C)

44F (6.7C) 46F (7.8C)

22

Operation

Figure 11 Fluid temperature controls

23

Operation

4.1.2

Current Sensing Relays

If supplied, be sure that the current sensing relays (CSR) are wired as per the wiring schematic using 24V Class 2 copper wiring. When the thermostat closes, a 24-volt signal will be sent to the relevant terminals of the CSR. When this occurs, a time delay starts, allowing the amperage to be sensed on the load side of the contactors. First, set selection under amperage on selector switch, then start all fans. Set the trip delay for 50%. Disconnect one of the load side wires from a fan being monitored by the control. Turn the potentiometer until the LED is lit. Reconnect the fan wire. Check and repeat for the other circuits. Be sure to set the fluid temperature controls as per the specifications, as illustrated within the unit electrical schematic (supplied with the unit), or refer to 4.1.1 - Control Setpoints and Table 11. See Figure 12 for current sensing relay layout.

Figure 12 Current sensing relays

4.1.3

Cold Weather Operation

For operation of units located where outdoor ambients will include temperatures at or below freezing, a glycol solution should be used. Please refer to the installation sections referring to piping (3.5 - Piping Connections) and glycol solutions (3.6.2 - Glycol Solutions) for further details.

24

System Maintenance

5.0

SYSTEM MAINTENANCE
!

WARNING

UNIT CONTAINS POTENTIALLY LETHAL ELECTRICAL VOLTAGE. The fans may start unexpectedly. Disconnect power supply before working on unit. Line side of factory disconnect remains energized when disconnect is off. Use a voltmeter to make sure power is turned off before checking any electrical connections or functions

5.1

General Procedures
NOTE When ordering replacement parts for equipment, it is necessary to specify unit model number, serial number, and voltage. Please record those numbers in the spaces below. Model Number___________________ Serial Number___________________ Voltage__________________________ Periodic attention is necessary for continued satisfactory operation of your unit. A daily inspection of the system should be made to verify that the unit is performing satisfactorily. It is suggested that a daily log be maintained recording inlet and outlet coolant temperature, ambient temperature and the coolant pressure gauge readings. The coolant sight glass should be checked and the fans checked for unusual sounds which may indicate wear or future trouble. Monthly inspections should include removal and cleaning of strainer, and cleaning and inspection of coil. The coil can be cleaned with water, compressed air or steam as required. During monthly inspections, it is also wise to check the coolant to assure sufficient glycol in the mixture to prevent freeze-up. Each fan motor amp draw should be checked. If performance or operation problems are also detected, refer to 6.0 - Troubleshooting for required action. Use copies of 5.2.2 - Maintenance Inspection Checklist Restricted air flow through the drycooler coil will reduce the operating efficiency of the unit and can result in high fluid temperatures and loss of cooling. Clean the drycooler coil of all debris that will inhibit air flow. This can be done with compressed air or a commercial coil cleaner. Check for bent or damaged coil fins and repair as necessary. In winter, do not permit snow to accumulate around the sides or underneath the drycooler. Check all fluid lines and capillaries for vibration isolation. Support as necessary. Visually inspect all fluid lines for signs of fluid leaks. Inspect the motor/fan assemblies to insure bearings are free and the motor is secure within the mount. The glycol level in drycooler systems must be periodically checked. At the high point of the system, check for: Positive pressure Air to be vented An unclogged expansion tank Proper concentration of inhibitors and antifreeze

The first three checks may give an indication of leaks in the system.

25

System Maintenance

5.2
5.2.1

Special Procedures
Drycooler Cleaning
Keeping the outdoor drycooler coils clean is an important factor in maintaining peak efficiency, reliability and long life of the equipment. It is much easier to keep up on frequent cleanings rather than wait until heavy build up has occurred which may create head pressure problems with the evaporator units.

When to Clean
Normal conditions typically dictate cleaning twice a year, spring and fall. On-site or area conditions such as cottonwood trees, construction, etc., can increase cleaning frequency. On your standard bimonthly or quarterly preventive maintenance schedule, a visual inspection of the coil is recommended to monitor conditions.

What to Use
The best overall condenser coil cleaner to use is plain water. If the coil has been maintained and cleaned at regular intervals, water is sufficient to remove dirt and debris from the fins. Heavy build up on the exterior of the fins can be removed with a brush. Water pressure from a garden hose and sprayer usually works well. If a pressure washer is used, make sure the equipment is set to a lower pressure setting and that the nozzle is set to the fan spray, not stream. Otherwise, damage to the fins could result. If a cleaner is required, we recommend a non-acidic type cleaner be used. Acid-type cleaners can be aggressive to the coil fins as well as surrounding areas. Many sites do not allow the use of acidic cleaners for environmental reasons.

How to Clean
The absolute best way to clean coils is from the inside out. This requires removing the coil guards or grilles (if provided), the fan guards and blades to access the coil surface. The sprayer can then be worked across the coil pushing the dirt and debris out. Although this does extend the time involved, the results are well worth it. This method should be used at least once a year. Spraying the coil from the outside repeatedly can push a majority of the dirt to the inner section of the fins and continue to restrict air flow. Keep in mind you may not have the luxury of shutting the unit(s) down for an extended time. A pre-scheduled shutdown with the operator may be in order. If you are using a cleaner along with the spraying process, follow recommended manufacturer instructions and be sure to rinse the coil thoroughly. Any residue left on the coil can act as a magnet to dirt.

26

System Maintenance

5.2.2

Maintenance Inspection Checklist

Prepared By:____________________________________ Serial Number:__________________________________

Date:____________________________________ Model #:_________________________________

NOTE Regular inspections are necessary to assure proper cleanliness of the cooling fins. Should inspection reveal dirt or corrosion, appropriate cleaning should be performed.

Monthly Drycooler
___ 1. Coil surfaces free of debris ___ 2. Fans/grilles free of debris ___ 3. Fan motors securely mounted ___ 4. Motor bearings in good condition ___ 5. No glycol leaks

Semiannually Drycooler
___ 1. Complete all monthly items ___ 2. Piping in good condition ___ 3. Piping secure ___ 4. Wash coil as needed

Pump Package
___ 1. Complete all monthly items ___ 2. Test changeover operation ___ 3. Pump #1 amp draw __________ Pump #2 amp draw __________ Pump #3 amp draw ___________ ___ 4. Glycol level and general condition ___ 5. Glycol freeze point ____F and pH ____ ___ 6. Check all electrical connections ___ 7. Check contactors for pitting

Pump Package
___ 1. Pump rotation ___ 2. Pump securely mounted ___ 3. No glycol leaks ___ 4. No abnormal noises

Drycooler Electric Panel

___ 1. Check all electrical connections ___ 2. Check contactors for pitting ___ 3. Operational sequence/setpoints

Fan Motors
___ 1. Motor #1 amp draw __________ amps ___ 2. Motor #2 amp draw __________ amps ___ 3. Motor #3 amp draw __________ amps ___ 4. Motor #4 amp draw __________ amps ___ 5. Motor #5 amp draw __________ amps ___ 6. Motor #6 amp draw __________ amps ___ 7. Motor #7 amp draw __________ amps ___ 8. Motor #8 amp draw __________ amps ___ 9. Motor #9 amp draw __________ amps ___ 10. Motor #10 amp draw _________ amps

Notes:

Signature: ______________________________________________________________________
Make photocopies of this form for your records

27

Troubleshooting

6.0

TROUBLESHOOTING
Symptom Possible Cause No main power Disconnect switch open Blown fuse or circuit breaker tripped Control fuse or circuit breaker tripped Improperly wired No output voltage from transformer Motor protector defective Motor protector too small Fan or pump motor has shorted winding Low or unbalanced voltage Low or no coolant flow Ambient air temperature higher than design Heat load higher than design Throttling valve improperly Air in system Check Or Remedy Check L1, L2 and L3 for rated voltage Close disconnect switch Check fuses or circuit breaker Check for 24VAC. If no voltage, check for short. Replace fuse or reset circuit breaker. Check wiring diagram Check for 24VAC. If no voltage, check primary voltage Replace protector Check amp. draw Repair motor Determine reason and correct See Pump will not operate or no coolant flow entry in this table Correct possible hot air discharge to fans from another source Check for misapplication, need larger cooler. Correct possible additional heat load being added to cooling circuit. Reset valve to proper differential pressure Vent all high points, repeat as necessary. Check liquid level in surge tank.

Unit will not operate

Unit runs, but motor protector keeps tripping

Outlet temperature from unit too high

Liquid squirts from surge tank fill cap when pump is turned off Pump suddenly stops pumping Pumping suddenly slows Excessive leakage around the pump shaft while operating

Clogged strainer or impeller Clean out debris Clogged impeller, diffuser or line Worn seal or packing Clean out debris and use strainer Replace seal or packing Replace with new impeller or seal Relocate pump closer to supply Larger lead wires may be required. Check for proper line voltage, 10% Replace pump Replace pump Throttle discharge -- improve conditions Remove cover and clean out Adjust system pressures Reset valve to proper differential pressure Open all valves downstream of unit Remove strainer plug and clean See Unit will not operate in this table Check coolant level Flush coil with reputable cleaner Open all valves Remove strainer plug and clean Possibility of air in lines. Bleed all components. Check surge tank to pump inlet connection. Check for piping restrictions.

Worn impeller or seal Suction lift too high Pump performance poor Motor not up to speed; low voltage Worn bearings Worn motor bearings Low discharge head Pump has noisy operation Debris lodged in impeller Cavitating pumps Throttling valve improperly set Pump discharge pressure too high Valve closed in circuit Strainer clogged or dirty No power to pump motor Low coolant level Tubes plugged in cooling coil Pump will not operate or no Valve closed downstream coolant flow of cooling unit Strainer clogged or dirty Pump cavitating (erratic gauge operation)

28

HEAT REMOVAL/PRECISION AIR

10 Fan Drycooler/Fluid Cooler

INCLUDING QUIETLINE MODELS
The Company Behind the Products
With over a million installations around the globe, Liebert is the world leader in computer protection systems. Since its founding in 1965, Liebert has developed a complete range of support and protection systems for sensitive electronics: Environmental systemsclose-control air conditioning from 1 to 60 tons Power conditioning and UPS with power ranges from 300 VA to more than 1000 kVA Integrated systems that provide both environmental and power protection in a single, flexible package Monitoring and controlfrom systems of any size or location, on-site or remote Service and support through more than 100 service centers around the world and a 24/7 Customer Response Center

USER MANUAL
Technical Support/Service
Web Site www.liebert.com Monitoring 800-222-5877 monitoring@liebert.com Outside the US: 614-841-6755 Single-Phase UPS 800-222-5877 upstech@liebert.com Outside the US: 614-841-6755 Three-Phase UPS 800-543-2378 powertech@liebert.com Environmental Systems 800-543-2778 Outside the United States 614-888-0246

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. 2005 Liebert Corporation All rights reserved throughout the world. Specifications subject to change without notice. Liebert and the Liebert logo are registered trademarks of Liebert Corporation. All names referred to are trademarks or registered trademarks of their respective owners.

Locations
United States 1050 Dearborn Drive P.O. Box 29186 Columbus, OH 43229 Italy Via Leonardo Da Vinci 8 Zona Industriale Tognana 35028 Piove Di Sacco (PD) +39 049 9719 111 Fax: +39 049 5841 257 Asia 23F, Allied Kajima Bldg. 138 Gloucester Road Wanchai Hong Kong +852 2 572 2201 Fax: +852 2 831 0114

SL-10061 (1/05)