Emerson Liebert InteleCool2 User Manual
Precision Cooling
For Business-Critical Continuity
Liebert InteleCool2
User Manual - Outdoor Wall-Mount Air Conditioner,1.5 - 5 Tons, 50 & 60 Hz
™
TABLE OF CONTENTS
1.0 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Standard Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Optional Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3.1 Refrigeration System Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 Ancillary Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.0 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2.1 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1.1 Room Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1.2 Location Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.1.3 Equipment Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2 Unit Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3 Piping Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4 Ducting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.5 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.5.1 Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.5.2 Control Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.6 Outside Air Damper - Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.7 Economizer - Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.0 CHECKLIST FOR COMPLETE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
4.0 START-UP PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.0 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.1 Compressorized Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.2 Economizer Cooling - Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.2.1 Enthalpy Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.2.2 Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.3 Heating - Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.4 Unit Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.4.1 Remote Control Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.4.2 High Pressure (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.4.3 Refrigeration Control Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.4.4 Anti-Short Cycle Timer - Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.4.5 Heater Protection - With Optional Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.4.6 Lockout Relay - Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.4.7 Common Alarm - Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.0 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
6.1 Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.2 Blower Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.3 Economizer - Optional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.4 Heat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
i
6.5 Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.5.1 Refrigerant Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.5.2 Discharge Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.5.3 Thermostatic Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.5.4 Air-Cooled Condenser. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.6 Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.6.1 Compressor Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7.0 SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
7.1 Dimensional Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
7.2 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
8.0 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
9.0 MAINTENANCE INSPECTION CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
10.0 PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
ii
FIGURES
Figure i Model number designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
Figure 1 Unit mounting dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 2 Low volt wiring terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Figure 3 Mounting minimum position potentiometer on actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Figure 4 Refrigeration system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Figure 5 Enthalpy control setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Figure 6 Dimensional data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Figure 7 Condenser/piping assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Figure 8 Crankcase heater (reciprocating compressor only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Figure 9 Evaporator blower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Figure 10 Evaporator coil and expansion valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Figure 11 Electric panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Figure 12 Heater assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Figure 13 Economizer assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Figure 14 Common alarm assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Figure 15 Soft start device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
TABLES
Table 1 Mounting dimensional data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Table 2 Operating modes/contact closures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Table 3 Recommended applications for control options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Table 4 Pressure information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Table 5 InteleCool2 dimensional data in. (mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Table 6 Technical data, 60 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Table 7 Technical data, 60 Hz, continued . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Table 8 Technical data, 50 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Table 9 Technical data, 50 Hz, continued . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Table 10 Optional heater capacity, 60 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Table 11 Optional heater capacity, 50 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Table 12 Electrical data, 60 Hz - amps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Table 13 Electrical data, 50 Hz - amps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Table 14 Troubleshooting guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Table 15 Refrigeration system parts, 1.5 and 2 ton units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Table 16 Refrigeration system parts, 3 ton units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Table 17 Refrigeration system parts, 4-ton units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Table 18 Refrigeration system parts, 5-ton units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Table 19 Electric panel, 1.5- and 2-ton units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Table 20 Electric panel parts, 3-ton units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Table 21 Electric panel parts, 4-ton unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Table 22 Electric panel parts, 5-ton unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Table 23 Motor parts, heater, Economizer, 1.5- and 2-ton units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Table 24 Motor parts, heater, Economizer, 3-ton units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Table 25 Motor parts, heater, Economizer, 4-ton units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Table 26 Motor parts, heater, Economizer, 5-ton units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
iii
Figure i Model number designation
External Telecommunication
0=Standard Supply & Return
Openings
3=4 or 5 Ton Unit With 3 Ton
Supply & Return Openings
ET 0 36 H R P F B T
Nominal Btuhs (1000)
H = Hermetic Compressor
S = Scroll Compressor
R = Right Compressor
L = Left Compressor
P = 208/230V – 1 ph - 60 hz
S = 220/240 – 1 ph - 60 hz
A = 460V – 3 ph - 60 hz
Y = 208/230V – 3 ph - 60 hz
N = 200/230 – 3 ph - 50 hz
M = 380/415V – 3ph - 50 hz
0 = Standard
F = Fixed Outside Air Damper
E = Economizer
0 = No Heat
A = 5 kW Heat
B = 10 kW Heat
C = 15 kW Heat
T = Tan, Painted Steel Panels
C = Custom Color, Painted Steel Panels
A = Aluminum Panels
iv
1.0 INTRODUCTION
1.1 General
The Liebert InteleCool®2 Environmental Control System was designed for convenience and dependability in unmanned and remote locations typical of the telecommunications industry. Ease of installation,
operation and service coupled with the use of high quality, high reliability components make InteleCool2
ideally suited for maintaining an environment for sensitive electronic equipment. Standard units are
NRTL-C listed/certified to meet U.S. and Canadian safety standards, and MEA listed for New York City
applications. These agency listings insure fast, hassle-free inspection and building code approvals.
Self-Contained
The InteleCool2 product is completely self-contained. All components are enclosed in the weatherproof cabinet.
Space Savings
The InteleCool2 does not use any of the valuable floor space inside the secure space. Instead, it is
mounted on the outside wall. No additional space is required outside or on a roof.
Easy to Install
The InteleCool2 is assembled, wired, piped, charged with refrigerant, and fully factory tested as a system to ensure trouble free installation and start-up.
1.2 Standard Features
Reciprocating Hermetic Compressor—1.5, 2 and 3 Ton Units
The heart of the refrigeration system is a reciprocating hermetic compressor. The compressor features
a suction gas cooled motor, internal centrifugal oil pump, vibration isolating mountings, internal
thermal overloads, and crankcase heater.
Scroll Compressor—4 and 5 Ton Units
The quiet and efficient scroll compressor features a suction gas cooled motor, internal centrifugal oil
pump, vibration isolating mountings and internal thermal overloads.
Refrigeration System
The refrigeration circuit includes a liquid line filter drier, an externally equalized expansion valve,
and a high-pressure switch.
Evaporator Coil
The evaporator coil is constructed of mechanically expanded copper tubes in enhanced surface aluminum fins. A coated, galvanized steel condensate drain pan is provided.
Condenser Coil
The air-cooled condenser coil is constructed of mechanically expanded copper tubes in enhanced surface aluminum fins. Components rated for up to 115°F (46°C) ambient.
Evaporator Blower
Evaporator air is supplied by a direct drive blower package. Fans are centrifugal, double width, double inlet.
Filter
The filter is 2 inches deep, pleated, with a minimum efficiency rating of 20% (based on ASHRAE standard 52.1). Located within the cabinet, the filter is serviceable from the front of the unit.
Cabinet
The exterior cabinet is constructed of painted steel. Internal structural parts (including base) are hot
dipped galvanized steel. The evaporator compartment is insulated with 1/2" thick, 2 lb. density, neoprene-faced, fiberglass insulation.
Control Interface
The unit is supplied with customary HVAC wiring designations (R, G, W, Y) inside the low voltage
partition of the unit electric box. The control interface can be provided by sources ranging from a wall
mounted thermostat, a Liebert control and monitoring system or a third party building management
control.
Introduction
1
1.3 Optional Features
4 or 5 Ton Unit With 3 Ton Openings
The 4 or 5 ton units with 3 ton supply and return openings are designed to replace 3 ton wall mounted
air conditioners using existing wall openings. The economizer/fresh air option is not available. Return
filter is located in the return air grille and must be selected from accessory equipment.
Scroll Compressor—Optional on 1.5, 2 and 3 Ton Units
The quiet and efficient scroll compressor features a suction gas cooled motor, internal centrifugal oil
pump, vibration isolating mountings and internal thermal overloads.
Compressor Location
The standard compressor location is on the right when viewing the unit when it is mounted on the
wall. The optional compressor location is on the left, to improve serviceability of the compressor when
the unit is installed as one unit of a pair.
Compressor Crankcase Heater
An optional compressor crankcase heater is available for use with the scroll compressor but is not
required because the refrigerant charge of the InteleCool2 unit with scroll compressor is less than the
compressor critical charge.
High Ambient Condenser
This option is provided for applications where the ambient temperature exceeds the normal design
capabilities of the units. It consists of a condenser motor and fan blades which are sized to provide
additional airflow across the condenser coil. Designed for applications up to 125°F (51°C) ambient.
Introduction
Heat
Heat is provided in a single stage from an open wire electric resistance element. Heating capacity
options available are 5 kW, 10 kW, and 15 kW depending on unit model size.
Economizer
The Economizer allows outside air to be introduced to the space through the evaporator filter when
conditions are favorable for Economizer cooling. It contains a modulating damper, spring return
direct drive actuator, enthalpy control for switchover, outside air hood and a mixed air controller set
at 55°F (12.8°C). Mechanical cooling and Economizer operation do not operate simultaneously.
Fresh Air Damper
Allows outside air to be brought in to meet indoor air requirements. Air is drawn in through the evaporator filter. The amount of air to be introduced to the space is field selectable.
Panel Colors
Optional color choices for the steel panels are almond (light tan, the color option for the original
InteleCool), desert brown, or bright white.
Lockout Relay
The lockout relay latches the detection of a high-pressure condition in the refrigeration circuit and
prohibits operation of the compressor until the abnormal pressure conditions are acknowledged. The
lockout relay is reset by cycling the unit main power or by changing the setpoint on the thermostat to
temporarily eliminate a call for cooling. A normally open set of contacts is provided to terminals 2 and
3 of the customer terminal strip for monitoring the status of the lock out relay when this option is supplied without the Common Alarm option.
Common Alarm
The common alarm provides the necessary components to detect high pressure, low pressure, high
temperature, or loss of indoor airflow, and to provide a customer signal via a contact closure. To detect
low pressure, the optional low pressure switch with bypass, T-pack1 or T-pack2 must also be selected.
Soft Start
Provides a PTC resistor to assist the start of the compressor motor in low voltage operation. Available
only on single phase units.
2
1.3.1 Refrigeration System Options
Low Pressure Switch and Low Pressure Bypass Timer
Low Pressure Switch: Used to protect the InteleCool2 if the evaporator blower fails, the air filter
becomes clogged, the refrigeration circuit malfunctions or if there is loss of refrigerant. The low pressure switch is activated when the suction pressure drops below its cutout setting. When activated, the
low pressure switch inhibits operation of the compressor and condenser fan. The switch will automatically reset once the system pressure rises above its cut-in setting.
Low Pressure Bypass Timer: Also known as the Condenser Low Ambient Control or Winter Start
Option), the low pressure switch is used when starting the system when the outdoor temperature is
low. A few minutes after start-up, the low pressure switch resumes normal operation. This option can
be used for applications down to 50°F (10°C). For control down to -20°F (-28.9°C), use the T-pack1 or
T-pack2.
T-pack1
This option provides a Low Pressure Switch, a Low Pressure Bypass Timer (described above), and a
Fan Cycle Control. This option package is one of the preferred control packages for telecommunication industry applications.
The Fan Cycle Control, also known as the Condenser Fan Cycling Control, consists of a reverse-acting
pressure switch. When the outdoor temperature is low, the pressure switch cycles the condenser fan
to maintain discharge pressures that will allow the systems to function. It is to be used when the outdoor ambient temperature is lower than 50°F (10°C) down to -20°F (-28.9°C).
T-pack2
This option includes a Low Pressure Switch, a Low Pressure Bypass Timer (described above), and an
adjustable Fan Cycle Control, which acts as described in the preceding paragraph, except that it is
adjustable. This option package is one of the preferred control packages for telecommunication industry applications.
Introduction
1.4 Ancillary Components
Wall-Mounted Thermostat
The thermostat provides for heating/cooling application with separate fan control. Supplied with a
thermostat sub-base.
Indoor Supply/Return Grilles
The supply grille is an aluminum louvered, double deflection type grille allowing user adjustment of
direction of air distribution. The return grille is an aluminum louvered, fixed, single-deflection style
grille.
Additional Spare Filters
Additional sets of the 20% efficiency rated filters (efficiency based on ASHRAE standard 52-1) may be
selected.
1.5 Accessories
Dual Unit Control
The hinged cover dual unit control (DUC) has a two-stage heat/cool thermostat with individual heating and cooling setpoints, adjustable interstage differentials, and bimetallic elements. The control
features a solid state timer with 1-2-4-8 day sequence. Unit lead selector, unit 1 & 2 power-on LEDs,
unit 1 or 2 lead unit LEDs, 48 hour program save on loss of power, industry standard connections and
24V power from each unit. The DUC provides auto sequencing and displays on-status and operatingstatus parameters.
Tele2 C ontro l
This microprocessor-based controller controls two InteleCool2 units. The unit has a 10-key keypad,
four-row by 20-column LCD, an RS-232 modem port, and an RS-232 terminal port. It allows up to
eight customer-selectable, isolated normally open, dry contact alarm inputs. The Tele2 control
requires either a THS28-30 or a THS28-60 sensor assembly. Models are available for
120/50-60/1 VAC, 230/50-60/1 VAC or 48 VDC power.
3
2.0 INSTALLATION
2.1 Preparation
2.1.1 Room Preparation
The room should be well-insulated and should be sealed to reduce airborne contaminants from penetrating the site. Outside air may be introduced through the damper option or be used for economized
cooling by using the Economizer option. However, uncontrolled outside air should be kept to a minimum. Outside air adds to the cooling, heating, and filtration loads of the site. Doors should be properly sealed to minimize leaks and should not contain grilles.
2.1.2 Location Considerations
The InteleCool2 unit is field-mounted on an outside wall. Additional framing in the wall may be
required to ensure adequate structural support.
The outdoor area near the condenser supply and discharge must also be considered. To assure adequate air supply, the unit should be mounted in a clean area, away from loose dirt and foreign matter
that may clog the condenser coil. The unit should not be located near steam, hot air, or fume exhausts.
Also, the unit should not be mounted closer than 12 feet (3.7 m) from an opposing wall, obstruction or
unit. For service clearance, provide 36 inches (914 mm) in front of the unit, and 30 inches (762 mm) on
each side. When mounting units side by side, provide a minimum of 36 inches (914 mm) between adjacent units unless the adjacent units will not be run at the same time. In this case, the units may be
placed as close as 18 inches (457 mm) apart. However, this will make the units more difficult to service.
In such situations, consider the compressor location option for improved serviceability. Before mounting units, check local codes for applicable clearances.
2.1.3 Equipment Inspection
Upon delivery of the unit, inspect all items for visible damage. Concealed damage may be discovered
later during installation. Report any damage to the shipper immediately and file a damage claim.
Also, forward a copy of the damage claim to your Liebert supplier.
Installation
2.2 Unit Installation
The InteleCool2 unit is installed against, and through, an outside wall. Two (2) openings in the wall
are required for the evaporator supply and return. Provide 1/2" clearance on wall openings for supply
and return air. Install the unit in a level position to assure proper refrigerant flow, oil return, and
condensate drain. To install the unit, follow the instructions below.
1. Verify that an adequate structural support is provided for the unit.
2. Using a chalk line, mark the outside wall with a level horizontal line, where the bottom of the unit
is to rest.
3. Prepare supply and return openings in an outside wall, measuring up from the chalk base line.
4. Prepare mounting holes. The mounting holes may be pilot holes for lag screws or clearance holes
for bolts that will extend completely through the wall. Refer to Figure 1 for the location of these
holes.
5. Fasten the unit mounting base angle to the outside wall with six 5/16" bolts or lag screws (not
supplied), just below chalk line and centered on the opening in the wall.
WARNING
!
Use caution and adequate equipment to safely handle unit. Weight of each unit ranges
from 330 to 490 lbs. (150 to 222 kg), depending on model.
6. With the unit front panel removed, lift the unit onto the base angle, making certain that the rear
unit angle falls behind the turned up front edge of the mounting angle. Insert top and side unit
fasteners in holes and tighten, drawing the unit into place. Do not attach ducts to unit prior
to installing unit.
7. Caulk and flash the top and sides as required to form a watertight seal. Top flashing (not factory
supplied) is recommended to ensure that water does not run behind unit. All unit tops are sloped
to allow water to run off.
4
Figure 1 Unit mounting dimensions
Installation
11"
(279mm)
11"
(279mm)
11"
(279mm)
P
J
E
K
A
C
F
K
K
K
DB
G
H
K
See Table 1 below for
keys to dimensions.
L
M ref.
N
Wf
Table 1 Mounting dimensional data
InteleCool 2 dimensional data in. (mm)
Model Wf A B C D E F G H J K L M N P
1.5-2 Ton
3 Ton
4-5 Ton
4 or 5 Ton Unit
w/3 Ton
Openings
38-3/4
(984)20(508)20(508)
38-3/4
(984)28(711)28(711)
42-3/4
30-1/4
(1086)
42-3/4
(1086)
(768)
28
(711)28(711)
29-7/8
(759)
9-3/8
9-13/32
(238)
(239)8(203)
5-3/8
5-3/8
(137)
(137)8(203)18(457)14(356)26(660)
6-1/4
6-7/16
(159)
(164)
7-3/8
7-3/8
(187)
(187)8(203)18(457)14(356)
20-3/4
(527)12(305)
9-7/8
(251)30(762)
15-7/8
(403)
25-1/16
(638)
25-25/64
(645)
37-1/2
(952)
5-15/32
(139)12(305)
5-15/32
(139)12(305)
1-45/64
(43)16(406)
1-45/64
(43)16(406)
3-25/32
(96)
32-5/32
(96)
6-1/64
(24)
15/16
(24)
4-1/2
(114)
4-1/2
(114)
6-1/2
(165)
6-1/2
(165)
2.3 Piping Connections
The InteleCool2 is a self-contained, packaged unit. All refrigerant piping connections are made at the
factory, so no external condenser is required. The evaporator coil condensate drain is factory-supplied
and drains outdoors through the unit base pan. The condensate drain tubing should be checked to be
certain that it is placed through the hole provided in the base pan.
37-7/8
(962)
37-7/8
(962)
41-3/4
(1060)
41-3/4
(1060)
2-15/32
(63)
2-15/32
(63)
4-3/8
(111)
4-3/8
(111)
5
2.4 Ducting
Field-supplied ducting can be attached to the unit duct connection once the unit has been mounted to
the outside wall. The total external static pressure for the duct, including grille, must not exceed the
values shown in Table 5 and Table 6. Indoor discharge air rates are also given in the same tables.
2.5 Electrical Connections
WARNING
!
Use voltmeter to make sure power is turned off before making any electrical connections.
CAUTION
!
Refer to electrical schematic when making connections.
Each unit is shipped from the factory with all internal wiring completed. Refer to the electrical schematic when making connections. Electrical connections to be made at the installation site are: line
voltage power supply to the power input and control wiring to remote control (customer supplied or
Liebert option). DO NOT RUN CONTROL WIRING WITH HIGH VOLTAGE!
2.5.1 Power Connections
All power and control wiring and ground connections must be in accordance with the National Electrical Code and local codes
Use copper wiring only. Make sure that all connections are tight.
Make sure that the voltage supplied agrees with the voltage specified on the unit nameplate. The
InteleCool2 comes standard with a factory-installed circuit breaker, accessible through an external
access panel. An external, wall-mounted power disconnect switch (field-supplied) may be required for
local codes. If necessary, this switch should be wired according to those codes.
For access to the electrical enclosure:
• Remove the screws securing the middle panel and pull the panel down and forward to remove.
• Remove the screws securing the electric box cover and remove cover.
• Verify that the unit wiring is correct for the actual input power. Some units are built with multivoltage serial tags. The transformer may need to be re-tapped if the actual input voltage is different (see serial tag and electrical schematic).
Route the supply power to the customer-supplied disconnect switch (if required) and then to the unit
circuit breaker inside the unit. Route the conduit to the hole provided in the cabinet. Connect the
earth ground to the lug provided near the circuit breaker. Refer to the unit wiring diagram supplied
on the inside of the electrical enclosure cover.
Installation
CAUTION
!
The optional three-phase scroll compressor must rotate in the correct direction to ensure
proper system operation. Wiring must be phased and connected as shown:
• PHASE “A” to T1 or L1
• PHASE “B” to T2 or L2
• PHASE “C” to T3 or L3
2.5.2 Control Connections
Control wiring will be required for the remote control device. This remote device may be a factory- or
field-supplied wall thermostat or similar device. Connections to the unit are made using customary
HVAC low volt wiring terminals R, G, W, and Y. For detailed locations of the low volt wiring terminals, please refer to the Figure 11 - Electric panels.
6
Figure 2 Low volt wiring terminals
Liebert Thermostat
See 2.5.2 - Control Connections for further information, refer to the detailed instructions that ship
with the thermostat.
NOTE
This control contains mercury in a sealed tube. Do not place control in the trash at the end of is
useful life. If this control is replacing a control that contains mercury in a sealed tube, do not
place your old control in the trash. Contact your local waste management authority for
instructions regarding recycling and the proper disposal of this control, or of an old control
containing mercury in a sealed tube.
If you have questions, call the thermostat manufacturer, Honeywell, at 800-468-1502.
Installation
Dual Unit Control
The InteleCool® Dual Unit Control is designed to control two InteleCools in a “lead/lag” fashion. The
control contains an electronic timer for switching the operating sequence of two units on a one-, two-,
four-, or eight-day basis. It also contains a two-stage heat/two-stage cool thermostat with individual
heat and cool set points. Light emitting diodes (LEDs) indicate Lead Unit 1 or 2 and power from
Unit 1 or 2. The schedule for lead/lag switchover is adjustable by moving jumpers on the printed circuit board. A jumper is also used to change lead and lag unit before a scheduled changeover (if necessary for servicing).
WARNING
!
The original Dual Unit Control (part # 153054G1, produced through March 2002), is phase
sensitive. The latest version Dual Unit Control (Part # 171170G1) is not. Please refer to
specific installation instructions supplied with each control. Failure to follow specific
instructions may damage the control and/or the unit and void the warranty.
NOTE
This control contains mercury in a sealed tube. Do not place control in the trash at the end of
its useful life. If this control is replacing a control that contains mercury in a sealed tube, do
not place your old control in the trash. Contact your local waste management authority for
instructions regarding recycling and the proper disposal of this control, or of an old control
containing mercury in a sealed tube.
If you have questions, call the thermostat manufacturer, Honeywell, at 800-468-1502.
Tele2
Consult the Tele2 user manual for installation instructions.
7
2.6 Outside Air Damper - Optional
Units supplied with fixed (non-modulating) outdoor air damper can be adjusted as follows:
1. Remove the screws from the middle panel and remove panel.
2. Loosen the damper plate screws on the backside of the middle panel.
3. Adjust the damper plate to the desired position and tighten damper plate screws.
4. Replace panels.
2.7 Economizer - Optional
Installation
Insert the top flanged edge of the Economizer hood into the Economizer opening on the unit front
panel. Next, attach the bottom left and right corner of the hood with screws (supplied).
Adjustment
Units supplied with Economizer requiring outside air can be adjusted as follows:
1. Run motor to fully closed position and disconnect 24 VAC from terminals TR and TR1.
2. Connect minimum position potentiometer to terminals P and P1. (See Figure 3. T and T1 are
disconnected.)
3. Reconnect 24 VAC to terminals TR and TR1 and adjust potentiometer for desired minimum
position by turning Q709 adjustment screw clockwise to increase minimum position;
counterclockwise to decrease minimum position.
Installation
Figure 3 Mounting minimum position potentiometer on actuator
Push onto
actuator
8
3.0 CHECKLIST FOR COMPLETE INSTALLATION
___ 1. Proper clearance for service access has been maintained.
___ 2. Equipment is level and mounting fasteners are tight.
___ 3. Ducting completed, if required.
___ 4. Line voltage to power wiring matches equipment nameplate.
___ 5. Power wiring connections completed to disconnect switches, including earth ground. Proper
phase rotation has been observed so that scroll compressor will rotate in the correct direction.
___ 6. Power line circuit breakers or fuses have proper ratings for equipment installed.
___ 7. Control wiring connections completed to optional controls.
___ 8. All wiring connections are tight.
___ 9. Foreign materials have been removed from in and around all equipment installed (shipping
materials, construction materials, tools, etc.).
___ 10. Fans and blowers rotate freely without unusual noise.
WARNING
!
Potentially lethal voltages exist within this equipment during operation. Observe all cautions
and warnings in this manual. Failure to do so could result in serious injury or death. Only
qualified service and maintenance personnel should work with this equipment.
Checklist for Complete Installation
9
4.0 START-UP PROCEDURE
Verify that installation is complete by using the Checklist for Complete Installation.
1. Disconnect all power to the InteleCool2 unit.
2. Adjust remote control to prevent compressor, heat and fan operation.
3. Turn on main breaker and check line voltage on main unit disconnect switch. Line voltage must
be within ± 10 volts of nameplate voltage.
4. Turn ON main unit disconnect switch and check secondary voltage at transformer T1. Voltage at
T1 must be 24 VAC ±2.5V.
5. From the remote control, verify proper operation in all modes.
6. Make sure all blowers, fans, and the scroll compressor are rotating in the correct direction.
7. Check the current draw on all line voltage components and compare with unit nameplate.
8. Check adjustment of the optional outside air damper for the desired balance between the flow of
room air and outdoor air. Use a gauge or non-polluting airflow indicator.
NOTE
If the unit is supplied with crankcase heaters, Liebert recommends that the high voltage be
applied between four and six hours before start-up.
Start-Up Procedure
10
5.0 OPERATION
5.1 Compressorized Cooling
Compressorized cooling is provided by a high efficiency system consisting of a compressor, thermostatic expansion valve, evaporator, and condenser coil.
The InteleCool2 uses R-22 refrigerant in a conventional vapor-compression refrigeration cycle. Heat
is removed from the air in the space by blowing the air across the evaporator coil. As heat is transferred to the refrigerant in the evaporator, the refrigerant boils and turns to a warm vapor. The
refrigerant vapor enters the compressor and is compressed, resulting in high pressure and temperature. After entering the condenser, the hot vapor is condensed to a liquid by the air blown across the
condenser coil. Liquid refrigerant then passes through the thermal expansion valve and into the evaporator. The expansion reduces the pressure and temperature to complete the cycle.
Figure 4 Refrigeration system
Evaporator
Operation
Thermal expansion
valve (not shown)
Liquid line
Filter drier
Compressors:
Hermetic Reciprocating (1.5, 2 and 3 ton units)
or Scroll
Optional compressor location available
Liquid line
Condenser
11
Loading...