Emerson Liebert DCP Water-Based Pumping Unit 200kW User Manual

Liebert® DCP™ with Liebert iCOM® Control

User Manual–50-60 Hz; 200kW Nominal Capacity

TABLE OF CONTENTS

1.0 PRODUCT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

1.1 General Product Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.2 Equipment Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.3 Equipment Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.0 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

2.1 Mechanical Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.2 Electrical Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2.3 Field Connections—Optional for All Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2.4 Remote Sensor Installation—Proper Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.0 PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

3.1 Connection Sizes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3.2 Air Bleeders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3.3 Liebert DCP Interconnection with Cooling Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3.4 Piping Installation Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.5 Bypass Flow Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.6 Piping Details—Shutoff/Isolation Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3.7 Filling Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3.8 Checklist for Proper Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

4.0 LIEBERT ICOM® CONTROL—FIRMWARE VERSION XP1.00.DCP.01R . . . . . . . . . . . . . . . . 25

4.1 Liebert iCOM Components and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4.2 Display Lamp Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

4.3 Navigating Through the Liebert iCOM® Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

4.4 Changing Liebert iCOM®’s Display Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

4.5 Changing Operational Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

4.6 Graphical Data Record. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

4.7 Liebert iCOM® User Menu Icons and Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

4.8 Liebert iCOM® User Menu Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

4.9 Liebert iCOM® Service Menu Icons and Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

4.10 Liebert iCOM® Service Menu Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

5.0 START THE LIEBERT DCP WITH LIEBERT ICOM® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

5.1 Checklist for Liebert DCP Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

5.2 Starting the Liebert DCP with Liebert iCOM Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

6.0 ALARM DESCRIPTIONS AND SOLUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64

6.1 Alarm Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

6.2 Warning Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

6.3 System Shutdown Causes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

7.0 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

8.0 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69

9.0 SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70

FIGURES

Figure 1 Model number nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Figure 2 Liebert DCP components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Figure 3 Unpacking the Liebert DCP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Figure 4 Use a forklift to remove the Liebert DCP from the skid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Figure 5 Removing the unit from the skid using rigging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Figure 6 Securing the Liebert DCP to piano jacks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Figure 7 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Figure 8 Piping access points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Figure 9 Front view of Liebert DCP and electrical enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Figure 10 Electrical enclosure knockout location for hazardous voltage wiring . . . . . . . . . . . . . . . . . . . . . . 11

Figure 11 High voltage connections—60Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Figure 12 High voltage connections—50Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Figure 13 Electrical enclosure knockout locations for Extra Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Figure 14 Connecting the remote temperature/humidity sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Figure 15 DIP switch and jumper settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Figure 16 Unit-to-unit networking connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Figure 17 Liebert DCP extra low voltage field connections points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Figure 18 Suggested remote sensor placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Figure 19 Liebert DCW system diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Figure 20 General piping details. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Figure 21 Standpipe filling components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Figure 22 Liebert DCP filling components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Figure 23 Liebert DCD™ bleed valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Figure 24 Liebert XDK-W™ bleed valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Figure 25 Liebert iCOM display components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Figure 26 Liebert iCOM default home screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Figure 27 Cooling module overview, first 10 modules—Applies only to Liebert XDP . . . . . . . . . . . . . . . . . . 28

Figure 28 Entering the password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Figure 29 Display setup screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Figure 30 Liebert iCOM User Menu icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Figure 31 Liebert DCP User Menu screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Figure 32 Setpoints screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Figure 33 Set Alarms screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Figure 34 Sensor Data screen, page 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Figure 35 Sensor Data screen, page 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Figure 36 Display Setup screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Figure 37 Module Status screen, page 1 of 20—Applies to Liebert XD™ smart modules only . . . . . . . . . . . 38

Figure 38 Liebert XDV™ Smart Module Status screen—Applies to Liebert XD smart modules only . . . . . 38

Figure 39 Liebert XDH™ Smart Module Status screen—each bank shown separately—Applies to

Liebert XD™ smart modules only. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Figure 40 Liebert XDO™ Smart Module Status screen—Applies to Liebert XD™ smart modules only. . . . 39

Figure 41 Total Run Hours screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Figure 42 Liebert iCOM Service Menu icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Figure 43 Liebert DCP Service Menu screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Figure 44 Setpoints screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Figure 45 Maintenance—Basic Settings screen, page 1 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Figure 46 Maintenance—Pump 1 Settings screen, page 2 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Figure 47 Maintenance—Pump 2 Settings screen, page 3 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Figure 48 Maintenance screens, pages 4 through 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Figure 49 Diagnostics/Service Mode screen, page 1 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Figure 50 Diagnostics/Service Mode screen, page 2 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Figure 51 Diagnostics/Service Mode screen, page 3 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Figure 52 Diagnostics/Service Mode screen, page 4 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Figure 53 Diagnostics/Service Mode screen, page 5 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Figure 54 Diagnostics/Service Mode screen, page 6 of 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Figure 55 Set Alarms screen, page 1 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Figure 56 Set Alarms screen, page 2 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Figure 57 Set Alarms screen, page 3 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Figure 58 Set Alarms screen, page 4 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Figure 59 Set Alarms screens, pages 5 and 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Figure 60 Set Alarms screen, page 7 of 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Figure 61 Sensor Calibration/Setup screen, page 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Figure 62 Sensor Calibration/Setup screen, page 2 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Figure 63 Sensor Calibration/Setup screen, page 3 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Figure 64 System/Network Setup screen—System, page 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Figure 65 System/Network Setup screen—System, page 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Figure 66 System/Network Setup screen—Unit, page 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Figure 67 System/Network Setup screen—Unit, page 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Figure 68 Options Setup screen, page 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Figure 69 Options Setup screen, page 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Figure 70 Module Setup screen, page 1 of 20—Applies to Liebert XD™ smart modules only. . . . . . . . . . . . 61

Figure 71 Module Setup screen, page 1 of 20—Applies to Liebert XD™ smart modules only. . . . . . . . . . . . 62

TABLES

Table 1 Supply and return requirements for Liebert DCD/Liebert XDK-W loop. . . . . . . . . . . . . . . . . . . . 18

Table 2 Water quality to limit corrosion and erosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Table 3 Keyboard icons and functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Table 4 Troubleshooting the Liebert DCP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Table 5 Liebert DCP200 specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

iii

IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS

This manual contains important safety instructions that should be followed during the installation and maintenance of the Liebert DCP. 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, notices and installation, operating and safety instructions on the unit and in this manual. Follow all operating and user instructions.

Follow all local codes.

WARNING

Risk of arc flash and electric shock. Can cause property damage, injury or death. Open all local and remote electric power supply disconnect switches, verify with a voltmeter

that power is off and wear protective equipment per NFPA 70E before working within electric control enclosure. Failure to comply can cause serious injury or death.

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

mode. Some internal components require and receive power even during the Unit Off mode of Liebert iCOM.

The line side of the disconnect switch on the front of the unit 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.

microprocessor does not isolate power from the unit, even in the Unit Off

Important Safety Instructions

WARNING

Risk of unit falling over. Can cause property damage, injury or death. The Liebert DCP is top-heavy. Use extreme caution and care when moving and installing this

unit.Verify that all equipment used for lifting and moving is rated for the weight of the unit. See Table 5 for unit weights.

CAUTION

Risk of sharp edges, splinters and exposed fasteners. Can cause injury. Only properly trained and qualified personnel wearing appropriate safety headgear, gloves,

shoes and glasses should attempt to move, lift, remove packaging from or prepare the unit for installation.

NOTE

This document is intended to be used together with site specific documentation and documentation for other parts of the system (heat rejection devices and cooling modules).

NOTE

Inform the facility manager before beginning any action that could cause a disturbance in the Liebert DCW action is taken and the work is finished.

™

system’s cooling function. In addition, inform the facility manager after the

1Liebert

DCP

™

NOTICE

Redundant

Pumps

DCP 200 B *

Revision

level

Liebert

Data Center

Pumping Unit

Nominal

Capacity

Example: DCP200RA– –*

A = 460V-3ph-60Hz

(voltage-phase-frequency) C = 208V-3ph-60Hz M = 380/415V-3ph-50Hz

2 = 12°F (°C)

Heat Exchanger

B = Bottom

Piping for Secondary Loop

B = Bottom

Chilled Water Connection

Risk of leaking chilled water and drain lines. Can cause equipment and building damage. Lines and joints must be inspected regularly. 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 Network Power installing monitored leak detection equipment for the unit and its factory- and field-installed supply, return and drain lines.

Figure 1 Model number nomenclature

Important Safety Instructions

recommends

Liebert® DCP

™

1.0 PRODUCT DESCRIPTION

Liebert DCP

Control

Valve

Liebert DCD

Liebert XDK-W

Heat Exchanger

Pump(s)

Chilled

Water

1.1 General Product Information

1.1.1 Product/System Description

The Liebert DCP chilled water distribution unit is an interface between the building chilled water system and the cooling modules in the Liebert DCW chilled water to the cooling modules that are in the room with heat-producing equipment. The Liebert DCP is rated for 200kW (682,000BTU/H) of cooling.

The Liebert DCP consists of a cabinet that includes a heat exchanger, circulating pump(s), control valve, receiver, controls, valves and piping.

The Liebert DCP monitors room conditions and prevents coil condensation by maintaining the chilled water being pumped to the cooling modules at a temperature above the room’s dew point.

All functions, such as switching pumps (if applicable), controlling water temperature, etc., are automatic.

Figure 2 Liebert DCP components

Product Description

™

system. It is designed to circulate and control

1.2 Equipment Inspection

When the unit is delivered, inspect all items for visible and concealed damage. Damage should be immediately reported to the carrier and a damage claim filed with a copy sent to Emerson your sales representative.

and to

3Liebert

DCP

™

1.3 Equipment Handling

WARNING

Risk of unit falling over. Can cause injury or death. The Liebert DCP is top-heavy. Use extreme caution and care when moving and installing this

unit. Use lifting equipment that is rated for the weight of the unit by an OSHA-certified rating organization. See Table 5 for unit weights. Personnel should be properly trained and certified to move and rig equipment

CAUTION

Risk of sharp edges, splinters and exposed fasteners. Can cause injury.

Only properly trained and qualified personnel wearing appropriate safety headgear, gloves, shoes and glasses should attempt to move, lift, remove packaging from or prepare the unit for installation.

1.3.1 Handling the Liebert DCP While it is on Skid and Packaged

• Always keep the unit upright, indoors and protected from damage.

• If possible, transport the unit using a forklift truck. Otherwise use a crane with belts or cables. In either case, do NOT press on the top edges of the packaging.

• If using a forklift, make sure the forks (if adjustable) are spread to the widest allowable distance to still fit under the skid.

• When moving the skidded unit with a forklift truck, do not lift the unit any higher than 6"

(152mm). If circumstances require the unit to be lifted higher than 6" (152mm), great care must be exercised and all by-standing personnel are to be no closer than 20 feet (6m) from the lift point of the unit.

Product Description

NOTICE

Risk of structural interference. Can cause equipment or building damage. While on the skid, the unit is too tall (83" [2108mm] overall height) and may be too wide to fit

through a standard doorway. Any attempt to move the unit, while skidded, through a standard doorway will cause damage to the unit and to the building.

Measure the unit and doorway, and verify that the unit will fit through before attempting to move it through the doorway.

NOTICE

Risk of improper forklift operation. Can cause unit damage.

Keep tines of the forklift level and at a height suitable to fit below the top boards of the skid and/or the bottom of the unit to prevent exterior and/or underside damage.

NOTICE

Risk of improper storage. Can cause unit damage.

Keep the Liebert DCP upright, indoors and protected from dampness, freezing temperatures and contact damage.

NOTICE

Risk of overtightening securing straps. Can cause damage to panels. Place a protective material between the straps of the piano jacks and the unit. Ensure that

the straps are not tightened to a point of damaging panels.

Liebert® DCP

™

1.3.2 Unpacking the Liebert DCP

Remove Stretch Wrap Remove Packaging Planks

Stretch

Wrap

1. Remove the exterior stretch wrap packaging from the unit, exposing the protective corner and side packaging planks.

2. Remove the corner and side packaging planks from the unit, exposing the bag over the unit. The bag may remain in place for dust and panel protection or removed for immediate unit installation.

3. Remove the bag from the unit when ready to remove the skid for installation.

Figure 3 Unpacking the Liebert DCP

Product Description

1.3.3 Removing the Unit from the Skid Using a Forklift

1. Align the forklift with either the front or rear side of the unit. Make sure the tines of the forklift are locked to the widest position. Use the center of gravity indicators to determine the entry points for the tines. The tines must be

equally spaced on either side of the center of gravity indicator.

2. Insert the tines of the forklift under the unit. Make sure the tines are level. The tines must be low enough to fit under the unit without

damaging it. Make sure the tines extend beyond the opposite side of the unit.

3. Remove the 12 lag bolts and two brackets that secure the unit to the skid.

NOTE

Each lag bolt is 1-1/2" (38mm) long. They can be removed with a 9/16" socket or wrench.

4. Lift the unit to a height that it is not being support by the skid.

5. Move the skid from under the unit.

5Liebert

DCP

™

Figure 4 Use a forklift to remove the Liebert DCP from the skid

Fit the forklift tines under the Liebert DCP.

Move the forklift forward until the tines are fully under the unit.

The forklift tines must be equally spaced on either side of the center of gravity indicator.

1.3.4 Removing the Unit from the Skid using Rigging

1. Use the center of gravity indicators on the unit to position the slings. The slings must be equally spaced on either side of the center of gravity indicator. Refer to

2. Place slings under the unit using spaces provided between the skid deck boards.

Product Description

Figure 5.

NOTE

Unit is shown without outer packaging. These instructions may be applied with the outer packaging in place.

3. Use spreader bars or an equivalent method to ensure proper protection of the unit.

4. Ensure that the panels, if attached, are well protected from the slings.

NOTE

If rigging is to be used to move the unit closer to the site for installation, place one or two horizontal straps around the unit and vertical straps at mid height.

5. Remove the 12 lag bolts and two brackets that secure the unit to the skid.

NOTE

Each lag bolt is 1-1/2" (38mm) long. They can be removed with a 9/16" socket or wrench.

6. Lift the unit off of the skid to an elevation point where the skid is not supporting the weight of the unit.

7. Remove the skid from under the unit.

Liebert® DCP

™

Figure 5 Removing the unit from the skid using rigging

Equally Spaced

Center of Gravity Symbols

Spreader

Bars

Lag Bolts

Bracket

If rigging will be used to transport the Liebert DCP, place one or two horizontal straps around the unit and the vertical straps about this height.

Cushioning material not shown for clarity.

Product Description

1.3.5 Moving the Liebert DCP Using Piano Jacks

1. Elevate the Liebert DCP with a lifting mechanism, such as a forklift or rigging.

2. Position one piano jack at each end of the Liebert DCP.

3. Lower the unit to a height suitable for placing it on the piano jacks.

4. Put protective material between the Liebert DCP and the piano jacks and straps.

5. Secure the Liebert DCP to the piano jacks.

6. Release the Liebert DCP from the straps securing it to the lifting mechanism and move the mechanism away from the unit.

Using the piano jacks, at least two properly trained and qualified personnel can move the unit.

7Liebert

DCP

™

Figure 6 Securing the Liebert DCP to piano jacks

Using a forklift to put a

Liebert DCP on piano jacks

Using rigging to put a

Liebert DCP on piano jacks

Liebert DCP Secured

to piano jacks

Product Description

1.3.6 Removing the Unit from the Piano Jacks

1. Lower the Liebert DCP as far as the piano jacks will allow.

2. Undo all strapping holding the piano jacks to the unit.

3. Lift one end of the Liebert DCP off one piano jack with a pry bar or similar device, taking care not to damage the unit’s cabinet.

4. Repeat Step 3 to remove the piano jack from under the opposite end of the Liebert DCP.

5. Remove all material used to protect the unit from the piano jacks and strapping.

Liebert® DCP

™

2.0 INSTALLATION

Drip tray dimensions

Shipping Weight Domestic: 1100 Lb. (500kg) Export: 1275 Lb. (575kg)

Drip tray dimensions

Does not include Disconnect Switch Bezel

DPN002400 Pg. 2, Rev. 1

27"

(686mm)

11-1/2"

(292mm)

(25mm)

33"

(838mm)

33"

(838mm)

Cutout

33-1/8"

(841mm)

Side Panel

38" (965mm)

Overall

34" (864mm)

Overall

Floor Cutout Dimensions

78" (1981mm)

Height of Unit

The shaded area indicates a recommended clearance of 36" (914mm) for component access.

36"

(914mm)

36"

(914mm)

2.1 Mechanical Considerations

2.1.1 Positioning the Liebert DCP

Install the Liebert DCP according to the site specific documentation and secure the unit to the floor.

The Liebert DCP can be installed near a wall or another Liebert DCP. However, there must be at least 3

Figure 7 Dimensions

feet (92cm) clearance in front of the Liebert DCP as service access for components in the unit.

Installation

9Liebert

DCP

™

Figure 8 Piping access points

Floor Piping

16-5/8"

(422mm)

2-1/2"

(64mm)

Secondary In

7-1/4" (184mm)

33"

(838mm)

Each piping outlet connection - A, B, C and D - is 2-5/8".

Rear

BCW OUT

(86mm)

Secondary Out

BCW IN

36" (914mm)

Front

3-3/8"

Installation

3-1/4"

(83mm)

6-1/2"

(165mm)

DPN002400 Pg. 3, Rev. 1

2.2 Electrical Considerations

Make sure the actual supply voltage and frequency correspond to the voltage and frequency indicated on the Liebert DCP’s rating plate. The unit must be installed in accordance with national wiring regulations.

Connect cables for high voltage supply to the electrical box in the Liebert DCP according to Figure 11 and make sure that the phases are correctly connected.

WARNING

Risk of electric shock. Can cause injury or death. Open all local and remote electric power supply disconnect switches and verify with a

voltmeter that power is Off before working within the unit’s electrical connection enclosures.

WARNING

Risk of electrical shock, short circuit and/or control malfunction. Can cause equipment damage, injury or death.

Damage to wiring or components can make unit unsafe to operate.

Use caution when installing wiring to prevent damage to factory wiring.

Install protective bushings in wiring knockouts as required to protect wiring from sharp edges.

Do not disturb factory wiring or route field-installed wiring over electrical terminals.

Use NEC Class 1 wiring for all hazardous voltage electrical power supplies.

Liebert® DCP

Check and retighten all wiring connections before starting the unit.

™

2.2.1 Connecting High-Voltage Cables

Liebert DCP Input Power Knockout

Enclosure Cover Not Shown

1. Turn the Liebert DCP’s disconnect switch to the Off position (see Figure 9). Open the front doors and push down on the enclosure cover latch to open the hazardous voltage enclosure cover.

Figure 9 Front view of Liebert DCP and electrical enclosure

Installation

Disconnect Switch

Front of Liebert DCP

Hazardous Voltage Enclosure Cover

2. Determine which knockouts in the electrical enclosure will be used and remove them (see Figure 10).

Figure 10 Electrical enclosure knockout location for hazardous voltage wiring

Liebert iCOM User Interface

Enclosure Cover Latch

Hazardous Voltage Enclosure Cover

11 Liebert® DCP

™

3. Route the input hazardous voltage electrical power wiring through the top left knockout (see

Customer Power Connection

Ground Lug

Disconnect Switch

Fuse Blocks

Power Block

Pump Fuse Blocks

Pump Contactors

Transformer 1

Transformer 2 (supplied on 460V units only)

Transformer 6

Busbar

Customer Power Connection

Pump Circuit Breakers

Pump Contactors

Ground Lug

Disconnect Switch

Transformer 1

Power Block

Transformer 2

Transformer 6

Fuse Blocks

Figure 10) to the disconnect switch L1, L2 and L3 (see Figures 11 and 12). Observe proper phasing.

4. Connect the ground wire to the ground lug (see Figures 11 and 12), which is in the middle left of the enclosure.

Figure 11 High voltage connections—60Hz

Installation

Figure 12 High voltage connections—50Hz

Liebert® DCP

™

2.2.2 Extra Low Voltage (ELV) Connections

Extra Low Voltage power output is 30V and 100VA or less.

1. Turn off all unit power before connecting cables or wires. Failure to do so may damage this equipment (refer to

2. Route low voltage electrical connections through the appropriate knockouts as indicated below.

Figure 13 Electrical enclosure knockout locations for Extra Low Voltage

Figure 13).

User Interface Wiring

Temperature/Humidity Sensor Wiring

Installation

Alternate Knockout for Temperature/Humidity Sensor Wiring

Enclosure Cover Not Shown

13 Liebert® DCP

™

Figure 14 Connecting the remote temperature/humidity sensors

Installation

CAN Cable

See Note 4

P64

See Note 4

Unit Display (Rear View)

Red Crossover Ethernet Cable

Crossover Coupler

See Note 6

P66

CAN Ground Coupler

P67

Termination Plug

See Note 8

P2 P4

CAN Iso Adaptor

P3P1

See Note 9

T6 Isolation

Transformer

T1 Unit Control

Transformer

P66

Liebert XD

Cooling Module

See Note 8

P66

P67

See Note 5

P67

CAN Ground Coupler

Remote T/H Sensor BRemote T/H Sensor A

See Note 7

24VAC Nominal

P66

P67

P66 P67

Liebert XD

Cooling Module

See Note 5

See Note 3

Liebert IntelliSlot 1

Liebert IntelliSlot 2

Ribbon Cables

Not Used

Cable B

Cable A

P63

See Note 2

P65

Liebert IntelliSlot Power Supply

1. See unit electrical schematic, installation and user manuals.

2. Cable “A” provided with each unit. Liebert IntelliSlot-based communications - Cable “A” is preconnected to P65 on the microprocessor and input/output board and P65 on the Liebert IntelliSlot power supply non-Liebert IntelliSlot-based communications.

3. Install applicable Liebert IntelliSlot cards.

4. Both cables (P64 and P66) are required.

5. It is not necessary to connect the ground coupling on the end of the cable connected to Sensor “A” or Sensor “B.”

6. A crossover coupler is provided for unit-to-unit (U2U) networking. Unplug the red cable from P64 on the microprocessor and input/output board and connect it to one side of the crossover coupler. The first customer

P13

P11

P67

P64

P61

P65

P18

P12

P66

P78

SW2

OFF ON

21436

P68

P43

E1 E2 E3 E4

TB1

P54

P51

P24

Control

Fuse

Board

P45

Liebert iCOM Microprocessor

P41

and I/O Board

P52

P53

P39

See Table for

P40

P32

Plug Assignments

P34

P33

P36

P35

P22 P38

302211 Rev. 3

connection point is to P64 on the microprocessor and input/output board. The second customer connection point is to the other side of the crossover coupler. This connects the microprocessor and input/output board and display to the private U2U network.

7. The remote sensors are interchangeable as to which connects to the Liebert XD cooling module and which connects to P2 on CAN Iso.

8. Field-install cables with factory-installed ferrite beads (when provided, typically two places). Each cable must make three passes through the ferrite bead. Locate the ferrite bead on top of the electric box. See the instruction sheet provided with the cable assembly.

9. Factory-installed ferrite bead (when provided). The cable passes through the ferrite bead three times.

Liebert® DCP

™

2.2.3 DIP Switch and Jumper Settings for Remote Sensors

P68

135

246

SW2

MICROPROCESSOR AND I/O BOARD

REMOTE T/HSENSOR “A” REMOTE T/H SENSOR “B”

SW1SW1

OFF

Jumper on 1-2

P78

DIP

Switches

1 3 4 9

OFF

2 5 6 7 8

Jumpers

on 1-2, 5-6

OFF ON

1 2 3 4 5 6 7 8 9

DIP

Switches

None

OFF

1 2 3 4 5 6 7 8

P78

UNIT DISPLAY

Jumper on 1-2

1 2 3 4 5 6 7 81 2 3 4 5 6 7 8

DIP

Switches

1 5

OFF

2 3 4 6 7 8

DIP

Switc hes

2 5

OFF

1 3 4 6 7 8

SW3

1 2 3 4 5 6 7 8

OFF ON

321

Jumper on 2-3

321

Jumper on 2-3

302211 Rev. 3

Termination Plug

Liebert iCOM Microprocessor & I/O Board

Customer Connection Points

Crossover Coupler

Red Crossover Ethernet Cable

Straight Through Ethernet Cables

U2U Networking Switch

(Field-Supplied)

Unit Display (Rear View)

Not Used

P64

P66

P64

P66P67

To / From Other Networked Units

CAN Cable

See Note 1

P65

P61

P63

P11 P13

P12

P67

1. Both cables (P64 and P66) are required.

2. A crossover coupler is provided for unit-to-unit (U2U) networking. Unplug the red cable from P64 on the microprocessor and I/O board and connect it to one side of the crossover coupler. The first customer connection point is to P64 on the microprocessor and I/O board. The second customer connection point is to the other side of the crossover coupler. This connects the microprocessor and I/O board and display to the private U2U network.

The Liebert DCP is shipped with jumpers and DIP switch settings for normal operation; refer to Figure 15.

Figure 15 DIP switch and jumper settings

Installation

Figure 16 Unit-to-unit networking connections

15 Liebert® DCP

™

2.3 Field Connections—Optional for All Units

K11COM

K11NO

K11NCL

TS-24

TS-50

TS-51

TS-54

K3COM

K3NO

K3NCL

TS-37

TS-38

TS-77

TS-78

K11COM

K11NO

K11NC

K11

24 50

5424

5124

3837

K3COM

K3NO

K3NC

(-)

R or W

(+)

DPN002400 Pg. 5, Rev. 1

Control wiring must be Class 2 and installed in accordance with the National Electrical Code (NEC).

Requires shielded cable.

COMMON WARNING OUTPUT

FOR CONTACTS INDICATING AN ALARM CONDITION.

(MAX) 1.0AMP @ 24V

TO REMOTE ALARM

CIRCUIT BY OTHERS

INPUT: REMOTE ALARM DEVICE

FOR INDICATION OF ALARM, WIRE N.O. CONTACTS FROM REMOTE ALARM DEVICE AS SHOWN.

N.O. CONTACT BY OTHERS

INPUT: CONDENSATION DETECTION

ALARM WHEN CLOSED.

N.O. CONTACTS REQUIRED

INPUT: FAN BREAKER STATUS

ALARM WHEN CLOSED.

N.O. CONTACTS REQUIRED

INPUT: REMOTE SHUTDOWN

FOR SHUTDOWN OF CONTROL CIRCUIT, REMOVE JUMPER BETWEEN TERMINALS 37 & 38 AND REPLACE WITH N.C. CONTACT.

N.C. CONTACTS BY OTHERS

LIEBERT SITE MONITOR

FOR DIGITAL COMMUNICATION WITH LIEBERT SITE MONITORS ONLY. CONNECT 2 WIRE TWISTED PAIR TO 77 & 78. ALSO SEE SITE MONITOR INSTALLATION MANUAL.

COMMON ALARM OUTPUT

FOR CONTACTS INDICATING AN ALARM CONDITION.

(MAX) 1.0AMP @ 24V

TO REMOTE ALARM CIRCUIT BY OTHERS

Factory-Wired Temperature Sensor

UNIT DISPLAY

(Rear View)

P64

P66 P67

To Remote T/H Sensor A

To Optional External Connections

To Remote T/H Sensor B

To P64 on Liebert iCOM Control Board Red Ethernet Cable

Termination Plug

To P66 on Liebert iCOM Control Board

DO NOT USE

P67

Connect optional field wiring from remote devices to remote alarm device, common alarm outputs, site monitor and remote shutdown, if applicable. See terminal strip descriptions in

Figure 17 Liebert DCP extra low voltage field connections points

Installation

Figure 17.

Liebert® DCP

™

2.4 Remote Sensor Installation—Proper Placement

Placement of the two remote temperature/humidity sensors is critical to effective cooling of the conditioned space.

Installation

The remote sensors must be installed in areas where conditions are representative of the space conditioned by the Liebert DCP. Emerson the cooling modules served by the Liebert DCP. If the return air side of the primary air mover, such as a Liebert DS

™

, represents the conditions where the cooling modules are located, one sensor could be placed there. Emerson suggests placing the other sensor on the wall opposite the heat load area (see

Figure 18 for guidance).

Do not install the sensors where ambient air might cause false readings, for example, near unsealed doors or windows, or areas with stagnant air.

1. Unpack the two remote temperature/humidity sensors and cables.

One sensor is labeled Sensor A and the other Sensor B. The sensor cables are interchangeable; each bears labels indicating Sensor End and Unit End.

2. Connect the Sensor End of one of the supplied sensor cables to P66 on Sensor A (see Figure 14).

3. Connect the Unit End of the sensor cable to P67 on the Liebert iCOM® input/output board inside

the Liebert DCP. Secure the ring terminal on the cable shield to the electric box adjacent to P67 (see

Figure 14).

4. Connect the Sensor End of the second sensor cable to P66 on Sensor B (see Figure 14).

5. Connect the Unit End of the cable to P67 on the Liebert iCOM display (see Figure 14). Secure the

ring terminal on the cable shield to the grounding screw adjacent to P67.

Figure 18 Suggested remote sensor placement

recommends installing the sensors in different areas near

17 Liebert® DCP

™

3.0 PIPING

Liebert DCP Cooling Modules

To Building

Chilled Water

3.1 Connection Sizes

The copper pipe connections on the Liebert DCP are:

Building Chilled Water Supply 2-5/8" OD

Chilled Water Return 2-5/8" OD

Coolant Supply 2-5/8" OD

Coolant Return 2-5/8" OD

Fill Water Source 5/8" OD

3.1.1 Recommended Pipe Size

Connect the main pipes between the Liebert DCP and the Liebert DCD™/Liebert XDK-W™ according to site-specific documentation and the configuration guide for the Liebert DCD/Liebert XDK-W unit.

Elbows and restrictions should be minimized to get good fluid flow.

Table 1 Supply and return requirements for Liebert DCD/Liebert XDK-W loop

Maximum Total

Nominal Pipe Size

inches (mm)

2.5 (64) 75 (23) Type L Copper

3 (76) 150 (46) Copper or Schedule 40 Steel

3.5 (89) 300 (91) Copper or Schedule 40 Steel

Equivalent Length

Piping

ft. (m) Piping Material

3.2 Air Bleeders

Install air bleeders at each high point in the piping circuits.

3.3 Liebert DCP Interconnection with Cooling Modules

All piping must be ASTM (American Society for Testing and Materials) Type ACR copper pipe. The Liebert DCP may be connected to Liebert DCD or Liebert XDK-W cooling modules with either

prefabricated piping assembly or rigid, off-the-shelf piping. The cooling modules are connected in parallel between main return and supply pipes going to and from the Liebert DCP. represents a typical configuration.

Figure 19 Liebert DCW system diagram

Figure 19

Liebert® DCP

™

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