Emerson Liebert Prop Fan Condensing Unit User Manual

Precision Cooling
For Business-Critical Continuity™

Liebert Prop Fan Condensing Unit

Installation, Operation and Maintenance Manual - 50 & 60Hz

™

Figure i Model number nomenclature

Prop Fan Condensing
Unit with Hot-Gas
Bypass

0 = Standard Noise Level
Z =Quiet-Line

Nominal Capacity
1000 BTU/Hr

P = 208/230-1ph-60Hz
Y = 208/230-3ph-60Hz
A = 460-3ph-60Hz
B = 575-3ph-60Hz
S = 220-1ph-50Hz
N = 200/230-3ph-50Hz
M = 380/415-3ph-50Hz

R-407C Refrigerant

— = Standard Coil
C = Coated Coil

PFH 0 37 — P L 7

A = Air Cooled

A

L = 95°F (35°C) Ambient

Liebert Lee-Temp

H = 105°F (41°C) Ambient

Liebert Lee-Temp

Not all options and/or voltage combinations are available.

Example: PFH037A-PL7

TABLE OF CONTENTS

1.0 PRODUCT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

1.1 Prop Fan Condensing Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.1.1 Base System 95°F (35°C) Ambient Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.1.2 105°F (41°C) Ambient Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.1.3 Quiet-Line Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.2 Optional Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.2.1 Coated Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.2.2 Pre-Charged Refrigeration Line Sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.2.3 Refrigerant Line Sweat Adapter Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.2.4 277V Step-Down Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2.0 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

2.1 Equipment Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2.2 Location Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2.3 Dimensional Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.4 Piping and Electrical Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.5 Piping Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.5.1 Piping for Elevation Differences between PFH and Evaporator . . . . . . . . . . . . . . . . . . . . . . . 14

2.5.2 Pre-Charged Line Sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2.5.3 Field-Fabricated Line Sets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2.5.4 Installation of Piping to Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2.5.5 R-407C PFH Installed as a Replacement Condensing Unit in an R-22 System . . . . . . . . . . . 18

2.5.6 General System Charge Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

2.6 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2.6.1 Low-Voltage Control Wire Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2.6.2 Low-Voltage Control Wire Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

2.7 Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

2.8 Checklist for Completed Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3.0 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

3.1 Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

3.2 High Head Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

3.3 Liebert Lee-Temp Flood Back Head Pressure Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

3.4 Hot Gas Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

3.4.1 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

3.4.2 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

4.0 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

4.2 Compressor Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

4.2.1 Electrical Failure—Burnout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

4.2.2 Mechanical Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

4.3 Compressor Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

4.4 Field Charge Verification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

5.0 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

i

FIGURES

Figure i Model number nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inside Front Cover

Figure 1 Dimensions, horizontal air discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Figure 2 Dimensions, top air discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Figure 3 Dimensional data, 277V step-down transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Figure 4 Piping and electrical connections, horizontal discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Figure 5 Piping and electrical connections, top air discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Figure 6 General piping arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Figure 7 Electrical field connections, 1- to 5-ton units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Figure 8 Electrical field connections, 8-ton units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Figure 9 Single-phase, 1-3 ton model schematic, typical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Figure 10 Three-phase, 3-5 ton model schematic, typical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Figure 11 Three-phase, 8 ton model schematic, typical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Figure 12 Refrigerant piping diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Figure 13 Hot gas bypass diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

TABLES

Table 1 Cabinet and floor planning data, horizontal air discharge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Table 2 Electrical and piping connections, top air discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Table 3 Electrical and piping connections, horizontal air discharge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Table 4 Piping and electrical connections, top air discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Table 5 Pipe length and condenser elevation relative to evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Table 6 Equivalent lengths for various pipe fittings, ft (m). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Table 7 Refrigerant charge in Liebert pre-charged R-407C line sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Table 8 Liebert PFH unit charge levels and coupling size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Table 9 Recommended line sizes, OD Cu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Table 10 Piping connection sizes and torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Table 11 Line charges - refrigerant per 100 ft. (30m) of Type L copper tube . . . . . . . . . . . . . . . . . . . . . . . . 18

Table 12 Evaporator Charge Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Table 13 Design refrigerant pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Table 14 Application limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Table 15 Recommended minimum wire size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Table 16 Electrical data—Standard sound and ambient models (95°F/35°C) 60Hz . . . . . . . . . . . . . . . . . . 22

Table 17 Electrical data—High ambient models (105°F/41°C) 60Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Table 18 Electrical data—Quiet-Line models (95°F/35°C) 60Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Table 19 Electrical data—Standard sound and ambient models (95°F/35°C) 50Hz . . . . . . . . . . . . . . . . . . 23

Table 20 Electrical data—High ambient models (105°F/41°C) 50Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Table 21 Electrical data - Quiet-Line models (95°F/35°C) 50Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Table 22 Field verification charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Table 23 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

ii

1.0 PRODUCT DESCRIPTION

1.1 Prop Fan Condensing Units

Liebert propeller fan condensing units are available in a range of sizes and configurations to offer
flexibility in designing a precision environmental control system. The appropriate propeller fan con­densing unit paired with a corresponding Liebert fan coil evaporator model such as Liebert Data­Mate, Liebert Mini-Mate2 or Liebert Challenger 3000 is an effective solution for your environmental
control application requirements.

Split system condensing units are connected to the evaporator unit by two refrigerant lines (four in
8-ton systems) and a low-voltage control cable. The condensing unit requires a separate power source
and power disconnect switch.

1.1.1 Base System 95°F (35°C) Ambient Models

The heart of the refrigeration system is a quiet, high efficiency scroll compressor with internal vibra­tion isolation mountings, pressure safety controls and built-in overload protection. Standard features
include crankcase heater, high pressure switch, condenser coil, sight glass, filter drier, hot gas bypass
system with liquid quenching valve, direct drive propeller fan and motor, and Liebert Lee-Temp flood­back head pressure control. These models are designed to provide catalog capacity of the appropriate
evaporator section up to 95°F (35°C) outside ambient temperature.

1.1.2 105°F (41°C) Ambient Models

These models contain similar components to the base models except the coils and fans are sized to
provide catalog capacity of the appropriate evaporator section up to 105°F (41°C) outside ambient
temperature.

Product Description

1.1.3 Quiet-Line Models

These models contain similar components to the base models except the coils and fans are sized to
provide catalog capacity of the appropriate evaporator section up to 95°F (35°C) outside ambient tem­perature with a noise level of less than 58 dBA.

1.2 Optional Equipment

1.2.1 Coated Coil

This option provides a phenolic coating for the condenser coil (extended lead time is required for this
option; consult factory).

1.2.2 Pre-Charged Refrigeration Line Sets

For efficient condenser/evaporator connection, factory pre-charged line sets with quick connect fit­tings are available in 15-ft. and 30-ft. (4.5m and 9m) lengths. Each set includes an insulated copper
suction line and copper liquid line, both charged with R-407C refrigerant and sealed. Line sets are
only available for 1 to 3.5 Ton Units.

1.2.3 Refrigerant Line Sweat Adapter Kit

This kit includes the compatible fittings required (two for the insulated suction line and two for the liq­uid line) when using field-supplied interconnecting refrigerant lines instead of the pre-charged line sets.

1.2.4 277V Step-Down Transformer

A 37.5A, 277V step-down transformer is available for 1-to 3-Ton 60Hz condensing units needing
277/1/60 input power. Apply this transformer to a 208/230/1/60 condensing unit. The transformer is
coated with epoxy and contained in an enclosed, non-ventilated electrical box with adaptable mount­ing brackets.

1

2.0 INSTALLATION

Read this entire installation section before starting installation. This section details dimensional,
electrical and piping information and specifications that affect the placement of the PFH unit in rela­tion the connected evaporator unit, other outside units, barriers and walls.

Be particularly mindful of service and airflow clearances and maximum equirvalent piping distances
and in elevation differences between PFH and connected evaporator unit. Consult and confirm appli­cations with your Emerson Network Power representative when applications exceed any of these
specifications.

2.1 Equipment Inspection

When the unit arrives, inspect all items for any visible or concealed damage. Report any damage to
the carrier immediately and file a damage claim; send a copy of the claim to Emerson Network Power
or your local Emerson sales representative.

If possible, maintain equipment and packaging until it is at the installation location.

2.2 Location Considerations

To ensure an adequate air supply, locate all condensing units in a clean-air area, away from loose dirt
and debris that can clog the coil. Avoid ground-level sites with public access or areas that are exposed
to heavy snow accumulation. Locate unit to allow maximum security and maintenance accessibility.

Installation

Do not locate condensing units near steam, hot air or fume exhausts. Do locate units at least 18 in.
(457mm) from walls, obstructions or adjacent units. For multiple unit installations, space unit so that
the hot condenser exhaust air is not directed toward the condenser air inlet of an adjacent unit.

Install a solid base at least 2 in. (51mm) higher than the surrounding grade and 2 in. (51mm) larger
than condensing unit base dimensions and capable of supporting the condenser’s weight.

2

2.3 Dimensional Data

A

B

C

C

Fan Rotation
CCW
(left side)

Shaded area
indicates a minimum
clearance of 18" (457mm)
for proper air flo w.

Shaded area
indicates a minimum
clearance of 18" (457mm)
for proper air flow

Shaded area
indicates a recommended
clearance of 24" (610mm)
for component access and
removal.

DPN000130
Rev. 0

Removable panel for access
to high-voltage and low-voltage
connections and refrigeration
components

Right Air Discharge

Removable (right) panel
for access to
refrigeration component

Left Air Intake

Figure 1 Dimensions, horizontal air discharge

Installation

Table 1 Cabinet and floor planning data, horizontal air discharge

Model Numbers Dimensional Data, in. (mm)

60Hz 50Hz A B C

PFH014A-L PFH013A-L

PFH027A-L PFH026A-L

PFH027A-H PFH026A-H

PFHZ27A-L PFHZ26A-L

PFH037A-L PFH036A-L

PFH042A-L PFH041A-L

PFH037A-H PFH036A-H

PFHZ37A-L PFHZ36A-L

PFH042A-H PFH041A-H

PFHZ42A-L PFHZ41A-L

PFH067A-L PFH066A-L

40 (1016) 23-1/2 (597) 18 (457) 200 (91)PFH020A-L PFH019A-L

48 (1219) 31 (787) 18 (457) 241 (109)

53 (1343) 36-1/4 (918) 18 (457) 351 (159)

3

Net Weight

lb. (kg)

Figure 2 Dimensions, top air discharge

Guard Height

Fan Rotation

CW

Shaded area
indicates a minimum
clearance of 18" (457mm)
for proper air flow.

Shaded area
indicates a minimum
clearance of 18" (457mm)
for proper air flow

Shaded area
indicates a recommended
clearance of 24" (610mm)
for component access and
removal.

DPN000131
Rev. 0

Removable panel for access
to high-voltage and low-voltage
connections and refrigeration
components

To p A i r
Discharge

Right Air Intake

Left Air
Intake

4-23/32"

(120mm)

36-1/8"

(918mm)

25-3/32"

(637mm)

46-7/32"

(1174mm)

2"

(51mm)

2"

(51mm) typ.

2"

(51mm)

2"

(51mm)

53-3/16"

(1351mm)

4"

(102mm) typ.

32-1/8"

(816mm)

FOOTPRINT DIMENSIONS

1/2" Bolt-Down Holes
(6 places)

Installation

Table 2 Electrical and piping connections, top air discharge

Model Numbers Dimensional Data in. (mm) Module Net

PFH067A-H PFH066A-H

PFHZ67A-L PFHZ66A-L

PFH096A-L PFH095A-L 570 (259)

53 (1343) 36-1/4 (918) 38-1/2 (978) 5-1/2 (140)

4

Weight lb.

(kg) .60Hz50HzABCD

488 (222)

Figure 3 Dimensional data, 277V step-down transformer

DPN000647
REV. 0

Notes:

1. 1D18214P1 = Acme catalog no. T-1-37921 for all small systems except 3-ton Liebert DataMate
with integral condenser.

2. 1D18214P2 = Acme catalog no. T-1-37922 for 3-ton Liebert DataMate with integral condenser.

3. Epoxy coated. Suitable for indoor/outdoor service. Horizontal- or vertical-mount.
Totally enclosed, non-ventilated.

4. Both brackets are shipped loose with transformer.

WIRING FOR TRANSFORMER

WALL MOUNTING

RIGID MOUNTING

4.92"

(125mm)

5.5"

(140mm)

.281" (7mm) Dia.
For wall mounting

1D18214P1

10.3" (262mm)
1D18214P2

11.68" (297mm)

Remove screws &
attach bracket

Access to electrical
connections from
bottom

.31" (8mm) Dia.
For rigid mounting
and shipping

1/4-20 (2 screws &
lock washers) for
rigid mounting and
shipping

277V line voltage

Jumpers

H4

H3

H2

H1

X4

X3 X1X2

230V to unit

Notes:

1. Jumper as shown.

2. Connect 277V line to H4 and X1

3. Connect 230V load to H1 and H4

Installation

5

2.4 Piping and Electrical Connections

B

C

A

F

G

D

E

DPN000132
Rev. 0

Liquid Line
Quick Connect
(Male Coupling)

Suction Line
Quick Connect
(Male Coupling)

Electrical Entrance for
High-Voltage Connection

Electrical Entrance for
Low-Voltage Connection

Figure 4 Piping and electrical connections, horizontal discharge

Installation

Table 3 Electrical and piping connections, horizontal air discharge

Model Numbers Electrical Connections, in (mm) Piping Connections, in. (mm)

60Hz 50Hz A B C D E F G

PFH014A-L PFH013A-L

PFH027A-L PFH026A-L

PFH027A-H PFH026A-H

PFHZ27A-L PFHZ26A-L

PFH037A-L PFH036A-L

PFH042A-L PFH041A-L

PFH037A-H PFH036A-H

PFHZ37A-L PFHZ36A-L

PFH042A-H PFH041A-H

PFHZ42A-L PFHZ41A-L

PFH067A-L PFH066A-L

2-1/4 (57) 5-1/4 (133) 7-3/4 (197) 8-3/4 (222) — 5 (127) 7-1/4 (184)PFH020A-L PFH019A-L

2 (51) 5-3/4 (146) 8-1/2 (216) 4-3/4 (121) 6-3/4 (171) — 8-1/2 (216)

2 (51) 6 (152) 8-1/2 (216) 4-3/4 (121) 7-3/4 (197) — 8-1/2 (216)

6

Figure 5 Piping and electrical connections, top air discharge

* Sy stem 1 and System 2 on 8 Ton only

Electrical Entrance for
High-Voltage Connection

Electrical Entrance for
Low-Voltage Connection

Liquid Line
Quick Connect
(Male C oupling)

Suction Line
Quick Connect
(Male Coupling)

* System 2 (5 Ton)

DPN000133
Rev. 0

* Sy stem 1 (3 Ton)

Installation

Table 4 Piping and electrical connections, top air discharge

Electrical Connections

Model Numbers

60Hz 50Hz A B C D E F G

PFH067A- H PFH066A-H

PFHZ67A- L PFHZ66A-L —

PFH096A- L PFH095A-L 11-1/2 (292)

2

(51)

in. (mm)

6

(152)

8-1/2
(216)

4-3/4
(121)

Piping Connections

in. (mm)

7-3/4
(197)

8-1/2
(216)

—

7

Figure 6 General piping arrangement

Pressure Balancing
Valve

DPN000129 REV 1

Condenser
Coil

High Pressure
Switch

Compressor *

Hot Gas Bypass
Solenoid Valve

Hot Gas Bypass
Control Valve

3 - Way Head
Pressure
Control Valve

Check Valve

Liquid Injection
Valve Bulb

Pressure Relief Valve

Sight
Glass

Liebert Lee-Temp
Receiver

Liquid Line
Solenoid Valve

Liquid Line Male Quick
Connect Coupling

Liquid Injection
Val ve

Suction Line
Male Quick
Connect Coupling

SINGLE CIRCUIT SHOWN

SINGLE CIRCUIT = 1 - 5 Tons

DUAL CIRCUIT = 8 Tons

Receiver Heater
Pressure Limiting
Switch

* Reciprocating compressor 1 Ton, 60Hz
Scroll compressor 1 Ton, 50Hz and 1-1/2 to 8 Tons

Installation

8

Figure 7 Electrical field connections, 1- to 5-ton units

Horizontal Air Discharge Models

DPN000134
Rev. 1

Field-supplied unit
disconnect switch

Single- or three-phase
electric service not provided
by Liebert

Factory-wired
to components on
electric panel

Heat rejection connection.
Field-supplied 24V NEC
Class 2 wiring.
Wire connections from
evaporator module:

1. 24V GND

2. 24V Supply

3. High Pressure Alarm

4. Hot Gas Bypass Connection

Electric service connection
to contactor or terminal block

Single- or three-phase electric
service not provided by Liebert

High-voltage electric power
supply entrance

Low-voltage electric
power supply
entrance

Earth ground connection
terminal for field wiring

Field-supplied unit
disconnect switch

Single- or three-phase
electric service not provided
by Liebert

Field-supplied 24V
NEC Class 2 wiring
to evaporator module

Field-supplied 24V
NEC Class 2 wiring
to evaporator module

Top Air Discharge Models

(5 Ton High Ambient or 5 Ton Quiet-Line)

Refer to tables or unit serial label
for FLA, WSA and OPD values.

Installation

9

Figure 8 Electrical field connections, 8-ton units

Factory-wired
to components on
electric panel

DPN000135
Rev. 1

Electric service
connection to contactor
or terminal block

Single- or three-phase electric
service not provided by Liebert

High-voltage
electric power
supply entrance

Low-voltage electric
power supply
entrance

Earth ground connection
terminal for field wiring

Field-supplied unit
disconnect switch

Single- or three-phase
electric service not provided
by Liebert

Field-supplied 24V
NEC Class 2 wiring
to evaporator module

Heat rejection connection.
Field-supplied 24V NEC
Class 2 wiring.
Wire connections from evaporator module:

1. 24V GND System 1

2. 24V Supply System 1

3. High Pressure Alarm System 1

4. Hot Gas Bypass Connection System 1

5. 24V GND System 2

6. 24V Supply System 2

7. High Pressure Alarm System 2

8. Hot Gas Bypass Connection System 2

9. 24V GND Condenser Fan

10. 24V SUPPLY Condenser Fan

Refer to tables or unit serial label
for FLA, WSA and OPD values.

Installation

10

Figure 9 Single-phase, 1-3 ton model schematic, typical

3

2

4

1

C1

HG1

BR

W

BL

1

4

2

3

BK

BK

R

R

R

LLSV

BK

BK

R

'FM'

FAN

MOTOR

2C1

1C1

R

BK

RHTR

BK

BK

RRR BK

BR

Y

Optional on
Selected Units

Supplied on
1-Ton PFC
Models Only

BR

CRS
COMP

1

5

2

PR

BDR

C

CSR

A

B

Y

Conductors Field-Supplied
(See Note 5)

HGBP Signal
Output
Connection

EVAPORATOR UNIT

Unit Alarm
Input
Connection

24V Ground

Earth Ground
By Others

1-Phase Line
Voltage Supply
By Others
(See Notes 1 & 3)

OUTDOOR CONDENSING MODULE

See Note 6

HG1

CHTR

BK

BK

BK

BR

CAP2

CAP1

CAP3

BR

L1

L2

HP1

HP2

HGSV

24V Power
Supply
From Unit
Min 40 Va

1. All units 208/230V, 1 phase. On 208/230V units installed
in Canada only, CSA requires that L1 and L2 are non-neutral
supply conductors. L1 et L2 pour conducteurs d'alimentation
non-neutres. On other units, L2 is designated neutral. See
unit name plate and installation manual for main supply wiring
information. Use copper conductors onl y.

2. Use copper conductors onl y. See unit nameplate for main supply
wire sizing data. Wire per local codes.

3. A remote disconnect switch is to be field-supplied and mounted
within sight of the condensing unit. See unit nameplate for voltage
and amperage requirements.

4. All motors have internal line break overload protectors.
Three-phase motors protected for primary single-phasing conditions.

25,
27

Factory-Supplied Line Voltage
Field-Installed Line Voltage Wiring
Optional Line Voltage Wiring
Factory-Supplied 24V NEC Class 2 Wiring
Optional 24V Wiring
Factory-Supplied 24V NEC Class 2 Wiring
Factory-Supplied Earth Grounding Wire
Pigtail Leads 24V Wiring
Terminal Strip Connection

OR - Orange
R - Red
BR - Brown
P - Purple
GN - Green
Y - Yellow
BL - Blue
BK - Black
W - White

WIRE COLOR CODE

Insulation Color

GN / Y

Tracer Color

191642
Rev. 0

NOMENCLATURE

Standard Devices

BDR -- Bleed Resistor
C1 -- Condenser Contactor
CAP1 -- Compressor Capacitor
Run
CAP2 -- Fan Motor Capacitor
CAP3 -- Compressor Capacitor
Start
CHTR -- Compressor Heater
COMP -- Compressor
FM -- Fan Motor
HP1 -- High Pressure Switch
(Auto Reset)
HP2 -- Pressure Switch Receiver
(Auto Reset)
LLSV -- Liquid Line Solenoid Valve
PR -- Potential Relay
RHTR -- Receiver Heater

Optional Devices

CSR -- Compressor Start Resistor
HG1 -- Hot Gas Relay
HGSV -- Hot Gas Solenoid Valve

5. Terminals 1,2,3, and 4 are for connection of control circuit from

evaporator unit. Wiring by others to be NEC Class 2 and sized
for 1V maximum drop.

6. Wire '1' is connected to the grounded side of the 24V Class 2 circuit.

Grounding Lug Connection

Installation

11

Figure 10 Three-phase, 3-5 ton model schematic, typical

3

2

4

1

L1

L2

L3

27

27,29,30

HP1

C1

HG1

W

BL

BR

1

4

2

3

BK

CHTR

BR BR

R

BK

HP2

R

BK

RHTR1

RHTR2

HG1 HGSV

LLSV1

BR

R OR

T3

T2

T1

COMP

R

BK

Y

CAP2

BR

1C1

2C1

3C1

BR

BR

F1

F2

TX1

BK

BK

Conductors Field-Supplied
(See Note 5)

HGBP Signal
Output
Connection

EVAPORATOR UNIT

Unit Alarm
Input
Connection

Earth Ground
By Others

3-Phase Line
Voltage Supply
By Others
(See Note 3)

OUTDOOR CONDENSING MODULE

See Note 7

See Note 1

See Note 6

24V Power
Supply
From Unit
Min 40VA

24V Ground

'FM'
Fan

Motor

1. Transformer 'TX1' provided on units with nameplate voltages greater
than 240V.

2. Use copper conductors onl y. See unit nameplate for main supply wire
sizing data. Wire per local codes.

3. A remote disconnect switch is to be field supplied and mounted
within sight of the condensing unit. See unit nameplate for voltage
and amperage requirements.

4. All motors have internal line break overload protectors. Three-phase
motors protected for primary single-phasing conditions.

5. Terminals 1, 2, 3 and 4 are for connection of control circuit from evaporator
unit. Wiring by others to be NEC Class 2 and sized for 1 volt maximum drop.

6. Wire '1' is connected to the grounded side of the 24V Class 2 circuit.

7. Receiver heater No.2 'RHTR2' supplied on 4- and 5-ton standard models and
3/3.5-ton high ambient and Quiet-Line models.

NOMENCLATURE

Standard Devices

C1 -- Condenser Contactor
CAP2 -- Fan Motor Capacitor
CHTR -- Compressor Heater
COMP -- Compressor
F1 -- Transformer Fuse 1
F2 -- Transformer Fuse 2
FM -- Fan Motor
HP1 -- High Pressure Switch
(Auto Reset)
HP2 -- Pressure Switch Receiver
(Auto Reset)

Optional Devices

HG1 -- Hot Gas Relay
HGSV -- Hot Gas Solenoid Valve

Factory-Supplied Line Voltage
Field-Installed Line Voltage Wiring
Optional Line Voltage Wiring
Factory-Supplied 24V NEC Class 2 Wiring
Optional 24V Wiring
Factory-Supplied 24V NEC Class 2 Wiring
Factory-Supplied Earth Grounding Wire
Pigtail Leads 24V Wiring
Terminal Strip Connection

OR - Orange
R - Red
BR - Brown
P - Purple
GN - Green
Y - Yellow
BL - Blue
BK - Black
W - White

WIRE COLOR CODE

Insulation Color

GN / Y

Tracer Color

191643
Rev. 0

LLSV -- Liquid Line Solenoid Valve
RHTR1 -- Receiver Heater No. 1
RHTR2 -- Receiver Heater No. 2
(3-,4-,and 5-ton only)
TX1 -- Transformer Line

Voltage to230V

Grounding Lug Connection

Installation

12

Figure 11 Three-phase, 8 ton model schematic, typical

3

2

10

9

4

1

7

6

8

5

6

L1

L2

L3

See Note 6

See Note 8

See Note 7

See Note 7

See Note 8

See Note 8

See Note 1

See Note 6

C1 Aux.

C2 Aux.

HP1

MF

C1

C2BK

HP2

W

BL

BR

R

BR

R

W

BL

R

BR

5

8

7

1

4

9

10

2

3

BK

BR BR

R

BK

HP3

R

BK

BK

RHTR1

RHTR2

HP4

1C1

2C1

3C1

HG1 HGSV1

LLSV1

BR

BR

BR

1MF

2MF

3MF

BR R OR

T3T2T1

COMP1

T3T2T1

COMP2

BR R OR

1C2

2C2

3C2

HG2

HGSV2

LLSV2

R

F1

F2

TX1

BK

BK

NOTES

1. Transformer TX1 provided on units with nameplate voltages greater than 250V.

2. Use copper conductors only. See unit nameplate for main supply wire sizing data.
Wire per local codes.

3. A remote disconnect switch is to be field-supplied and mounted within sight of the
condensing unit. See unit nameplate for voltage and amperage.

4. All motors have internal line break overload protectors.Three-phase motors
protected for primary single-phasing conditions.

5. Terminals 1 thru 8 are for connection of control circuit from evaporator unit.
(Terminals 4 and 8 are not used by some evaporator models . See Note 7). Wiring by
others to be NEC Class 2 and sized for 1V maximum drop.

6. Connection to Terminals 3 and 7 is used for high head alarm input connection in
evaporator unit.

7. Connection to Terminals 4 and 8 is required only on models with (HGBP) hot gas
bypass control signal output in evaporator unit.

8. Wires 1, 5 and 9 are separately connected to the grounded side of the 24V
Class 2 circuit. Do not connect them together.

STANDARD DEVICES
C1 - Compressor Contactor 1
C2 - Compressor Contactor 2
CHTR1 - Compressor Heater 1
CHTR2 - Compressor Heater 2
COMP1 - Compressor #1
COMP2 - Compressor #2
F1 - Transformer Fuse
F2 - Transformer Fuse
FM - Fan Motor
HP1 - High Pre ssure Switch 1
(Auto Reset)
HP2 - High Pre ssure Switch 2
(Auto Reset)
HP3 - Pressure Switch 3
Receiver (Auto Reset)
HP4 - Pressure Switch 4
Receiver (Auto Reset)
LLSV1 - Liquid Line Solenoid Valve 1
LLSV2 - Liquid Line Solenoid Valve 2
MF - Fan Motor Contactor
RHTR1 - Receiver Heater No.1
RHTR2 - Receiver Heater No.2
TX1 - Transformer Line Voltage to 230V
OPTIONAL DEVICES
HG1 - Hot Gas Relay 1
HG2 - Hot Gas Relay 2
HGSV1 - Hot Gas Solenoid 1
HGSV2 - Hot Gas Solenoid 2

WIRING LEGEND
Factory-supplied line voltage
Field-installed line voltage wiring
Optional line voltage wiring
Factory-supplied 24V NEC Class 2 wiring
Optional 24V wiring
Field-supplied 24V NEC Class 2 wiring
Field-supplied earth grounding wire
Pigtail leads
Terminal strip connection

Grounding lug connection

WIRE COLOR CODE
OR - Orange
R - Red
BR - Brown
P - Purple
GN - Green

Y - Yellow
BL - Blue
BK - Black
W - White

Insulation Color

GN / Y

Tracer Color

COMP2

Conductors Field-Supplied

(See Note 5)

Evaporator Unit

HIGH HEAD 1

24V GND

COMP1

HGBP1

HIGH HEAD 2

COOLING 2

COOLING 1

HGBP2

OUTDOOR CONDENSING MODULE

3-Phase Line
Voltage Supply
By Others
(See Notes 2 and 3)

Earth Ground
By Others

CHTR1

CHTR2

FM

Fan

Motor

HG2

HG1

Installation

13

2.5 Piping Considerations

The Liebert Mini-Mate2, Liebert DataMate and the 3-ton Liebert Challenger 3000 split system units
are designed with quick-connect fittings and are factory-charged to proper refrigerant levels. This
permits connecting units without brazing inside critical spaces. These split systems require two
refrigerant lines—an insulated copper suction line and a copper liquid line—between the evaporator
and condensing units. The 8-ton Liebert Mini-Mate2 split system units will require four refrigerant
lines between the evaporator and condensing units. Each refrigeration circuit will need one insulated
copper suction line and one copper liquid line.

Two methods exist for installing the copper suction and liquid lines:

• Using optional pre-charged line sets (for 1- to 3.5-ton R-407C model units only).

• Using optional Sweat Adapter Kit(s) and hard piping between units.

NOTICE

Risk of improper handling of refrigerant. Can cause environmental damage and violation of
environmental regulations.

Refrigerant must handled in accordance with all national, regional and local codes.

NOTE

Proper safety equipment and proper refrigeration tools are required in working with R-407C
refrigerant. Check unit serial tag for correct refrigerant type before topping off or recharging a
system.

Installation

NOTE

Refrigerant R-407C uses a POE (polyol ester) lubricant. The R-407C refrigerant must be
introduced and charged from the cylinder only as a liquid.

NOTE

When installing field piping, care must be taken to protect all refrigerant lines from the
atmosphere, especially when using refrigerants with POE oils. Do not allow the piping to stand
open to air for more than 15 minutes. Units designed for R-407C have a compressor which
contains POE oil that is very hygroscopic; that is, it quickly absorbs water from the air. The
longer the compressor piping is left open to air, the harder it will be to fully evacuate. If left
open too long, the POE oil may need to be replaced before achieving the required vacuum level.

NOTE

Complete all piping and evacuate lines before connecting quick connects when using an
optional sweat adapter kit and field installed hard piping.

Follow all proper brazing practices including a dry nitrogen purge to maintain system
cleanliness.

2.5.1 Piping for Elevation Differences between PFH and Evaporator

System sizes affect the maximum equivalent piping lengths and maximum relative elevation differ­ences between evaporator and condensing unit mounting locations. See Table 5 for requirements.

Traps in refrigerant piping are required when elevation differences exist between evaporator and con­densing unit mounting locations. See Figure 12 for requirements. Table 6 should be used when
traps are required with field-fabricated piping assemblies, to calculate equivalent pipe lengths to
determine if installation will comply with Table 5 requirements.

14

Figure 12 Refrigerant piping diagram

Evaporator

Evaporator

Condensing
Unit

Condensing
Unit

NOTE
When installing remote condensing units below the
evaporator, the suction gas line should be trapped with
an inverted trap to the height of the evaporator . This
prevents refrigerant migration to the compressors
during off cycles . Maximum recommended vertical
level drop to condensing unit is 15 ft. (4. 6m ) .

Pitch down 1/2" (13mm) per 10 ft. (3m)

Suction Line Piping
Condensing Unit Above Evaporator
Traps recommended at the base of riser
exceeding 5 ft (1 .5m) and every 20 feet
(6m) of vertical rise.

Suction Line Piping
Condensing Unit
Below Evaporator

See Table 5 for maximum
vertical rise recommendation
above evaporator.

NOTE
When installing remote condensing units below the
evaporator, the suction gas line should be trapped
with an inverted trap to the height of the evaporator.
This prevents refrigerant migration to the compres­sors during off cycles. Maximum recommended verti­cal level drop to condensing unit is 15 ft. (4.6m).

Installation

Table 5 Pipe length and condenser elevation relative to evaporator

Nominal

System Size

Tons

1 or 1.5 50 (15) 40 (12) 15 (4.6)

2 100 (30) 40 (12) 15 (4.6)

3, 3.5, 5 or 8 150 (45) 50 (15) 15 (4.6)

Max. Equiv.

Pipe Length

ft. (m)

Table 6 Equivalent lengths for various pipe fittings, ft (m)

Copper Pipe

OD, in.

1/2 0.8 (0.24) 1.3 (0.39) 0.4 (0.12) 2.5 (0.76) 0.26 (0.07) 7.0 (2.13) 4.0 (1.21)

5/8 0.9 (0.27) 1.4 (0.42) 0.5 (0.15) 2.5 (0.76) 0.28 (0.08) 9.5 (2.89) 5.0 (1.52)

3/4 1.0 (0.3) 1.5 (0.45) 0.6 (0.18) 2.5 (0.76) 0.3 (0.09) 12.0 (3.65) 6.5 (1.98)

7/8 1.45 (0.44) 1.8 (0.54) 0.8 (0.24) 3.6 (1.09) 0.36 (0.1) 17.2 (5.24) 9.5 (2.89)

1-1/8 1.85 (0.56) 2.2 (0.67) 1.0 (0.3) 4.6 (1.4) 0.48 (0.14) 22.5 (6.85) 12.0 (3.65)

1-3/8 2.4 (0.73) 2.9 (0.88) 1.3 (0.39) 6.4 (1.95) 0.65 (0.19) 32.0 (9.75) 16.0 (4.87)

1-5/8 2.9 (0.88) 3.5 (1.06) 1.6 (0.48) 7.2 (2.19) 0.72 (0.21) 36.0 (10.97) 19.5 (5.94)

Refrigerant trap = Four times equivalent length of pipe per this table

90 Degree

Elbow Copper

Maximum PFH

Level Above

Evaporator, ft. (m)

90 Degree

Elbow Cast

45 Degree

Maximum PFH

Level Below

Evaporator, ft. (m)

Elbow Tee

Gate

Valve

Globe

Valve

Angle

Valve

15

2.5.2 Pre-Charged Line Sets

Liebert pre-charged line sets are available in 15 ft (4.5m) and 30 ft (9m) lengths (see Table 7).

NOTICE

Risk of improper handling and installation of pre-charged lines. Can cause kinks and similar
damage to lines.

Care must be taken to prevent kinking the pre-charged lines for 1-ton and 3.5-ton units.
Use tube benders and make all bends before making connections to either end of the pre-

charged pipes. Coil any excess tubing in a horizontal plane with the slope of the tubing toward
the condensing unit. Use a soft, flexible material to pack around the tubes when sealing
openings in walls to prevent tube damage and to reduce vibration transmission.

Table 7 Refrigerant charge in Liebert pre-charged R-407C line sets

Line Size,

in.

3/8 liquid

5/8 or 7/8
suction

2.5.3 Field-Fabricated Line Sets

Length,

ft. (m)

15 (4.5) 0-5 (0.14)

30 (9) 0-10 (0.28)

15 (4.5) 0-5 (0.14)

30 (9) 0-10 (0.28)

Charge R-407C,

lb-oz (kg)

Installation

All field-fabricated refrigeration piping should be copper piping, brazed using a brazing alloy with a
minimum temperature of 1350°F (732°C), such as Sil-Fos. Use a flow of dry nitrogen through the pip­ing during brazing to prevent formation of copper oxide scale inside the piping. Avoid soft solders such
as 50/50 or 95/5.

Use the sweat adapter kits to terminate the piping at each unit end. Consult factory representatives
to obtain the proper sweat adapter kit. Table 8 has PFH unit connection sizes. Use Table 9 for rec­ommended line sizes.

Prevailing good refrigeration practices should be employed for piping supports, leak testing, evacua­tion, dehydration and charging of the refrigeration circuits. The refrigeration piping should be iso­lated from the building by the use of vibration-isolating supports. Use a soft, flexible material to pack
around the tubes when sealing openings in walls to prevent tube damage and to reduce vibration
transmission.

Before connecting units together with field-fabricated piping, check for leaks and dehydrate
the field piping as follows:

1. Pressurize the field piping to 150 psig (1034 kPa) using dry nitrogen with a trace of refrigerant.
Check system for leaks with a suitable leak detector.

2. After completion of leak testing, release the test pressure (per local code) and triple evacuate the
field piping to 250 microns or lower, breaking the vacuum between the first two evacuations with
dry nitrogen.

3. After the third evacuation, verify 250 microns is maintained for at least one minute after the
piping is isolated from the vacuum pump by a shutoff valve.

Field piping is now ready to be installed between evaporator and condensing units.

16

Table 8 Liebert PFH unit charge levels and coupling size

Model Numbers R-407C Charge Coupling Size

60 Hz 50 Hz lb-oz (kg) Liquid Suction

95°F (35°C) Standard Sound

PFH014A-_L7 PFH013A-_L7

8-6 (3.8) #6 #11PFH020A-_L7 PFH019A-_L7

PFH027A-_L7 PFH026A-_L7

PFH037A-_L7 PFH036A-_L7

PFH042A-_L7 PFH041A-_L7

PFH067A-_L7 PFH066A-_L7 26-10 (12.08) #10 #12

PFH096A-_L7 PFH095A-_L7

3-ton Circuit 3-ton Circuit 22-9 (10.23) #6 #11

5-Ton Circuit 5-Ton Circuit 36-5 (16.47) #10 #12

105°F (41°C) High Ambient

PFH027A-_H7 PFH026A-_H7 13-5 (6.04) #6 #11

PFH037A-_H7 PFH036A-_H7

PFH042A-_H7 PFH041A-_H7

PFH067A-_H7 PFH066A-_H7 51-11 (23.45) #10 #12

Quiet-Line

PFHZ27A-_L7 PFHZ26A-_L7 13-5 (6.04) #6 #11

PFHZ37A-_L7 PFHZ36A-_L7

PFHZ42A-_L7 PFHZ41A-_L7

PFHZ67A-_L7 PFHZ66A-_L7 51-11 (23.45) #10 #12

13-5 (6.04) #6 #11

26-10 (12.08) #10 #12

26-10 (12.08) #10 #12

Installation

Table 9 Recommended line sizes, OD Cu

PFH_36A
PFH_37A

PFH_14A

Equiv.

ft. (m)

50 (15.2) 5/8" 3/8" 5/8" 3/8" 7/8" 3/8" 7/8" 1/2" 7/8" 1/2" 1-1/8" 1/2"

75 (22.9) * * * * 7/8" 1/2" 7/8" 1/2" 7/8" 1/2" 1-1/8" 5/8"

100 (30.5) * * * * 7/8" 1/2" 1-1/8" 1/2" 1-1/8" 1/2" 1-1/8" 5/8"

125 (38.1) * * * * * * 1-1/8" 1/2" 1-1/8" 5/8" 1-3/8" 5/8"

150 (45.7) * * * * * * 1-1/8" 5/8" 1-1/8" 5/8" 1-3/8" 5/8"

* Exceeds maximum recommended line length

PFH_13A

Suction Liquid Suction Liquid Suction Liquid Suction Liquid Suction Liquid Suction Liquid

PFH_20A
PFH_19A

PFH_27A
PFH_26A

3-ton circuit

of 8-ton model

PFH_42A
PFH_41A

PFH_67A
PFH_66A

5-ton circuit

of 8-ton model

17

2.5.4 Installation of Piping to Units

NOTE

When using hard piping, complete all piping and evacuate the lines before connecting
quick-connects.

NOTE

Liebert Challenger 5-ton evaporator includes a nitrogen holding charge only. This holding
charge must be evacuated and unit placed in a 250 micron vacuum prior to connecting piping.
See Table 12 for field charge required.

Use caution when connecting the quick-connect fittings. Read through the following steps before mak­ing the connections.

1. Remove protector caps and plugs.

2. Carefully wipe coupling seats and threaded surfaces with a clean cloth.

3. Lubricate the male diaphragm and synthetic rubber seal with refrigeration grade oil.

4. Thread the coupling halves together by hand to ensure that the threads mate properly.

5. Tighten the coupling body hex nut and union nut with the proper sized wrench until the coupling
bodies bottom out or until you feel a definite resistance.

6. Using a marker or pen, make a line lengthwise from the coupling union nut to the bulkhead.

7. Tighten the nuts an additional quarter turn; the misalignment of the lines shows how much the
coupling has been tightened. This final quarter turn is necessary to ensure that the joint will not
leak. Refer to Table 10 for torque requirements.

8. Add liquid refrigerant charge for any field-fabricated piping (refer to Table 11) and the 5-ton
Liebert Challenger evaporator if used (refer to Table 12).

Table 10 Piping connection sizes and torque

Line Size OD Cu Coupling Size Torque, lb-ft. (N-m)

1/4 or 3/8 #6 10-12 (145-175)

5/8 thru 7/8 #10 or #11 35-45 (510-655)

1-1/8 #12 50-65 (730-950)

Installation

Table 11 Line charges - refrigerant per 100 ft. (30m) of Type L copper tube

R-407C, lb/100 ft. (kg/30m)

Line Size,

O.D., in.

Liquid Line Suction Line

3/8 3.7 (1.7) —

1/2 6.9 (3.1) —

5/8 11.0 (5.0 0.4 (0.2)

3/4 15.7 (7.1) 0.6 (0.3)

7/8 23.0 (10.4) 1.0 (0.4)

1-1/8 — 1.7 (0.7)

1-3/8 — 2.7 (1.1)

2.5.5 R-407C PFH Installed as a Replacement Condensing Unit in an R-22 System

When replacing the condensing unit of an existing Liebert split system containing R-22 and mineral
oil, the following should be considered.

1. Check for proper operation of the system prior to replacing the outdoor unit. If this is not possible,
at minimum perform a leak check to ensure that the components that remain (line set,
evaporator) are leak tight.

2. Check for acid or contaminants in the mineral oil.

18

Installation

Remove Existing Condensing Unit

1. Recover refrigerant in system using proper refrigeration practices.

2. Oil removal: The majority of the oil will be in the old condensing unit (compressor, condenser and
receiver), which will be replaced with the new unit.

3. Remove high-voltage and low-voltage wiring.

NOTE

Wiring should be removed by a licensed electrician.

Existing low-voltage wiring may have a 3-wire lead. A 4-wire lead is required for hot gas
bypass control on the new condensing unit.

4. Cut the line set before the Aeroquip fittings entering the condensing unit.

5. Remove the existing filter drier in evaporator unit and discard. The filter drier may contain
contaminants that can be released out of the drier because of the POE oil.

Filter Drier Selection and Installation

Recommended

1. Install a replaceable-core filter drier approved for POE oil. The existing drier must be removed.
The replaceable core drier will not fit in the same location as the existing drier.

2. Ensure there is enough clearance for replacing cores when choosing a location.

3. Replace core a week after startup and inspect the removed replaceable core for contaminants to
determine if another replacement is needed. (If the system experienced a burnout, shorter
interval replacements will be needed.)

Optional

Install a new filter drier approved for POE oil in place of the existing one.

Install the New Condensing Unit

1. Install a stub tube kit on the existing line set connecting to the new condensing unit. This kit is
available from Emerson or your local Emerson representative.

2. Evacuate the evaporator-piping system twice to a minimum 250 microns, breaking the vacuum
with dry nitrogen each time.

3. Evacuate a third time to 250 microns and verify the above levels are maintained for at least one
minute after the unit is isolated from the vacuum pump by a shutoff valve.

4. Connect the condensing unit with the evaporator and piping (see 2.5.4 - Installation of Piping
to Units).

5. Add enough R-407C refrigerant for the evaporator unit and line set. See Table 11 for line set
charges required and Table 12 for standard evaporator units. If a non-standard evaporator was
used, refer to evaporator unit serial tag for charge amounts and use 1 oz. (0.0283kg) R-407C for
every 1 oz. (0.0283kg) R-22 used in old evaporator and piping.

19

2.5.6 General System Charge Requirements

Liebert split system units are designed with quick-connect fittings and are factory-charged to proper
levels. Due to the wide range of operating ambients and sensitivity of the system components to
charge level, the system charge must be maintained at recommended levels.

If there is any doubt that the system has the correct refrigerant charge level, the correct
procedure is to remove the entire system charge, evacuate the system and weigh in the
recommended factory charge total for both units and any line sets or field piping.

Tables 7, 8, 11 and 12 are included for field piping allowances, condensing unit charges, line sets and

evaporator charges.

Total refrigerant charge = evaporator + lines + condensing unit

NOTE

All condensing units and most evaporator units are fully charged with refrigerant. Some
evaporator units are shipped from the factory with a nitrogen holding charge only. (Refer to
evaporator serial tags.) If field-supplied refrigerant piping is installed, refrigerant must be
added to the system. Refer to Figure 12 for field-supplied piping guidelines.

Table 12 Evaporator Charge Levels

Installation

Evaporator

Indoor Unit

Liebert
Mini-Mate2

Liebert DataMate

Liebert Challenger
3000

* Evaporator is charged with nitrogen at the factory

Models

MMD11/12E 3 (0.085)

MMD17/18E 4 (0.113)

MMD23/24E 7 (0.198)

MMD35/36E 7 (0.198)

MMD59/60E 4 (0.113)

MMD95/96E 7 (0.198) each circuit

DME020E 4 (0.113)

DME027E 5 (0.141)

DME037E 6.5 (0.184)

BF/BU036E 9 (0.255)

BF/BU060E* 13 (0.368)

Charge R-407C

oz (kg)

20

2.6 Electrical Connections

!

!

!

Each unit is shipped from the factory with all internal wiring completed. All power, control wiring
and ground connections must be made in accordance with the National Electrical Code and local
codes. Refer to equipment nameplate regarding wire size and circuit protection requirements. Refer to
Figures 5, 7 and 8 and electrical schematic (reference Figures 9 through 11) when making connec­tions. A manual electrical disconnect switch should be installed within 5 feet (1.6 m) of the unit in
accordance with codes.

WARNING

Use voltmeter to be sure power is turned off before making any electrical connections.

CAUTION

Three-phase power must be connected to the unit line voltage terminals in proper sequence so
that scroll compressor rotates in the correct direction.

The three-phase scroll compressor requires proper phasing to ensure correct motor rotation. The com­ponent connections have been phase synchronized at the factory. Power phasing should be changed
only at the line voltage supply to the unit. To change phasing, switch any two power leads to the unit.
Observe system pressures to determine whether the unit is operating properly.

CAUTION

Apply power to condenser 8 hours before operating system. This time is required to allow
liquid refrigerant to be driven out of the compressor. This is especially important at low
ambient temperatures. The compressor crankcase heater is energized as long as power is
supplied to the unit.

Table 13 Design refrigerant pressures

Suction

Discharge
(At Design Ambient)

High Pressure Cutout 400 psig (2760 kPa)

53 - 95 PSIG
(365 to 655 kPa)

280 psig (1930 kPa)

Installation

Table 14 Application limits

Input voltage Dry Bulb Air Temperature at Condenser

Minimum Maximum Minimum Maximum

-10%

-5% 208/230V
single-phase

+10% -30°F (-34°C)

2.6.1 Low-Voltage Control Wire Connections

Field-supplied four-wire control connection (10-wire on 8-ton units) is required between the outdoor
condensing unit and the evaporator. Refer to Figures 5, 7 and 8 and to unit electrical schematic and
Figures 9 through 11.

2.6.2 Low-Voltage Control Wire Sizing

Low-voltage wiring should be sized to allow a 1 volt maximum drop due to line resistance between the
evaporator and condensing unit. Use NEC Class 1 or 2 wiring according to wire routing conditions
chosen, local codes and application limits in Tables 14 and 15.

Table 15 Recommended minimum wire size

Max. Distance*

ft. (m)

50 (15) 20 (0.75)

100 (30) 18 (1.0)

150 (45) 16 (1.5)

* One-way control wire run between outdoor condensing unit and evaporator.

Min. Wire Gauge

AWG (mm2)

115°F (46°C) Std

Ambient & Quiet-Line

125°F (52°C)

High Ambient Models

21

2.7 Electrical Data

Table 16 Electrical data—Standard sound and ambient models (95°F/35°C) 60Hz

Nominal

Model #

Capacity

Tons

* Electrical

Characteristic

208/230-1 208/230-3 460-3 575-3

FLA 8.4 — — —

14 1

WSA 10.2 — — —

OPD 15 — — —

FLA 12.1 — — —

20 1.5

WSA 14.8 — — —

OPD 25 — — —

FLA 13.5 — — —

27 2

WSA 16.5 — — —

OPD 25 — — —

FLA 19.3 12.8 6.4 5.9

37 3

WSA 23.8 15.7 7.8 7.1

OPD 40 25 15 15

FLA — 15.3 7.1 6.6

42 3.5

WSA — 18.8 8.7 8.0

OPD — 30 15 15

FLA — 24.1 11.7 9.1

67 5

WSA — 29.3 14.2 11.1

OPD — 45 20 15

FLA — 35.6 17.4 13.5

96 8

WSA — 40.8 19.9 15.4

OPD — 60 25 20

* FLA = Full Load Amps

WSA = Wire Size Amps (minimum supply circuit current capacity)
OPD = Overcurrent Protection Device (fuse or circuit breaker)

Input Voltage- Phase

Installation

Table 17 Electrical data—High ambient models (105°F/41°C) 60Hz

Nominal

Model #

Capacity,

Tons

* Electrical

Characteristic

208/230-1 208/230-3 460-3 575-3

FLA 21.3 14.8 7.4 5.9

37 3

WSA 25.8 17.7 8.8 7.1

OPD 40 25 15 15

FLA — 17.3 8.1 6.6

42 3.5

WSA — 20.8 9.7 8.0

OPD — 30 15 15

FLA — 24.2 11.7 9.3

67 5

WSA — 29.4 14.2 11.3

OPD — 50 20 15

* FLA = Full Load Amps

WSA = Wire Size Amps (minimum supply circuit current capacity)
OPD = Overcurrent Protection Device (fuse or circuit breaker)
Model # 14, 20 and 96 are not available in high ambient versions.

Input Voltage-Phase

22

Table 18 Electrical data—Quiet-Line models (95°F/35°C) 60Hz

Nominal

Model #

Capacity

Tons

* Electrical

Characteristic

208/230-1 208/230-3 460-3 575-3

FLA 13.0 — — —

27 2

WSA 16.0 — — —

OPD 25 — — —

FLA 18.8 12.3 6.4 5.2

37 3

WSA 23.3 15.2 7.8 6.4

OPD 40 25 15 15

FLA — 14.8 6.9 5.9

42 3.5

WSA — 18.3 8.5 7.3

OPD — 30 15 15

FLA — 21.1 10.9 8.8

67 5

WSA — 25.9 13.4 10.8

OPD — 45 20 15

* FLA = Full Load Amps

WSA = Wire Size Amps (minimum supply circuit current capacity)
OPD = Overcurrent Protection Device (fuse or circuit breaker)
Model # 14, 20 and 96 are not available in Quiet-Line versions.

Input Voltage-Phase

Installation

Table 19 Electrical data—Standard sound and ambient models (95°F/35°C) 50Hz

Nominal

Model #

Capacity

Tons

* Electrical

Characteristic

13 1 FLA 9.9 — —

19 1.5 FLA 10.9 — —

26 2 FLA 12.7 — 4.9

36 3 FLA 18.4 — 7.0

41 3.5 FLA — 15.3 8.5

66 5 FLA — 24.1 13.2

95 8 FLA — — 20.3

* FLA = Full Load Amps

Input Voltage-Phase

220-1 200/230-3 380/415-3

Table 20 Electrical data—High ambient models (105°F/41°C) 50Hz

Nominal

Model #

Capacity

Tons

* Electrical

Characteristic

13 1 FLA — — —

19 1.5 FLA — — —

26 2 FLA 14.8 — 6.0

36 3 FLA 20.5 — 13.1

41 3.5 FLA — 19.8 9.6

66 5 FLA — 24.2 13.2

95 8 FLA — — —

* FLA = Full Load Amps

Input Voltage-Phase

220-1 200/230-3 380/415-3

23

Table 21 Electrical data - Quiet-Line models (95°F/35°C) 50Hz

Nominal
Capacity

Model #

13 1 FLA — — —

19 1.5 FLA — — —

26 2 FLA 12.3 — 4.8

36 3 FLA 18.0 — 6.9

41 3.5 FLA — 17.3 8.4

66 5 FLA — 22.5 12.4

95 8 FLA — — —

* FLA = Full Load Amps

Tons

* Electrical

Characteristic

Input Voltage-Phase

220-1 200/230-3 380/415-3

2.8 Checklist for Completed Installation

___ 1. All items unpacked and checked.

___ 2. Proper clearances for service access maintained around equipment.

___ 3. Equipment is level and mounting fasteners are tight.

___ 4. Piping completed to refrigerant loop.

___ 5. All piping connections are tight.

___ 6. Piping routed to prevent chafing and rub-through.

___ 7. Piping has been evacuated and refrigerant charge added (if required).

___ 8. Line voltage to power wiring matches equipment nameplate.

___ 9. Power wiring connections completed, including earth ground.

___ 10. Power line circuit breakers or fuses have proper ratings for equipment installed.

___ 11. Control wiring connections completed.

___ 12. All wiring connections are tight.

___ 13. Foreign materials have been removed from area: in and around all equipment installed

(shipping materials, construction materials, tools, etc.).

___ 14. Fans and blowers rotate freely and in the proper direction.

___ 15. Blank startup sheet has been sent with the evaporator unit and is ready to be completed by

the installer.

Installation

24

3.0 OPERATION

3.1 Compressor

The scroll compressor is equipped with a band type crankcase heater to resist liquid refrigerant
migration into the compressor during the Off cycle. The three-phase scroll compressor requires proper
phasing to ensure correct motor rotation. The component connections have been phase synchronized
at the factory. Refer to 2.6 - Electrical Connections to verify proper compressor wiring.

3.2 High Head Pressure

Compressor high head pressure is monitored with a pressure switch. One SPDT pressure switch is
used for each compressor in the unit. If head pressure exceeds 400 psig (2760 kPa), the switch opens
the compressor contactor and sends an input signal to the evaporator wall-box control. The high head
pressure condition is acknowledged by pressing the alarm silence button, which will clear the alarm if
the high head pressure condition no longer exists.

If the compressor is off for 1 hour, the control goes into a special cold-start mode. In the cold-start
mode on a call for cooling or dehumidification, the liquid line solenoid valve (LLSV) is energized. If
the high pressure switch does NOT trip within 10 seconds, the control returns to normal operation of
monitoring the high head pressure switch for three occurrences in a 12-hour period. It is a rolling
timer and after the third high head alarm occurs and is acknowledged by the user, it will lock off the
compressor. If while in the cold-start mode the high head pressure switch DOES trip within 10 sec­onds of the activation of the LLSV, the control does not annunciate the alarm. The control will turn off
the LLSV and delay 10 seconds. The control will permit this occurrence two more times, or a total of
three times. If on the fourth try the high head pressure switch trips within 10 seconds, the control will
annunciate the alarm, turn off the LLSV, wait for the user to acknowledge the alarm and hold the
compressor off for 3 minutes, which is the normal short cycle control. The control will permit this
occurrence three times. On the third occurrence, the control will lock the compressor off until the con­trol power is reset.

Operation

Check for these conditions:

• Power shut off to the condensing unit

• Condensing unit fan not working

• Defective head pressure control valves

• Closed services valves

• Dirty condensing coils

•Crimped lines

3.3 Liebert Lee-Temp Flood Back Head Pressure Control

Outdoor condensing unit components for head pressure control include a receiver, heater and
three-way head pressure control valve. The head pressure control valve operates to maintain a mini­mum condensing pressure. During low ambient temperature operation, the valve meters discharge
gas into the receiver to maintain a discharge pressure operating against the valve dome. This closes
the condenser port, backing liquid refrigerant into the condenser coil, reducing its area available for
condensing. A receiver sized to hold the additional charge required to flood the condenser is provided.

A temperature-compensated heater maintains the liquid refrigerant pressure during Off cycles. A liq­uid pressure switch is also installed to turn the heater Off during operation, when the receiver pres­sure is high. The heater pressure switch has a cutout of 150 PSIG (1034 kPa) and a cut-in of 100 PSIG
(690 kPa). The receiver includes a pressure relief valve set for 475 PSIG (3275 kPa).

25

3.4 Hot Gas Bypass

3.4.1 Operation

When applying hot gas bypass with split system condensing units, bypassing discharge gas to the
compressor suction line offers more flexibility than conventional hot gas bypass to the evaporator
unit.

The hot gas bypass valve is installed between the compressor discharge piping and suction piping,
bypassing the condenser and evaporator coils. The discharge gas mixes with the suction gas, raising
the suction temperature and pressure and decreasing the mass flow through the evaporator. The
higher suction temperatures could cause compressor overheating, therefore a separate liquid quench­ing valve is provided to mix refrigerant from the system liquid line with the discharge gas before mix­ing with the suction gas entering the compressor. (Refer to Figure 13).

During normal operation, when the evaporator is under full load the hot gas bypass equalizer pres­sure will remain high enough to keep the valve port closed. If the evaporator load decreases the evap­orator temperature and pressure will drop. When the suction pressure reduces below the hot gas
bypass valve setting, the hot gas bypass valve opens, diverting some of the refrigerant flow back to
the compressor suction. The liquid quenching valve bulb senses this increased superheat and opens,
allowing liquid refrigerant to mix with the discharge gas, desuperheating it.

Proper mixing of the three refrigerant paths ensures stable operation and system performance. The
liquid quenching valve bulb must be located downstream of all these connections to control superheat
at the compressor inlet. Superheat settings for the liquid quenching valve are chosen to maintain con­sistency with the system expansion valve. During hot gas bypass operation higher superheats,
50-60°F (10-15°C), may be observed at the compressor. The liquid-quenching valve is internally
equalized and superheat is not adjustable.

Operation

To aid in lubricating the compressor, the hot gas bypass solenoid is delayed for 30 seconds on the ini­tial call for cooling and de-energized for 30 seconds during every 60 minutes of continuous operation.

3.4.2 Adjustment

Upon deciding what evaporator temperature is desired, the following procedure should be used to
adjust the hot gas bypass valve:

1. Install the suction and discharge pressure gauge.

2. Adjust temperature setpoint to call for cooling so that the refrigeration compressor will run
continuously.

3. Remove the TOP adjusting nut from the valve.

4. Insert an Allen wrench in the brass hole at top of valve in adjusting port and turn clockwise if a
higher evaporator temperature is required. Adjust no more than 1/4 turn at a time. Let the
system stabilize for 15 minutes before determining if additional adjustments are necessary.

5. After obtaining the suction pressure required, reinstall cap tightly making sure there are no
leaks.

6. Let the system operate for approximately 10 to 15 minutes to make sure the suction pressure is
within the range desired.

7. There may be a variation of approximately 3 to 6 PSIG (21 to 41 kPa) on the evaporator due to the
differential on the hot gas bypass.

8. Return temperature setpoint to the desired setting.

26

Figure 13 Hot gas bypass diagram

Operation

27

4.0 MAINTENANCE

!

!

!

!

!

4.1 General

Access the condensing unit by removing the unit housing panel. Clean the air cooled condenser coil of
all debris that will inhibit airflow. This can be done with compressed air or with a commercial coil
cleaner. Check for bent or damaged coil fins and repair as necessary. During winter, do not permit
snow to accumulate on or around the condensing unit. Check all refrigerant lines and capillaries for
vibration isolation and support as necessary. Check all refrigerant lines for signs of leaks.

WARNING

Turn Off power to unit at disconnect switch unless you are performing tests that require
power. With power and controls energized, unit could begin operating automatically at any
time.

WARNING

Hazardous voltage will still be present at condenser even with power turned Off at the control
panel. To isolate unit for maintenance, turn the unit Off at disconnect switch.

CAUTION

If condenser power is disconnected for a long period, do not attempt to start the condensing
unit until 8 hours after restoring power. This allows time for liquid refrigerant to be driven
out of the compressor. This is especially important at low ambient temperatures.

Maintenance

4.2 Compressor Failure

If a compressor motor burns out, the stator wiring insulation decomposes, forming carbon, water and
acid. Not only must the compressor be replaced, but the entire refrigeration circuit must be cleaned of
the harmful contaminants left by the burnout. Successive burnouts of the same system can usually be
attributed to improper system cleaning.

WARNING

Damage to a replacement compressor caused by improper system cleaning constitutes abuse
under the terms of the warranty.

Before proceeding with a suspected burnout, check all electrical components: fuses, contactors and
wiring. Check high-pressure switch operation. If a compressor failure has occurred, determine
whether it is an electrical or mechanical failure. An electrical failure will be indicated by a distinct,
pungent odor. If a severe burnout has occurred, the oil will be black and acidic. In the case of a
mechanical failure, there will be no burn odor and the motor will attempt to run.

4.2.1 Electrical Failure—Burnout

In the event that there is an electrical failure and a complete burnout of the refrigeration compressor
motor, the proper procedures must be performed in order to clean the system to remove any acids that
would cause a future failure.

NOTE

Failure to properly clean the system after a compressor motor burnout will void the compressor
warranty. Follow the manufacturer’s procedure.

CAUTION

Avoid touching or contacting the gas and oils with exposed skin. Severe burns may result. Use
long rubber gloves in handling contaminated parts.

4.2.2 Mechanical Failure

If a mechanical failure has occurred, the compressor must be replaced.

28

4.3 Compressor Replacement

!

Replacement compressors are available from Emerson. They will be shipped in a permanent crate to
the job site as required by the service contractor.

Upon shipping a replacement compressor, the service contractor will be billed in full for the compres­sor. Credit for warranty replacement compressors will not be issued until the replacement has been
returned to the factory. The compressor should be returned in the same container used for shipping to
the job. The possible damage causes or conditions that were found must be recorded by marking the
compressor return tag.

CAUTION

Do not loosen any refrigeration or electrical connections before relieving pressure.

NOTE

Release of refrigerant to the atmosphere is harmful to the environment. Refrigerant must be
recycled or discarded in accordance with federal, state, and local regulations.

1. Disconnect power.

2. Attach suction and discharge gauges to access fittings.

3. Recover refrigerant using approved recovery procedures and equipment. Use a filter drier when
charging the system with recovered refrigerant.

4. Unsweat refrigerant connections and disconnect electrical connections.

5. Remove failed compressor.

6. Install replacement compressor and make all connections.

7. Pressurize and leak test the system.

8. Follow manufacturer’s instructions for cleanout kits.

9. Evacuate the system twice to a minimum 250 microns, breaking the vacuum with dry nitrogen
each time. The third time, evacuate to 250 microns and verify the above levels are maintained for
at least one minute after the unit is isolated by a shutoff valve from the vacuum pump.

10. With the system in a 250 micron or lower vacuum, charge the system with liquid refrigerant
based on requirements of the evaporator, condensing unit and lines. Refer to 2.5.6 - General
System Charge Requirements or unit nameplate for system charge requirements.

11. Apply power and operate system. Check for proper operation. Refer to design pressures in
Table 13.

Maintenance

29

4.4 Field Charge Verification

An integral sightglass is provided with the receiver to assist in field charge verification. During
charge verification set the control temperature down to keep the system running. If the system is
equipped with hot gas bypass, de-energize it by removing power from the hot gas solenoid valve coil.
To remove power, disconnect the solenoid leads from the unit contactor in the electric box (refer to
specific unit schematic; reference Figures 7 through 10). When charge verification has been com­pleted, replace and secure all wire connections and covers.

During operation at design ambients (95 or 105°F; 35 or 41°C) the charge level will be above the sight­glass in the receiver. If levels are below the sightglass an undercharge condition is likely. If levels are
above the sightglass and higher discharge pressures than normal are observed an overcharge condi­tion may be likely. However, verify that other high discharge pressure causes such as dirty coil and
restricted airflow are not responsible before removing charge.

At temperatures below design ambient, refrigerant backs into the condenser coil and the level in the
receiver will drop below the sightglass. If you are trying to verify charge level at lower ambients, block
the condenser coil to maintain 230 psig (1585 kPa) discharge pressure to ensure the head pressure con­trol valve is closed. At these conditions the charge level should be above the sightglass in the receiver.

NOTE

The 5-ton high ambient, 5-ton Quiet-Line and 8-ton models consist of two condenser coils and
two receivers. When restricting airflow on these units, the coils should be blocked off
proportionally. If one coil is restricted significantly more than the other, liquid can remain in
the restricted coil causing lower levels in the receivers. The receiver liquid level should be above
the sightglasses in both receivers. There may be some variation in charge level between the two
receiver sightglasses due to piping and assembly variations. When adding charge, determine
which receiver level is lower and use that sightglass to gauge charge level.

Maintenance

NOTE

If no level is visible in the sightglass, add charge until the level is in the middle of the
sightglass. Check the discharge pressure during this procedure and adjust coil restrictions to
maintain 230 psig (1585 kPa). Once the charge is in the middle of the sightglass, add
additional system charge per Table 22. After charging, unblock the coil and allow the unit to
operate normally. After conditions have stabilized, restrict the coil if required to maintain 230
psig (1585 kPa) discharge pressure and verify that the charge level is above the sightglass.

Table 22 Field verification charge

Model Numbers R-407C

60 Hz 50 Hz oz (kg)

PFH014A-_L PFH013A-_L

4 (0.11)PFH020A-_L PFH019A-_L

PFH027A-_L PFH026A-_L

PFH027A-_H PFH026A-_H

PFHZ27A-_L PFHZ26A-_L

PFH037A-_L PFH036A-_L

PFH042A-_L PFH041A-_L

PFH037A-_H PFH036A-_H

PFHZ37A-_L PFHZ36A-_L

PFH042A-_H PFH041A-_H

PFHZ42A-_L PFHZ41A-_L

PFH067A-_L PFH066A-_L 18 (0.51)

PFH067A-_H PFH066A-_H

PFHZ67A-_L PFHZ66A-_L

PFH096A-_L

3-ton circuit
5-ton circuit

PFH095A-_L

3-ton circuit
5-ton circuit

18 (0.51)

8 (0.23)

50 (1.42)

18 (0.51)
18 (0.51)

30

5.0 TROUBLESHOOTING

Table 23 Troubleshooting

Problem Cause Remedy

No power to unit Check voltage at input terminal block.

Check for 24VAC ±2VAC at control connections 1 & 2. If

Unit will not start

High discharge
pressure

Low discharge pressure

Low suction pressure /
compressor cycling

Low compressor
capacity/ no cooling

Compressor noisy

Pipe Rattle Loose pipe connections Check pipe connections.

Compressor running hot Compression ratio too high

Compressor motor
protectors tripping or
cycling

Compressor cycles on
locked rotor

Motor burnout

Compressor contactor not pulling in

Control voltage circuit breaker (at
transformer in evaporator module)
open

Short cycle prevention control

Compressor high discharge
pressure/ lockout relay

Insufficient air flow across
condenser coil

High refrigerant charge Check refrigerant charge.
Faulty head pressure control valve Replace if defective.
Compressor rotation in reverse

direction
Insufficient refrigerant in system Check for leaks; repair and add refrigerant.
Plugged filter drier Replace filter drier.

Improper superheat adjustment

Defective liquid line solenoid valve Check valve and coil; replace if necessary.
Defective liquid line solenoid valve Check valve and coil; replace if necessary.

Plugged filter drier

Low refrigerant charge

Loose compressor or piping
support

Compressor rotation in reverse
direction

High discharge pressure Check for blocked condenser fan or coil.

High suction temperature

Loose power or control circuit
wiring connection

Defective motor

Low line voltage Check line voltage and determine location of voltage drop.
Compressor motor defective Check for motor winding short or ground.

Single phasing

Check control panel for welded
contactor contacts or welded
overload contacts.

no voltage, check control setting requires cooling. If there
is voltage, lockout relay may be energized. Check for
24VAC at control connections 2 & 3. If there is voltage,
see compressor high-discharge pressure/lockout relay.

Locate short and reset circuit breaker.

Control software delays compressor 3 minutes from stop
to start.

Check for 24VAC ±2VAC at control connections 2 & 3.
Remove 24VAC signal at Connection 2 by turning indoor
unit control off, then back on, or by raising the setpoint to
remove the cab for cooling, then resetting to re-establish
operation.

Check fan operation. Remove debris from coil and air
inlets.

Check for proper power phase wiring to unit and to
compressor motor.

Reset expansion valve for 10-15°F (5.6 to 8.4°C)
superheat at evaporator.

Check pressure drop across filter drier. Replace filter
drier.

Check for normal system operating pressures. Refer to
abnormal pressure causes if applicable. Check for leaks.
Proper refrigerant charge is very important at low ambient
operation.

Tighten clamps.

Check for proper power phase wiring to unit and to
compressor motor.

Check for normal system operating pressures. Refer to
abnormal pressure causes if applicable.

Check expansion valve and hot gas bypass valve setting.
Check liquid quenching valve operation.

Check all power and control circuit connections.

Check for motor ground or short. Replace compressor if
either condition is found.

Check voltage across all 3 legs at contactor. Correct
source of problem.

Replace defective components.

Troubleshooting

31

Ensuring The High Availability
Of Mission-Critical Data And Applications.

Emerson Network Power, the global leader in enabling business-critical
continuity, ensures network resiliency and adaptability through
a family of technologies—including Liebert power and cooling
technologies—that protect and support business-critical systems.
Liebert solutions employ an adaptive architecture that responds
to changes in criticality, density and capacity. Enterprises benefit
from greater IT system availability, operational flexibility and
reduced capital equipment and operating costs.

While every precaution has been taken to ensure the accuracy
and completeness of this literature, Liebert Corporation assumes no
responsibility and disclaims all liability for damages resulting from use of
this information or for any errors or omissions.
© 2008 Liebert Corporation
All rights reserved throughout the world. Specifications subject to change
without notice.
® Liebert is a registered trademark of Liebert Corporation.
All names referred to are trademarks
or registered trademarks of their respective owners.

SL-10059_REV02_10-09

Technical Support / Service

Web Site

www.liebert.com

Monitoring

[e-mail]

800-222-5877

Outside North America: [phone]

Single-Phase & Three-Phase UPS

[e-mail]

800-222-5877

Outside North America: [phone]

Environmental Systems

800-543-2778

Outside the United States: 614-888-0246

Locations

United States

1050 Dearborn Drive

P.O. Box 29186

Columbus, OH 43229

Europe

Via Leonardo Da Vinci 8

Zona Industriale Tognana

35028 Piove Di Sacco (PD) Italy

[phone]

Fax: [phone]

Asia

29/F, The Orient Square Building

F. Ortigas Jr. Road, Ortigas Center

Pasig City 1605

Philippines

[phone]

Fax: [phone]

Emerson Network Power.
The global leader in enabling Business-Critical Continuity.

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Connectivity

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Business-Critical Continuity, Emerson Network Power and the Emerson Network Power logo are trademarks and service marks of Emerson Electric Co.

©2008 Emerson Electric Co.

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