Liebert 50 -60Hz, Mini-Mate2 User Manual

Precision Cooling
For Business-Critical Continuity™

Liebert Mini-Mate2

™

User Manual - 8 Tons, 50 & 60Hz

TABLE OF CONTENTS

MODEL NUMBER NOMENCLATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .V

1.0 PRODUCT FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

1.1 Standard Product Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.1.1 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.1.2 Evaporator System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.1.3 Condensing Unit Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.2 Optional Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.2.1 Canister Humidifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.2.2 Electric Reheat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.2.3 SCR Electric Reheat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.2.4 Hot Gas Bypass (Condensing Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.2.5 Free-Cooling Coil (GLYCOOL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.2.6 Smoke Detector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.2.7 Firestat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.2.8 Filter Clog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.3 Ancillary (Ship Loose Accessories) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.3.1 Single Point Power Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.3.2 Refrigerant Line Sweat Adapter Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.3.3 Return Air Filter Box with Duct Collar Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.3.4 Condensate Pump Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.3.5 Remote Monitoring and Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1.3.6 Remote Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.0 SITE PREPARATION AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.1 Installation Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.1.1 Room Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.1.2 Location Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2.2 System Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.3 Equipment Inspection upon receipt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.4 Installing the Evaporator or Chilled-Water Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.4.1 Close Coupled Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.4.2 Evaporator Air Distribution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2.4.3 Piping Connections and Coolant Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.4.4 Electrical Connections, Evaporator or Chilled-Water Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2.5 Indoor Air-Cooled Centrifugal Fan Condensing Unit Installation . . . . . . . . . . . . . . . . . . . . 19

2.5.1 Location Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2.5.2 Ducting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2.5.3 Piping Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

2.5.4 Electrical Connections - Condensing Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

2.6 Outdoor Air-Cooled Condensing Unit Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2.6.1 Location Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2.6.2 Piping Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

2.6.3 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

i

2.7 Indoor Water- and Glycol-Cooled Condensing Unit Installation. . . . . . . . . . . . . . . . . . . . . . 27

2.7.1 Location Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

2.7.2 Piping Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

2.7.3 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

2.8 Optional Equipment Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

2.8.1 Free-Cooling Coil (GLYCOOL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

2.9 Checklist for Completed Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

3.0 MICROPROCESSOR CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

3.1 Feature Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

3.2 Main Menu <Menu>. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

3.3 Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

3.4 Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

3.5 Active Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

3.6 Alarm History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

3.7 Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

3.8 Date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

3.9 Setback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

3.10 Setup Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

3.10.1 Restart Time Delay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

3.10.2 C/F Degrees. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

3.10.3 Humidity Control Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

3.10.4 Lead Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

3.10.5 Show DIP Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

3.10.6 Valve Time (For Systems With a Modulating Chilled-Water Valve) . . . . . . . . . . . . . . . . . . . 38

3.10.7 CW Flush (For Systems With a Modulating Chilled-Water Valve). . . . . . . . . . . . . . . . . . . . . 39

3.11 Change Passwords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

3.12 Calibrate Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

3.13 Alarm Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

3.14 Alarm Time Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

3.15 Common Alarm Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

3.16 Custom Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

3.17 Custom Text . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

3.18 Run Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

4.0 SYSTEM PERFORMANCE MICROPROCESSOR CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . .45

4.1 Control Type Response Proportional Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

4.2 Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

4.2.1 Multi-Step Cooling, Compressorized Direct Expansion (DX) Systems . . . . . . . . . . . . . . . . . . 45

4.2.2 Chilled-Water Cooling (8 Ton) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

4.2.3 GLYCOOL Cooling (8 Ton) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

ii

4.3 Reheat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

4.3.1 Electric Reheat - Staged. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

4.3.2 SCR Electric Reheat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

4.4 Dehumidification / Humidification Percent Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

4.4.1 Staged Dehumidification, Compressorized Direct Expansion (DX) Systems . . . . . . . . . . . . . 46

4.4.2 Humidification Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

4.4.3 Dehumidification Lockout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

4.5 Load Control Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

4.6 Communications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

5.0 ALARMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

5.1 Alarms: Definitions and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

5.1.1 Custom Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

5.1.2 High Head Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

5.1.3 Humidity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

5.1.4 Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

5.1.5 Humidifier Problem Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

5.1.6 High-Water Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

5.1.7 Loss of Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

5.1.8 Short Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

5.2 Optional/Custom Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

5.2.1 Change Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

5.2.2 Firestat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

5.2.3 Smoke Detector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

6.0 SYSTEM OPERATION, TESTING, AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

6.1 System Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

6.1.1 Environmental Control Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

6.1.2 Cooling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

6.1.3 Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

6.1.4 Humidification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

6.1.5 Dehumidification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

6.1.6 Remote Shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

6.2 Maintenance and Component Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

6.2.1 Electric Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

6.2.2 Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

6.2.3 Blower System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

6.2.4 Electric Reheat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

6.2.5 Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

6.2.6 Steam Generating Humidifier - Operation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

6.2.7 Circuit Board Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

7.0 MAINTENANCE INSPECTION CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

8.0 T

ROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

iii

FIGURES

Figure 1 System configurations—air cooled systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Figure 2 System Configurations—water/glycol systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Figure 3 System Configurations—chilled water systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Figure 4 Threaded rod and hardware kit installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Figure 5 Close coupled installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Figure 6 Drain installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Figure 7 Condensate pump installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Figure 8 General arrangement diagram - chilled-water systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Figure 9 Refrigerant piping diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Figure 10 Evaporator or chilled-water unit dimensional data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Figure 11 Evaporator unit electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Figure 12 Piping connections - indoor air-cooled centrifugal fan condensing unit . . . . . . . . . . . . . . . . . . . . 20

Figure 13 Indoor air-cooled centrifugal condensing unit dimensions and pipe connections . . . . . . . . . . . . . 21

Figure 14 Indoor air-cooled centrifugal condenser electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Figure 15 Electrical field connections - outdoor condensing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Figure 16 Footprint dimensions - outdoor condensing unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Figure 17 Piping and electrical connections - outdoor condensing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Figure 18 Indoor water/glycol condensing unit dimensional data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Figure 19 Indoor water/glycol condensing unit electrical field connections . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Figure 20 System piping with indoor water/glycol-cooled condensing unit . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Figure 21 Optional free cooling coil (3-way valve) on water/glycol units . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Figure 22 Optional free cooling coil (3-way valve) on air-cooled units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Figure 23 Wall box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Figure 24 Control menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Figure 25 Control board (inside evaporator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Figure 26 Wall box board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

TABLES

Table i Heat rejection matchup – 60 Hz. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v

Table ii Heat rejection matchup – 50 Hz. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v

Table 1 Application limits, evaporator and chilled-water units* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Table 2 Application limits, indoor and outdoor air-cooled condensing units . . . . . . . . . . . . . . . . . . . . . . . . 4

Table 3 Application limits, indoor water/glycol-cooled condensing units . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Table 4 Unit weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Table 5 Evaporator external static pressure (60) at 3750 CFM (6371 CMH) . . . . . . . . . . . . . . . . . . . . . . . 10

Table 6 Recommended refrigerant line sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Table 7 8-ton unit refrigerant charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Table 8 Line charges (field piping)* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Table 9 Refrigerant quick connect sizes and torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Table 10 Default setpoints and allowable ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Table 11 Night and weekend setback plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Table 12 Setup functions, default values and allowable ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Table 13 Alarm default time delays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Table 14 Equipment switch settings (unit control board) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Table 15 Switch settings (wallbox board) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Table 16 Typical discharge pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Table 17 Humidifier control board DIP switch settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Table 18 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

iv

MODEL NUMBER NOMENCLATURE

Evaporators and Chilled-Water Units

MMD96E-AHEL0 (example)

MM Mini-Mate2 MC Mini-Mate2 Indoor Condensing Unit

0 = No Disconnect

D

96E-

A

H

E

L

0

D = Disconnect D= Disconnect
96E- = 8-ton Evaporator, 60 Hz
95E- = 8-ton Evaporator, 50 Hz 95A = 8-ton Air-Cooled Centrifugal, 50 Hz
8TCD = 8-ton Chilled-Water w/ 2-way valve 98W = 8-ton Water/Glycol-Cooled, 60 Hz
8TCT = 8-ton Chilled-Water w/ 3-way valve 97W = 8-ton Water/Glycol, 50 Hz
A = 460V-3ph-60 Hz
B = 575V-3ph-60 Hz 2 = 2-way Water/Glycol reg valve, 150 psi
C = 208V-3ph-60 Hz 3 = 3-way, Water/Glycol reg valve, 150 psi
D =230V-3ph-60 Hz D = 2-way, Water/Glycol reg valve, 350 psi
M = 380/415V-3ph-50 Hz T = 3-way, Water/Glycol reg valve, 350 psi
0 = No Humidifier
H = Humidifier B = 575V-3ph-60 Hz
0 = No Reheat Y = 208/230V-3ph-60 Hz
E= Electric Reheat M = 380/415-3ph-50 Hz
S = SCR Reheat
L = Low Fan Speed Drive, 2 hp H = Hot Gas Bypass
H = High Fan Speed Drive, 3 hp 0 0 = Revision Level

0 = None
A = Filter Clog
B = Smoke Detector
C = Firestat PF Prop Fan Condensing Unit

D = Filter Clog & Smoke Detector H H = Hot Gas Bypass

E = Filter Clog & Firestat
F = Smoke Detector & Firestat 095A = 8-ton Air-Cooled, 50 Hz
G = Filter Clog, Smoke Detector, & Firestat

D

96A

L

A

H

096A

-

A

L L = 95

0 0 = Revision Level

Indoor Condensing Units

MCD96ALA00 (example)

0 = No Disconnect

96A = 8-ton Air-Cooled Centrifugal, 60 Hz

L = Lee-temp Head Pressure Control (Air-Cooled)

A = 460V-3ph-60 Hz

0 = No Hot Gas Bypass

Prop Fan Condensing Units

PFC096A-AL0 (example)

096A = 8-ton Air-Cooled, 60 Hz

- = Standard Coil
C = Coated Coil
A = 460V-3ph-60 Hz
B = 575V-3ph-60 Hz
Y = 208/230V-3ph-60 Hz
M = 380/415V-3ph-50 Hz

°F Ambient, Lee-temp

Table iii Heat rejection matchup – 60 Hz

Nominal
Capacity

8 Tons MMD96E MCD96A PFC096A MCD98W

8 Tons MMD8TC Chilled Water Unit

Cooling

Unit

Indoor Air-Cooled

Centrifugal Fan

Table iv Heat rejection matchup – 50 Hz

Nominal
Capacity

8 Tons

Cooling

Unit

MMD95E MCD95A PFC095A MCD97W

MMD8TC Chilled Water Unit

Indoor Air-Cooled

Centrifugal Fan

Condensing Unit

Outdoor Air-Cooled

Propeller Fan

Condensing Unit

Outdoor Air-Cooled

Propeller Fan

v

Indoor

Water/Glycol

Indoor Remote

Water/Glycol Cooled

vi

1.0 PRODUCT FEATURES

1.1 Standard Product Features

The Mini-Mate2 is a temperature/humidity control system designed to be installed above a ceiling
grid system. The unit is available as a split system evaporator to be matched with an Indoor Centrif­ugal Fan Condensing Unit, Outdoor Prop Fan Condensing Unit, or Indoor Water/Glycol Condensing
Unit. A self-contained Chilled Water Fan Coil is also available.

1.1.1 Controls

The Mini-Mate2 system includes a wall-mounted display panel with a liquid crystal display (LCD)
screen and a 7 membrane keypad. The control is menu-driven for ease of use. Figure 24, Section 3,
depicts the complete menu tree for the control. All control setpoints and alarm setpoints are program­mable.

1.1.2 Evaporator System Components

DX Evaporator Section

The evaporator section includes the evaporator coil, thermostatic expansion valves, filter dryers, and
blower. The evaporator coil is constructed of copper tubes and aluminum fins and is designed for the
high sensible heat ratio required for electronic equipment. Room air circulation is accomplished by a
double inlet, belt driven centrifugal blower that has been dynamically balanced. The blower has self­aligning bearings. Both the blower and motor have permanently lubricated ball bearings.

Product Features

Chilled-Water Model

The Chilled-Water model is self-contained and is designed for use with an existing chilled-water loop.
It contains a chilled-water coil and a proportional modulating valve to control the flow of chilled
water.

1.1.3 Condensing Unit Components

The condensing unit is connected to the evaporator unit by four refrigerant lines and low voltage con­trol wires. The condensing unit requires a power source and a power disconnect switch. A single point
power kit is available for close coupled (attached) units.

Air-Cooled Condensing Unit (Indoor Centrifugal)

The Air-Cooled Condensing units (MC models) include: 3-ton and 5-ton scroll compressors with motor,
belt-driven centrifugal blower, crankcase heaters, high pressure switches, condenser coils, and Lee­Temp head pressure control with receivers.

Air-Cooled Condensing Unit (Outdoor Prop Fan)

Outdoor Air-Cooled Condensing Units (PFC models) include: 3-ton and 5-ton scroll compressors with
crankcase heaters, high-pressure switch, condenser coils, direct-driven propeller fan, and Lee-Temp
head pressure control with receivers.

Water/Glycol Condensing Unit (Indoor)

The Water/Glycol-Cooled Condensing units include: 3-ton and 5-ton scroll compressors with crank­case heaters, high pressure switches, coaxial condensers, and regulating valves. Drycooler and pumps
are selected separately for glycol systems.

1

1.2 Optional Equipment

1.2.1 Canister Humidifier

The optional, factory-installed steam generating humidifier adds pure water vapor to the room air to
control humidity. Room humidity setpoints are established by the user. The humidifier components
include: a steam canister (replaceable), control board, inlet strainer, fill and drain valves.

1.2.2 Electric Reheat

The 304/304 stainless steel electric reheat is energized when required to heat room air or to control
room temperature during dehumidification. A safety switch prevents the reheat from exceeding tem­perature limits.

1.2.3 SCR Electric Reheat

The 304/304 stainless steel reheat is pulsed rapidly to provide precise temperature control, while cool­ing is locked on. A safety switch prevents the reheat from exceeding temperature limits.

1.2.4 Hot Gas Bypass (Condensing Units)

This optional system bypasses compressor discharge around the condenser directly to suction to pro­vide capacity control and reduce compressor cycling. System includes liquid injection valve to main­tain proper suction superheat. Hot gas bypass is provided on both circuits.

1.2.5 Free-Cooling Coil (GLYCOOL)

Product Features

When ambient temperatures are low enough, cold fluid is piped to a secondary coil or a separate
source of chilled-water may be piped to this coil.

1.2.6 Smoke Detector

If smoke is detected in the return air, the unit display sounds an audible signal and the unit shuts
down.

1.2.7 Firestat

When the return air temperature limit of approximately 125°F (51.7°C) is exceeded, the unit shuts
down.

1.2.8 Filter Clog

If high pressure differential is detected across the return air filter, an adjustable pressure differential
switch sounds an audible signal.

2

1.3 Ancillary (Ship Loose Accessories)

1.3.1 Single Point Power Kit

A Single Point Power Kit allows the connection of a system (Evaporator and indoor condensing unit)
to a single power source when the units are close coupled. The kit includes a junction box with power
distribution, sub-fusing, and evaporator and condenser wiring.

1.3.2 Refrigerant Line Sweat Adapter Kits

This kit includes the compatible fittings required (four suction and four liquid line connections) when
using field supplied interconnecting refrigerant piping.

1.3.3 Return Air Filter Box with Duct Collar Kit

A return air filter box with duct flange, 4" (102 mm) filter, and a supply air duct flange are provided
for ducting the evaporator air.

1.3.4 Condensate Pump Kit

A condensate pump is required when the evaporator is installed below the level of the gravity-fed
drain line. Components include: the pump; check valve; sump; level sensor; float switch; and controls.
Refer to detailed instructions and drawings supplied with the pump.

1.3.5 Remote Monitoring and Control

Liebert can provide a variety of remote monitoring and control devices to enhance your Mini-Mate2
system. These include water detection, remote monitoring of a single unit, and remote control/moni­toring of multiple units.

Product Features

1.3.6 Remote Sensors

Remote temperature/humidity sensors can be mounted in the controlled space or in duct work and
includes 30 feet of control cable.

3

2.0 SITE PREPARATION AND INSTALLATION

NOTE

Before installing unit, determine whether any building alterations are required to run piping,
wiring, and duct work. Carefully follow all unit dimensional drawings and refer to the
submittal engineering dimensional drawings of individual units for proper clearances.

2.1 Installation Considerations

The evaporator unit is usually mounted above the suspended ceiling using field supplied threaded
rods. Refer to Figure 1 for possible configurations. The condensing unit may be:

• Indoor Air-Cooled Centrifugal Fan Condensing Unit mounted remotely or close coupled to the
evaporator in the ceiling space.

• Outdoor Air-Cooled Propeller Fan Condensing Unit.

• Indoor Water/Glycol-Cooled Condensing Unit, mounted remotely or close coupled to the evapora­tor.

Table 1 Application limits, evaporator and chilled-water units*

Input Voltage Range of Return Air Conditions to Unit

Min Max Dry Bulb Temp. Relative Humidity

-5% +10%

*Unit will operate at these conditions but will not control to these extremes.

65°F to 85°F

°C to 29°C)

(18

20% to 80%

Site Preparation and Installation

Table 2 Application limits, indoor and outdoor air-cooled condensing units

Input

Voltage

Min Max Min Max

Outdoor Prop Fan Condensing Unit

-5% +10%

Indoor Air-Cooled Centrifugal Condensing Unit

Table 3 Application limits, indoor water/glycol-cooled condensing units

Input Voltage Entering Fluid Temperature

Min Max Min Max

-5% +10% 65°F (18.3°C) * 115°F (46°C)

*Operation below 65°F (18°C) may result in reduced valve life and fluid noise.

2.1.1 Room Preparation

The room should be well-insulated and must have a sealed vapor barrier. The vapor barrier in the
ceiling and walls can be a polyethylene film. Paint on concrete walls and floors should be vapor resis­tant.

NOTE

The single most important requirement for maintaining environmental control in the
conditioned room is the vapor barrier.

Condensing Units Entering Dry Bulb

Air Temperature

°F (-34°C)

-30

°F (-29°C)

-20

120

°F (49°C)

°F (46°C)

115

Outside or fresh air should be kept to a minimum when tight temperature and humidity control is
required. Outside air adds to the cooling, heating, dehumidifying and humidifying loads of the site.
Doors should be properly sealed to minimize leaks and should not contain ventilation grilles.

4

2.1.2 Location Considerations

CAUTION

!

Units contain water. Water leaks can cause damage to sensitive equipment below. DO NOT
MOUNT UNITS OVER SENSITIVE EQUIPMENT. A field-supplied pan with drain must be
installed beneath cooling units and water/glycol-cooled condensing unit.

NOTE

Do not mount units in areas where normal unit operating sound may disturb the working
environment.

Locate the evaporator unit over an unobstructed floor space if possible. This will allow easy access for
routine maintenance or service. Do not attach additional devices to the exterior of the cabinet, as they
could interfere with maintenance or service.

Site Preparation and Installation

5

Figure 1 System configurations—air cooled systems

Site Preparation and Installation

Evaporator

Prop Fan

Condensing Unit

Evaporator

Figure 2 System Configurations—water/glycol systems

Cooling

Tower

Centrifugal Fan

Condensing Unit

Evaporator

Water/Glycol

Condensing Unit

WATER-COOLED SYSTEMS

GLYCOL-COOLED SYSTEMS

Drycooler

Evaporator

Water/Glycol

Condensing Unit

6

Figure 3 System Configurations—chilled water systems

Evaporator

CHILLED-WATER SYSTEMS

Condensate Pump

Site Preparation and Installation

COUPLED COMPONENTS

(AIR-COOLED SYSTEM

Evaporator

Condensing

Unit

2.2 System Weights

Table 4 Unit weights

Cooling Units* lbs kg

MMD96E 665 302

MMD95E 665 302

Condensing Units lbs kg

MCD96A 530 241

MCD95A 530 241

MCD98W 470 213

MCD97W 470 213

*Add 40 lbs. (20 kg.) to units with free cooling or hot water reheat coils.

2.3 Equipment Inspection upon receipt

When the unit arrives, do not uncrate equipment until it is close to its final location. All required
assemblies are banded and shipped in corrugated containers. If you discover any damage when you
uncrate the unit, report it to the shipper immediately. If you later find any concealed damage, report
it to the shipper and to your Liebert supplier.

Condensate Pump

7

2.4 Installing the Evaporator or Chilled-Water Units

WARNING

!

Be sure the supporting roof structure is capable of supporting the weight of the unit(s) and the
accessories during installation and service. (See 2.2 - System Weights.)

Be sure to securely anchor the top ends of the suspension rods. Make sure all nuts are tight.

The evaporator unit and indoor condensing unit are usually mounted above the ceiling and must be
securely mounted to the roof structure. The ceiling and ceiling supports of existing buildings may
require reinforcements. Be sure to follow all applicable codes. Use field-supplied 1/2"-13 tpi threaded
suspension rods and 1/2"-13 tpi hardware kit.

Recommended clearance between ceiling grids and building structural members is unit height plus 3
inches.

Install the four field-supplied rods by suspending them from suitable building structural members.
Locate the rods so that they will align with the four mounting holes in the flanges that are part of the
unit base.

Using a suitable lifting device, raise the unit up and pass the threaded rods through the four mount­ing holes in the flanges that are part of the unit base.

Attach the threaded rods to the unit flanges using the supplied, springs, and washers. (See Figure 4).
The coil springs provide vibration isolation.

Site Preparation and Installation

1. Use the plain nuts to hold unit in place. Adjust these nuts so that the weight of the unit is
supported by the four rods, does not rest on the ceiling grid, and is level. Ensure none of the
springs are compressed to solid height. The coil side of the unit is heavier, so these springs will be
compressed more than the other side.

NOTE

The units must be level in order to drain condensate properly.

2. Use the Nylock nuts to “jam” the plain nuts.

Figure 4 Threaded rod and hardware kit installation

1" O.D. spring

1/2" flat washer

1/2" Nylock
locking nut

1/2" threaded rod
(supplied by field)

hanging bracket

base pan (ref)

1/2" hex nut

8

2.4.1 Close Coupled Installations

If the evaporator and condensing units are to be mounted side-to-side (close coupled), hang each unit
before connecting them together (See Figure 5). If Single Point Power Kit is used, install the box into the
evaporator prior to suspending the units. Route power wire flex conduit into condensing unit as units are
suspended. Refer to instructions supplied with kit for details. Align bolt holes in the condensing unit and
in the evaporator. Insert rubber spacers and secure four (4) sets of hardware provided. Align the refriger­ant connections and tighten them as described in 2.4.3 - Piping Connections and Coolant Require-
ments. Remove “P” clamps from piping to aid fitting alignment.

Figure 5 Close coupled installation

Evaporator

Site Preparation and Installation

Condensing
Unit

Isolator rubber

5/16" lock washer

5/16" capscrew

Cage
nut

NOTE: Disconnect P-clamps on lines in the evaporator
for easy close coupling.
P-clamps are for shipping purposes only.

5/16" flat washer

9

2.4.2 Evaporator Air Distribution

Filter Box

The optional filter box mounts directly to the return air opening of the evaporator. The filter box is
supplied with two (2) 20% (Liebert part no. A-0320) or 30% (Liebert part no. A-0400) 25" x 20" x 4" fil­ters.

NOTE

Do not operate the unit without filters installed in return air system.

Connections for Ducted Systems

Use flexible duct work or non-flammable cloth collars to attach duct work to the unit and to help con­trol the transmission of vibrations to building structures. Insulation of duct work is vital to prevent
condensation during the cooling cycle. The use of a vapor barrier is required to prevent absorption of
moisture from the surrounding air into the insulation.

If the return air duct is short, or if noise is likely to be a problem, sound-absorbing insulation should
be used on the duct. Duct work should be fabricated and installed in accordance with local and
national codes.

Table 5 Evaporator external static pressure (60) at 3750 CFM (6371 CMH)

2 hp Motor (std) 3 hp Motor (opt)

Turns

Open

0n/a n/a 1146 1.9

0.5 n/a n/a 1125 1.8

1n/a n/a 1104 1.7

1.5 946 0.9 1083 1.6

2 922 0.8 1063 1.5

2.5 972 0.7 1042 1.4

3 899 0.6 1021 1.3

3.5 851 0.5 1000 1.2

4 828 0.4 979 1.1

4.5 804 0.3 958 1.0

5 780 0.2 938 0.9

5.5 757 0.1 917 0.8

6 733 0 896 0.7

If free-cooling or hot water coil is ordered, reduce available external static
pressure by 0.3" (8 mm). Contact Liebert Representative for other Air Volumes.
Factory setting is 0.5" (13 mm) with 2 hp motor. Field adjust to suit application.

RPM

External

Static, in. RPM

External

Static, in.

Site Preparation and Installation

NOTE

Maximum return air static pressure should not exceed 0.3" (8 mm) to provide proper drainage
of the unit.

10

2.4.3 Piping Connections and Coolant Requirements

Drain Line

CAUTION

!

The drain line must not be trapped outside the unit, or water may back-up in drain pan.
Drain is internally trapped.

This line may contain boiling water. Use copper or other suitable material for the drain line.
Sagging condensate drain lines may inadvertently create an external trap.

A 3/4 in. (19.1 mm) female pipe thread (FPT) connection is provided for the evaporator coil condensate
drain. This line also drains the humidifier, if applicable. The drain line must be located so it will not
be exposed to freezing temperatures. The drain should be the full size of the drain connection.

The evaporator drain pan includes a float switch to prevent unit operation if drain becomes blocked.

Figure 6 Drain installation

Site Preparation and Installation

Unit

Continuous slope

away from unit

Unit

Do not externally

trap the unit

IncorrectCorrect

Unit

These are external traps also, although
unintentional. Lines must be rigid
enough to not bow between supports.
Humidifier drain water can approach
100° Celsius.

Incorrect

11

Condensate Pump

The optional condensate pump kit is required when the evaporator is installed below the level of the
gravity-fed drain line. Refer to the installation instructions provided with the condensate pump kit.

Figure 7 Condensate pump installation

Drain Line
(field supplied)

Condensate Pump

AIR INLET

Site Preparation and Installation

3/8" Compression Fitting
Drain Connection

Power Supply from
Electric Service Power
Block in Fan/Coil Module.

Evaporator or

Chilled Water

Unit

10 9/16 "

(268.3mm)

Condensate
Pump
Support Bracke

6 5/8 "

(168.3mm)

t

3/4" (13mm)
Supplied on Pump Tank

Hose Barb

Notes:

1. 3/4" (13mm) Flexible Rubber Tubing Assembly (Supplied
with Pump Kit) must be installed on pump end.

2. The High Water Safety Float included with pump must be
interlocked with unit control. Wire to terminals 60 & 61 on
Evaporator terminal strip to shut down unit.

Humidifier Water Supply Line

21 1/2 "

(546mm)

FRONT OF UNIT

Condensate Drain

3/4" (13mm) FPT
Customer Connection

Flexible Rubber Tubing

DPN000239_Rev0

Units supplied with the optional humidifier package have a 1/4 in. (6.4 mm) FPT connection for water
inlet. Supply pressure range is 10 psig to 150 psig. Required flow rate is 1 gpm. A shut-off valve
should be installed in this line to isolate the humidifier for maintenance.

NOTE

DO NOT route humidifier supply line in front of filter box access panel.

12

Chilled-Water Piping—Chilled-water Systems Only

Refer to Figure 8 for recommended field installed hardware such as shut-off valves and hose bibs.

Chilled-water supply and return lines must be insulated to prevent condensation.

The minimum recommended water temperature is 42°F. Connection sizes are 1-1/4" FPT.

Figure 8 General arrangement diagram - chilled-water systems

Bleed Valve

d

Chille
Water
Supply

Chilled
Water

rn

Retu

** Shutoff Valves

Female Adapters

Chilled Water
Control Valve

Site Preparation and Installation

Chilled Water Coil

** Hose Bibs

* Field piping refers to the use of hard
piping using sweat adapter kit
or precharged line set.

** Component
Liebert but are recommended for
proper circuit operation and
maintenance.

s are not supplied by

Suppl

Return

y

3 - Way Chilled Water
Control Valve
(Optional)

FIELD PIPING

FACTORY PIPING

DPN000236_Rev0

13

Site Preparation and Installation

Refrigerant (R-22) Piping

All split systems require two sets of refrigerant lines (two insulated copper suction lines and two cop­per liquid lines) between the evaporator and the condensing unit.

Two possible methods exist for installing the copper suction and liquid lines.

• Close coupling the units together using the quick connects.

• Using an optional Sweat Adapter Kit and hard piping between the two units.

All refrigeration piping should be installed with high temperature brazed joints. 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. To prevent tube damage when sealing openings in walls and to
reduce vibration transmission, use a soft flexible material to pack around the tubes.

When installing remote condensing units above the evaporator, the suction gas line should be trapped
at the evaporator. This trap will retain refrigerant oil in the off cycle. When the unit starts, oil in the
trap is carried up the vertical riser and returns to the compressor.

Table 6 Recommended refrigerant line sizes

Equivalent

Feet Circuit Liquid Line

50 feet 3-ton 3/8" O.D. 7/8" O.D.

100 feet 3-ton 1/2" O.D. 7/8" O.D

150 feet 3-ton 5/8" O.D. 1-1/8" O.D

50 feet 5-ton 1/2" O.D. 1-1/8" O.D

100 feet 5-ton 5/8" O.D. 1-1/8" O.D

150 feet 5-ton 5/8" O.D. 1-3/8" O.D

Consult your Liebert representative for longer line lengths.

Suction

Line

NOTE

If field supplied refrigerant piping is installed, refrigerant (R-22) must be
added to the system.

Figure 9 Refrigerant piping diagram

Evaporator

Suction Line Piping
Condensing Unit Below Evaporator

Evaporator

Pitch down 1/2" per 10 feet

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 drop to condensing
unit is 20 feet (6.1 m).

Condensing Unit

Condensing Unit

Suction Line Piping
Condensing Unit Above Evaporator
Traps recommended every 25 feet (7.6 m) of vertical rise.

14

Site Preparation and Installation

Refrigerant Charge Requirements: Total refrigerant charge (R-22) will be required only if units

are evacuated during installation or maintenance. For safe and effective operation, refer to 2.4.3 ­Piping Connections and Coolant Requirements.

Total refrigerant = Units and Lines

Table 7 8-ton unit refrigerant charge

Evaporator

Charge (ounces)

Model No.

MMD96E 7 7

MMD95E 7 7

Model No Charge (ounces)

MCD96A 361 581

MCD95A 361 581

MCD98W 54 94

MCD97W 54 94

Table 8 Line charges (field piping)*

O.D. Liquid Line Suction Line

1/2" 7.3 (1.1) 0.2 (0.1)

5/8" 11.7 (1.7) 0.3 (0.1)

7/8" 24.4 (3.6) 0.7 (0.1)

1-1/8" 41.6 (6.2) 1.2 (0.2)

*weight of R-22 in type “L” copper tube: lb per 100 ft (kg per 10 m)

3-ton circuit 5-ton circuit

Condensing Units

Quick Connect Fittings

NOTE

When hard piping is used, complete all piping and evacuate lines before
connecting quick connects.

Be especially careful 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 refrigerant oil.

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

5. Tighten the coupling body hex nut and union nut with the proper size wrench until the coupling
bodies “bottom out” or until a definite resistance is felt.

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 insure that the joint will not
leak. Refer to Table 9 for torque requirements.

Table 9 Refrigerant quick connect sizes and torque

Size O.D. Cu Coupling Size Torque (lb-ft)

3/8" #6 10-12

1/2" #10 35-45

7/8" #11 35-45

1-1/8" #12 50-65

15

Figure 10 Evaporator or chilled-water unit dimensional data

Customer Supplied
threaded rods for module
support from ceiling (1/2" minimum
diameter recommended) (typ. 4).

54 1/8 "

(1375mm)

CABINET

DIMENSION

15 5/8 "

2"

(50.8mm)

26 1/2 "

(673mm)

Air Outlet

Air Inlet

19 1/2 "
(495mm)

(397mm)

12 1/8 "

(308mm)

1 3/16 "

(30.2mm)

Site Preparation and Installation

9/16" (14mm) dia. holes for
threaded rods (typ. 2 each end)

16 13/16 "

(427mm)

FRONT

OF

UNIT

1"

(25.4mm)

19 1/2 "

(495.3mm)

1"

(25.4mm)

1"

(25.4mm)

17 1/2 "

(444.5mm)

49 "

(1244.6mm)

1"

(25.4mm)

50 "

(1270mm)

(1778mm)

(1828.8mm)

70 "

72 "

21 1/2 "

(546.1mm)

Hanger Bracket

(1270mm)

Shaded area indicates a
recommended clearance
of 30" (762mm)
and

filter removal.

for access

50 "

Shaded area indicates a
recommended clearance
of 30" (762mm)
and

filter removal.

Optional 1" (25.4mm)
Discharge Duct Connection
ships with Filter Box

for access

Duct Flange

47 "

(1193.8mm)

1"

(25.4mm)

(OPTIONAL) FILTER BOX

8"

(203mm)

16

15 5/8 "

(397mm)

16 13/16 "

(427mm)

DPN000240_Rev0

2.4.4 Electrical Connections, Evaporator or Chilled-Water Unit

WARNING

!

Unit contains hazardous electrical voltage. Disconnect power supply before working
within. Line side of factory disconnect remains energized when disconnect is off.

WARNING

!

UNIT CONTAINS HAZARDOUS ELECTRICAL VOLTAGE. More than one disconnect
may be required to remove power. Evaporator and condensing units may have separate
disconnects. Open all disconnects before working within.

Each unit is shipped from the factory with internal wiring completed. Refer to electrical sche­matic, Figure 11, Figure 25, and Figure 26 when making connections. Electrical connections
to be made at the installation site are:

• Power supply to each ceiling unit and control wiring between the evaporator unit and the con­densing unit, if applicable.

• Control wiring between the control panel (wallbox) and the evaporator or chilled-water unit
control board.

Power Connections

All power and control wiring and ground connections must be in accordance with the National
Electrical Code (NEC) and local codes. Refer to Unit serial tag data for electrical requirements.

Site Preparation and Installation

CAUTION

!

Use copper wiring only. Make sure that all connections are tight.

Voltage supplied must agree with the voltage specified on the unit serial tag. A field supplied dis­connect switch may be required. Consult local code.

Route the electrical service conduit through the hole provided in the cabinet and terminate it at
the electric box. Make connections at the factory terminal block or disconnect switch, L1, L2, L3.
Connect earth ground to lug provided. See transformer label for primary tap connections.
Installer will need to change transformer primary taps if applied unit voltage is other than pre­wired tap voltage.

An optional single point power kit is available for units that are close coupled (refer to Figure 11
and 2.4.3 - Piping Connections and Coolant Requirements). This kit should be mounted
inside the evaporator unit before installing the unit in the ceiling. Specific installation instruc­tions are included with the single point power kit.

Control Connections (10-wire on air-cooled, 8-wire on water/glycol cooled)

A field-supplied control connection (24 VAC) is required between the evaporator and the condens­ing unit. Control wiring must be installed in accordance with the National Electrical Code (NEC)
Class 2 circuit. Glycol-cooled units also require a two-wire control connection to the drycooler and
pump.

Control wiring between the evaporator and the condensing unit must not allow a voltage drop in
the line of more than 1 volt (16 gauge minimum for 75 feet). Do not connect additional electri-
cal devices to the control circuit. The internal control transformer is only sized for factory­supplied components.

Additional control wiring will be required if your system includes other optional monitoring and
control devices.

Four (4) wire (thermostat type) must be connected between the evaporator control board and the
wall box. See Figure 25 and Figure 26 and see Figure 11 for electrical connections.

17

Figure 11 Evaporator unit electrical connections

Earth Ground Connection
Connection terminal for field
supplied earth grounding wire.

High Volt Power Connections
Electric service connection terminals.

Optional factory installed
disconnect switch.

Site Preparation and Installation

Customer Remote Alarm
Connection TB50,51,56,24.
Field supplied 24V Class 2
wiring.

Common Alarm Connection.
Use field supplied 24V
Class 2 wire. TB75-76.

Drycooler/Circulating Pump Control
Circuit TB70-71. Optional
W/Glycool/Econ-O-Cycle models.
Use field supplied 24V class 2 wire.

Optional Condensate Pump
Auxiliary Float Switch Shut
Down Connection
TB60-61.

Microprocessor

Board

Optional Remote Sensor
Connection P16-1,2,3,4.

Field supplied unit disconnect switch
when factory unit disconnect switch
is not supplied.

Entrance for customer high
volt connections.

FRONT OF UNIT

Remote Control Panel Connection to
TB3-1,2,3,4 connected with field supplied
Thermostat wire (22ga, shielded/jacketed:
available from Liebert or others).

Heat Rejection Connection. Field supplied
24V NEC Class 2 wiring TB1-10. See note 2.

Remote Unit Shutdown. Use field supplied
24V Class 2 wire. Replace existing jumper
between TB37 & TB38 with NC switch
having a minimum 75 VA rating.

Site Monitoring Connection.
Terminals TB78 (+) TB77 (-) are for
connection of a 2 wire, twisted pair,
communication cable to optional
sitescan.

1

2

3

4

5

6

7

8

9

10

37

Electric service
not by Liebert

60

61

70

71

75

76

24

50

51

56

11

12

77

78

84

85

38

Remote Humidifier Contact
Field Supplied 24V class 2
wiring to terminals 11 & 12,
located in field wire
compartment.

Optional Main Fan Auxilary
Side Switch TB84-85.
Field supplied 24V Class 2
wire.

al entrance for

Electric
optional condensate
pump on left side of unit.

Optional Single

Point Power Kit

Entrance for customer low
voltage connections.

NOTES:

1. Refer to specification sheet
full load amp. an
ratings.

2. Control voltage wiring must be a
minimum of 16 GA (1.6mm) for up
to 75’ (23m) or not to exceed 1 volt
drop in control line.

Field supplied, field wired thermostat wire to remote wall box.

Entrance for customer low voltage connections

Field supplied 24V (NEC Class2 wiring) to condensing unit. (if applicable)

18

d wire size amp.

for

DPN000244_Rev0

Site Preparation and Installation

2.5 Indoor Air-Cooled Centrifugal Fan Condensing Unit Installation

2.5.1 Location Considerations

The centrifugal fan air-cooled condensing unit may be located above the dropped ceiling or any remote
indoor area. If noise is of concern, the condensing unit should be located away from personnel. Normal
operating sound may be objectionable if the condensing unit is placed near quiet work areas.

To mount the unit in the ceiling, refer to 2.4 - Installing the Evaporator or Chilled-Water Units
for hanging guidelines and to Figure 13 for dimensional data.

2.5.2 Ducting

Fan operation is designed for 5000 CFM (8495 CMH) at 0.5" external static pressure.

General Considerations

Use flexible duct work or nonflammable cloth collars to attach duct work to the unit and to control
vibration transmission to the building. Attach the duct work to the unit using the flanges provided.
Locate the unit and duct work so that the discharge air does not short circuit to the return air inlet.

Duct work that runs through a conditioned space or is exposed to areas where condensation may
occur must be insulated. Duct work should be suspended using flexible hangers. Duct work should not
be fastened directly to the building structure.

For multiple unit installations, space the units so that the hot condensing unit exhaust air is not
directed toward the air inlet of an adjacent unit.

Considerations for Specific Applications

In applications where the ceiling plenum is used as the heat rejection domain, the discharge
air must be directed away from the condensing unit air inlet and a screen must be added to the end of
the discharge duct to protect service personnel. Locate the air discharge a minimum of 4 feet from an
adjacent wall. Failure to do so may result in reduced air flow and poor system performance.

If the condensing unit draws air from the outside of the building, rain hoods must be
installed. Hood intake dimensions should be the same as the condensing unit duct dimensions. In
addition, install a triple layer bird screen over rain hood openings to eliminate the possibility of
insects, birds, water, or debris entering the unit. Avoid directing the hot exhaust air toward adjacent
doors or windows.

19

Site Preparation and Installation

2.5.3 Piping Connections

Details for refrigerant (R-22) loop piping are in 2.4.3 - Piping Connections and Coolant Require­ments.

Figure 12 Piping connections - indoor air-cooled centrifugal fan condensing unit

High Pressure
Switch

Hot Gas Bypass
Solenoid Valve

Hot Gas Bypass
Control Valve

Liquid Line
Solenoid Valve

3 - Way Head
Pressure
Control Valve

Check
Valve

Receiver Heater
Pressure Limiting
Switch

External Equalizer

Suction Line Male Quick
Connect Coupling

Suction Line Female Quick
Connect Coupling

Sensing Bulb

Service Access
Ports

Expansion Valve

Filter

Drier

Scroll
Compressor

Liquid Injection
Valve Bulb

*

Liquid Inject
Valve

Liquid
Connect Couplin

ion

*

Liquid Line Male Quick
Connect Coupling

Line Female Quick

(Two circuits required, single circuit shown for clarity)

g

Condenser Coil

3/8" (9.5mm) FLR
Pressure Relief Valve

Sight Glass

Lee - Temp
Receiver

Pressure Balancing
Valve

Evaporator Coil

2.5.4 Electrical Connections - Condensing Unit

Refer to 2.4.4 - Electrical Connections, Evaporator or Chilled-Water Unit and Figure 14 for
general wiring requirements and cautions. Refer to electrical schematic when making connections.
Refer to unit serial tag for full load amp and wire size amp ratings.

Power Connections

The condensing unit requires its own power source and earth ground, with a disconnect switch to iso­late the unit for maintenance.

NOTE

Refer to serial tag for full load amp and wire size amp ratings

Control Connections

Field-supplied control wires must be connected between the evaporator and the condensing unit (See
Figure 14 and the electrical schematic on the units for more details.) Seven (7) wires are required
between the evaporator and condensing unit. Eighth and ninth wires are required on systems with
hot gas bypass.

DPN000236_Rev0

20

Site Preparation and Installation

Figure 13 Indoor air-cooled centrifugal condensing unit dimensions and pipe connections

Customer supplied
threaded rods for module
support from ceiling (1/2"
minimum diameter
recommended) (typ. 4).

13/16"

(21mm)

23 7/8 "

(606mm)

66 9/32 "

(1683.5mm)

CABINET

DIMENSION

59 13/16 "

(1519mm)

42 17/32 "

(1080.3mm)

THREADED ROD

CENTERS

1 13/16 "

(40mm)

40 5/32 "

(1020mm)

CABINET

DIMENSION

19 1/32 "
(483mm)

64 1/4 "

632mm)

(1

THREADED ROD

CENTERS

Hanger
Bracket

8 13/16 "

(224mm)

1 3/32 "

(26mm)

16 5/16 "

(414mm)

26 3/8 "

(670mm)

Shaded area indicates a
recommended clearance of
30" (762mm) for
access and

component

removal.

NOTE: Unit is spaced evenly in
reference to threaded
rod centers.

Single Point

Power Kit

9/16" (14mm) dia. holes for
threaded rods (typ. 2 each end)

connection from Evaporator.

System 1 (3Ton) Suction Line Connection,
Aeroquip #11 Male.

System 2 (5Ton) Suction Line Connection,
Aeroquip #12 Male.

System 1 (3Ton) Liquid Line Connection,
Aeroquip #6 Male.

System 2 (5Ton) Liquid Line Connection,
Aeroquip #10 Male.

7/8" (22.2mm) dia. knockout
electrical entrance for alternate
control panel low voltage routing.

Air Inlet

7/8" (22mm) & 1 1/8" (29mm)

Air Outlet

dia. knoc
for high voltage connection

7/8" (22.2mm) dia. electrical entrance
for low voltage connection.

kouts electrical entrance

DPN000248_Rev1

21

Figure 14 Indoor air-cooled centrifugal condenser electrical connections

Field Supplied Unit Disconnect
Switch when Factory Unit
Disconnect Switch is not
Supplied.

Electric Service not
by Liebert.

Line Voltage

Conduit.

Removable
Access Panels

Electric Power Supply

Site Preparation and Installation

Connection Terminal for
Field Supplied Earth
Grounding Wire.

Optional Factory Installed
Disconnect Switch.

Openings for Field Supplied
24V NEC Class 2 Wiring
Between Condensing Unit and
Fan/Coil Unit.

NOTES:

1. Refer to specification sheet for full load amp. and wire size amp. ratings.

2. Control voltage wiring must be a minimum of 16 GA (1.6mm) for up to 75’ (23m) or not
to exceed 1 volt drop in control line.

Low VoltageElectric Power

Supply Conduit Entrance.

6"

(152.4mm)

8 1/2 "

(215.9mm)

12 1/2 "

(317.5mm)

16 1/2 "

(419.1mm)

4"

(101.6mm)

Heat rejection connection

.

Field
supplied 24V NEC class 2 wiring. See note 2.
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
(only on units with hot gas bypass.
If no hot gas bypass, connection is
provided in the evaporator module.
Connect wire 4 and wire 2 to the
24V supply).

5. 24V GND System 2

6. 24V Supply System 2

7. High Pressure Alarm System 2

8. Hot Gas Bypass Connection System 2
(only on units with hot gas bypass.
If no hot gas bypass, connection is
provided in the evaporator module.
Connect wire 8 and wire 6 to the
24V supply).

9. 24V GND Condenser Fan

10. 24V SUPPLY Condenser Fan

DPN000249_Rev0

22

2.6 Outdoor Air-Cooled Condensing Unit Installation

2.6.1 Location Considerations

To insure a satisfactory air supply, locate air-cooled propeller fan condensing units in an environment
providing clean air, away from loose dirt and foreign matter that may clog the coil. Condensing units
must not be located in the vicinity of steam, hot air, or fume exhausts, or closer than 18 inches from a
wall, obstruction, or adjacent unit. Avoid areas where heavy snow will accumulate at air inlet and dis­charge locations.

The condensing unit should be located for maximum security and maintenance accessibility. Avoid
ground-level sites with public access.

Install a solid base, capable of supporting the weight of the condensing unit. The base should be at
least 2 inches higher than the surrounding grade and 2 inches larger than the dimensions of the con­densing unit base. For snowy areas, a base of sufficient height to clear snow accumulation must be
installed.

2.6.2 Piping Connections

Details for refrigerant (R-22) loop piping are in Figure 12 - Piping connections - indoor air­cooled centrifugal fan condensing unit.

2.6.3 Electrical Connections

Refer to 2.4.4 - Electrical Connections, Evaporator or Chilled-Water Unit for general wiring
requirements and cautions. Refer to electrical schematic when making connections.

Site Preparation and Installation

Power Connections

The outdoor condensing unit requires its own power source and earth ground, with a disconnect
switch (field supplied) to isolate the unit for maintenance.

Control Connections

Field-supplied control wires must be connected between the evaporator and the condensing unit. (See
Figure 6 and the electrical schematic on the units for more details.) Seven (7) wires are required
between the evaporator and condensing unit. Eighth and ninth wires are required on systems with
hot gas bypass.

23

Figure 15 Electrical field connections - outdoor condensing unit

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.

Electric service

connection

to contactor
or terminal block.

Site Preparation and Installation

Factory wired
to components on
electric panel.

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.

NOTE:

Refer to specification sheet
for full load amp and wire size
amp ratings.

Heat rejection connection.Field

supplied 24V
Wire connections from evaporator module:
1 24V GND System 1
2 24V Supply System 1

High Pressure Alarm System 1

3
4 Hot Gas Bypass Connection System
(only on units with hot gas bypass
If no hot gas bypass, connection is
provided in the evaporator
Connect wire 4 and wire 2 to th
24V supply).
5 24V GND System 2
6 24V Supp
7 High Pressure Alarm System 2
8 Hot Gas Bypass Connection System 2
(only on units with hot gas bypass.
If no hot gas bypass, connection is
provided in the evaporator module.
Connect wire 8 and wire 6 to the
24V supply).
9 24V GND Condenser Fan
10 24V SUPPLY Condenser Fan

NEC class 2 wiring.

1

.

module.

e

ly System 2

DPN000135_Rev0

24

Figure 16 Footprint dimensions - outdoor condensing unit

GUARD
HEIGHT

D

B

TOP

AIR

DISCHARGE

Site Preparation and Installation

RIGHT

AIR

INTAKE

LEFT

AIR

INTAKE

(51mm)

SHADED AREA

INDICATES A RECOMMENDED

CLEARANCE OF 18" (457mm)

FOR PROPER

2"

AIR FLOW

36 1/8 "

(918mm)

A

REMOVABLE FRONT PANEL FOR

ACCESS TO HIGH VOLTAGE &

LOW VOLTAGE CONNECTIONS

AND REFRIGERATION COMPONENTS

4" TYP.

(102mm)

2" TYP.

(51mm)

INDICATES A RECOMMENDED

CLEARANCE OF 18" (457mm)

C

SHADED

INDICATES A RECOMMENDED

CLEARANCE OF 24" (610mm)

FOR COMPONENT

ACCESS AND REMOVAL

53 3/16 "

(1351mm)

SHADED AREA

FOR PROPER

AREA

1/2" Bolt-Down Holes

places)

(6

AIR FLOW

4 23/32 "
(120mm)

PFC096A-_L

PFH096A-_H

25 3/32 "
(637mm)

46 7/32 "

(1174mm)

2"

(51mm)

FOOTPRINT DIMENSIONS

Model Dimensional Data in. (mm)

PFC095A-_L
PFH095A-_L

53 (1343)
53 (1343)

25

36-1/4 (918)
36-1/4 (918)

38-1/2 (978)
38-1/2 (978)

2"

(51mm)

32 1/8 "

(816mm)

DPN000131_Rev0

Net Weight

lbs (kg) 60 Hz 50 Hz Width (A) Height (B) Depth (C)

488 (222)
488 (222)

Figure 17 Piping and electrical connections - outdoor condensing unit

Site Preparation and Installation

SL-11081Page7

Model Numbers Electrical Connections In. (mm) Piping Connections In. (mm)

60 Hz 50 Hz A B C D E F G

PFC096A-L PFC095A-L 2

(51)

6

(152)

26

8-1/2
(216)

4-3/4
(121)

7-3/4
(197)

8-1/2
(216)

11-1/2

(292)

Site Preparation and Installation

2.7 Indoor Water- and Glycol-Cooled Condensing Unit Installation

2.7.1 Location Considerations

The condensing unit may be located above the dropped ceiling or any remote indoor area. If noise is of
concern, the condensing unit should be located away from personnel. Normal operating sound may be
objectionable if the condensing unit is placed near quiet work areas.

To mount the unit in the ceiling, refer to 2.4 - Installing the Evaporator or Chilled-Water Units.

2.7.2 Piping Connections

Details for Refrigerant (R-22) Loop piping are in 2.4.3 - Piping Connections and Coolant
Requirements.

Water/Glycol Piping Considerations

Refer to Figure 20 for recommended field installed piping hardware such as shut-off valves and hose­bibs. Water filters should be installed if water quality is poor. Filters will extend the service life and
efficiency of the condensers.

Condensing Unit Fluid Requirements

The maximum fluid pressure is 150 psi standard pressure or 350 psi for high pressure units (Refer to
unit serial tag and model number description page at beginning of this manual).

NOTE

HVAC grade ethylene or propylene glycol should be used on glycol systems.
Automotive antifreeze must not be used.

Regulating Valve

Water/Glycol-cooled units include a coolant flow regulating valve which is factory adjusted and should
not need field adjustment.

Standard water pressure and high water pressure valves are adjusted differently. Contact Liebert
Service before making any adjustments.

2.7.3 Electrical Connections

Refer to 2.4.4 - Electrical Connections, Evaporator or Chilled-Water Unit for general wiring
requirements and cautions. Refer to electrical schematic when making connections. Refer to serial tag
for full load amp and wire size amp ratings.

Control Connections

A six-wire control connection is required from the evaporator unit to the water/glycol condensing unit.
Two (2) additional wires are required when hot gas bypass is ordered. Glycol-cooled units also

require a two-wire control connection to the drycooler and pump package.

27

Figure 18 Indoor water/glycol condensing unit dimensional data

Site Preparation and Installation

1. 24V GND System 1

2. 24V Supply System 1

3. High-Pressure Alarm
System 1

4. Hot Gas Bypass
Connection System 1
(only on units with hot
gas bypass. If no hot gas
bypass, connection is
provided in the
evaporator module.
Connect wire 4 and wire 2
to the 24V supply).

5. 24V GND System 2

6. 24V Supply System 2

7. High-Pressure Alarm
System 2

8. Hot Gas Bypass
Connection System 2
(only on units with hot
gas bypass. If no hot gas
bypass, connection is
provided in the
evaporator module.
Connect wire 8 and wire 6
to the 24V supply).

28

Figure 19 Indoor water/glycol condensing unit electrical field connections

Site Preparation and Installation

29

Figure 20 System piping with indoor water/glycol-cooled condensing unit

Two circuits provided. Single circuit shown.

Site Preparation and Installation

SL-11088Pg7

30

2.8 Optional Equipment Piping

2.8.1 Free-Cooling Coil (GLYCOOL)

The free-cooling coil is a secondary coil located upstream of the DX coil. To take maximum advantage
of available free-cooling, the secondary coil may operate at the same time as the DX coil. A tempera­ture sensor is factory-mounted to the free-cooling piping. When fluid temperature is sufficiently below
the room temperature, cooling is provided by circulating the fluid through the secondary cooling coil
(flow is controlled by a motorized valve). Compressors are staged on if needed to supplement the free­cooling. To keep deposits from building up in the free-cooling coil, the coil is flushed periodically.

NOTE

If the free-cooling coil is piped to an open water tower, a CU/NI (cupro-nickel) type coil must
be ordered to prevent corrosion of the copper tubes; or a heat exchanger must separate the
tower water from the free-cooling loop.

On water-cooled systems, the free-cooling coil outlet can be field piped to the condensing unit inlet,
provided a 3-way regulating valve has been installed within the water/glycol condensing unit (see
Figure 21).

Figure 21 Optional free cooling coil (3-way valve) on water/glycol units

Site Preparation and Installation

SL-11088Pg12

31

Figure 22 Optional free cooling coil (3-way valve) on air-cooled units

Site Preparation and Installation

SL-11088Pg12

32

2.9 Checklist for Completed Installation

___ 1. Proper clearance for service access has been maintained around the equipment.

___ 2. Equipment is level and lock-nuts are installed with the leveling nuts on the spring isolators.

___ 3. Piping completed to refrigerant or coolant loop (if required). Refrigerant charge added (if

required).

___ 4. Condensate pump installed (if required).

___ 5. Drain line Connected.

___ 6. Water supply line connected to humidifier (if required). Route to allow air filter removal.

___ 7. Field provided pan with drain installed under all cooling units and water/glycol condensing

units.

___ 8. Filter box installed.

___ 9. Ducting completed.

___ 10. Filter(s) installed in return air duct.

___ 11. Line voltage to power wiring matches equipment serial tag.

___ 12. Power wiring connections completed and phased correctly between disconnect switch,

evaporator, and condensing unit, including earth ground.

___ 13. Power line circuit breakers or fuses have proper ratings for equipment installed.

___ 14. Control wiring connections completed to evaporator and condensing unit (if required,

including wiring to wall-mounted control panel and optional controls).

___ 15. Control panel DIP switches set based on customer requirements.

___ 16. All wiring connections are tight.

___ 17. Foreign materials have been removed from in and around all equipment installed (shipping

materials, construction materials, tools, etc.)

___ 18. Fans and blowers rotate freely without unusual noise.

___ 19. Inspect all piping connections for leaks during initial operations. Correct as needed.

Site Preparation and Installation

33

3.0 MICROPROCESSOR CONTROL

The Microprocessor Control for the Liebert Mini-Mate2 unit features an easy to use menu-driven
LCD display. The menus, control features, and circuit board details are described in this section.
Detailed information concerning controls (4.0 - System Performance Microprocessor Controls)
and alarms (5.0 - Alarms) are provided.

3.1 Feature Overview

To turn the unit ON, press the ON/OFF (I/O) key after power is applied. To turn the unit OFF, press
the ON/OFF (I/O) key before power is disconnected.

The following control keys may be used to move through the menus, as prompted on the LCD display:

• ON/OFF (I/O) – turns unit on or off (top far left).

• Menu – Enables user to access the program menu to change control parameters, alarms, setback
schedule, etc. (top near left).

• Increase (UP) – Raises the value of displayed parameter while in a set mode (setpoints, time, etc.)
(Arrow-top near right) and navigates the program menu.

• Escape (ESC) – Allows user to move back to a previous menu (top far right).

• Alarm Silence/Help – If an alarm is present, pressing this keypad will silence he alarm. If this key
is pressed when no alarms are present, help text will appear (bottom near left).

• Decrease (DOWN) Arrow – Lowers the value of displayed parameter while in a set mode (bottom
near right) and navigates the program menu.

• Enter – After setting a control point, press ENTER to store the information in the microprocessor
(bottom far right) Also, press ENTER to select a menu item.

Microprocessor Control

Figure 23 Wall box

Active alarms are displayed on the LCD screen and sound an audible beeper. To silence an alarm,
press the Alarm Silence/Help key as prompted on the display.

Setpoints, DIP switch settings, and other selections were made during factory testing of your unit and
are based upon typical operating experience. (Other default selections were made according to options
included with your unit). MAKE ADJUSTMENTS TO THE FACTORY DEFAULT SELECTIONS
ONLY IF THEY DO NOT MEET YOUR SPECIFICATIONS.

Allowable ranges are displayed by pressing the help key. A password will be required (if enabled) to
change setpoints, time delays, etc.

The display normally shown includes the present room temperature, humidity, active status func­tions (cooling, heating, dehumidifying, humidifying), and active alarms. More detailed status and
alarm information is available from the menu.

34

3.2 Main Menu <Menu>

Press the MENU key to display the Main Menu. The Menu selections (in the following order) include:

• SETPOINTS

• STATUS

• ACTIVE ALARMS

•ALARM HISTORY

•TIME

•DATE

• SETBACK

• SETUP OPERATION

• SETPT PASSWORD

• SETUP PASSWORD

• CALIBRATE SENSOR

• ALARM ENABLE

• ALARM TIME DELAY

• COM ALARM ENABLE

• CUSTOM ALARMS

• CUSTOM TEXT

•DIAGNOSTICS

•end of MENU

Microprocessor Control

Use the UP/DOWN arrow to scroll through the selections, then, when ready to select a particular
function, press ENTER.

35

3.3 Setpoints

Setpoints and system setup parameters are kept in nonvolatile memory. Selecting SETPOINTS from
the Main Menu will display the following selections:

• TEMPERATURE SETPOINT

• TEMPERATURE SENSITIVITY

• HUMIDITY SETPOINT

• HUMIDITY SENSITIVITY

• HIGH TEMPERATURE ALARM

• LOW TEMPERATURE ALARM

• HIGH HUMIDITY ALARM

• LOW HUMIDITY ALARM

Scroll through this sub-menu by using the UP/DOWN arrow, then press ENTER to select a particu­lar function. To change a value, press ENTER and use the UP/DOWN arrows. When the value has
been changed, press ENTER to store the value. For example, to change the temperature setpoint
from the main status display:

1. Press MENU key to display main menu.

2. Scroll to “SETPOINTS” using the UP/DOWN arrow key. Press ENTER.

3. Scroll to “TEMP SETPT” using the UP/DOWN arrow key. Press ENTER.

4. Use the UP/DOWN arrow to change the value. Press ENTER.

Microprocessor Control

Table 10 Default setpoints and allowable ranges

Setpoint Default Range

Temperature Setpoint 72°F 40-90°F (5-32°C)

Temperature Sensitivity 2.0

Humidity Setpoint 50% 20-80% RH

Humidity Sensitivity 5% 1-30% RH

High Temperature Alarm 80

Low Temperature Alarm 65°F

High Humidity Alarm 60% 15-85% RH

Low Humidity Alarm 40% 15-85% RH

3.4 Status

The operator can monitor the percentage heating, cooling, dehumidifying, and humidifying status of
the unit by selecting “STATUS” from the main menu.

3.5 Active Alarms

The operator can monitor the alarms status by selecting “ACTIVE ALARMS” which will display a
“Alarm XX of YY” alert and description. If more than one alarm is activated, use the Up/Down arrow
to scroll through the alarms list. (“XX” reference is the number of the alarm shown, and the “YY” ref­erence is the total number of alarms activated).

°F1-9.9°F (0.6-5.6°C)

°F

°F

35-95

(2-35

35-95

(2-35

°C)

°F

°C)

3.6 Alarm History

A history of the 10 most recent alarms is kept in non-volatile memory complete with the date and
time of their occurrence. The first alarm in the history is the most recent, and the 10th is the oldest. If
the ALARM HISTORY is full (10 alarms) and a new alarm occurs, the oldest is lost and the newest is
saved in ALARM HISTORY location 1.The rest are moved down the list by 1. ALARM HISTORY on
new units may show the results of factory testing.

36

3.7 Time

The controller time clock must be set to allow for the setback control. The clock uses the 24-hour sys­tem (i.e., 12 midnight is entered 24:00). To change the time press ENTER to select the function, then
use the UP/DOWN arrow to change the first character, press ENTER to store, then press the UP/
DOWN arrow key to change the character, press ENTER to store, etc. The real time clock is backed­up.

3.8 Date

The controller date must be set to allow for setback control. To change the date press ENTER, then
use the UP/DOWN arrow to change the first character, press ENTER to store, press the UP/DOWN
arrow key to change the second character, etc.

3.9 Setback

The microprocessor can be programmed for night and weekend setback. Two (2) events can be pro­grammed for a five-day workweek and two (2) events can be programmed for a two-day weekend. The
following table can be used to devise a setback plan.

Table 11 Night and weekend setback plan

Time 1

Temperature1

Sensitivity 1

Humidity 1

Humidity Sensitivity 1

Time 2

Temperature 2

Sensitivity 2

Humidity 2

Humidity Sensitivity 2

Microprocessor Control

Event Weekend Weekday

3.10 Setup Operation

Selecting SETUP OPERATION from the Main Menu will display the following selections:

• RESTART TIME DELAY

• C/F DEGREES

• HUMIDITY CONTROL METHOD

• LEAD COMPRESSOR

•SHOW DIP SWITCH

• VALVE TIME (if valve present)

• CW FLUSH (if valve present)

Use the UP/DOWN ARROW to scroll through the submenu. Press ENTER to select a particular
function.

3.10.1 Restart Time Delay

This function delays unit restart after main power is restored to the unit. If several systems are oper­ating, the time delays should be set to different values to cause a sequential start. Delay can be set
from 0.1 minutes (6 seconds to 9.9 minutes. Setting the value to zero (0) will prevent unit restart
when power is restored. In this case, the unit must be restarted manually by pressing the ON/OFF
button on the keypad.

37

3.10.2 C/F Degrees

The control may be selected to show readings and setpoints in either degrees Fahrenheit (°F) or in
degrees Celsius (°C). To change the value use ENTER to select this function, then use the UP/DOWN
arrow to change the value. Press ENTER to store the value.

3.10.3 Humidity Control Method

The operator may select either relative (direct) or absolute (predictive) humidity control. If “relative”
is selected, the RH control is taken directly from the RH sensor. If “absolute” is selected, the RH con­trol is automatically adjusted whenever return air temperature deviates from the desired tempera­ture setpoint (i.e., predictive humidity control). The LCD display will indicate percentage relative
humidity for both methods of control. If the “absolute” feature is selected, the adjusted humidity read­ing will also be shown. When utilizing the predictive humidity control feature, the humidity level is
automatically adjusted ~2% RH for each degree difference between the return air temperature and
the temperature setpoint.

Unnecessary dehumidification can result when overcooling occurs during a dehumidification cycle.
This is due to a higher than normal RH reading caused by overcooling the room (about 2% RH for
each degree of overcooling). This drop in temperature extends the dehumidification cycle. Later, when
the dehumidification ends and the temperature rises to the setpoint, the RH reading falls. The final
RH reading will then be lower than actually desired. If the temperature drop was significant enough,
the percentage RH could be low enough to activate the humidifier.

If the absolute humidity control is selected, over-dehumidification may be avoided. When overcooling
occurs (i.e., causing an increase in the RH reading) the humidity control program estimates what the
RH will be when the dehumidification cycle ends and temperature returns to the setpoint. This allows
the dehumidification cycle to end at the proper time. Predictive humidity control can greatly reduce
energy consumption by minimizing both compressor/reheat operation. Use the UP/DOWN ARROW
key to select the desired humidity control method.

Microprocessor Control

3.10.4 Lead Compressor

This function allows the user to select which compressor is the lead: Compressor 1 (3 ton), Compres­sor 2 (5 ton), or Auto. The factory default is Auto. If Auto is selected, the control will determine which
compressor is to be the lead compressor based on the average room load over the previous one hour of
operation.

3.10.5 Show DIP Switch

This function shows the position of the DIP switches which are located on the control board in the
unit. 1 = Switch is “ON” and 0 = Switch is “OFF”. For more information on the DIP switches and their
functions, see Table 17 Equipment Switch Settings.

3.10.6 Valve Time (For Systems With a Modulating Chilled-Water Valve)

This function shows the full valve travel time of the modulating valve on a chilled-water system. This
is the time it takes for the valve to travel from full closed to full open. It is programmable from 50 to
250 seconds; factory default time is 165 seconds and should not be changed unless actual valve travel
time is not correct. The full valve travel time is used by the control to determine the appropriate valve
position. For example, if the valve travel time is 165 seconds and 50% cooling is being called for, the
valve will open for 83 seconds to achieve 50% open.

38

3.10.7 CW Flush (For Systems With a Modulating Chilled-Water Valve)

This function shows the interval time at which the system will perform a modulating chilled-water
valve system flush cycle. The factory default is 24 (hours) and is programmable from 0 (hours) which
signifies to never flush, to 99 (hours) which signifies to flush after every 99 hours of valve non-use. If
the valve is called on by the control to open within the programmed interval time, the timer will be
reset to 0. The flush cycle is active even when the fan is turned off, but power is applied to the unit.
When the interval timer reaches the programmed time, the valve will be opened for 3 minutes to flush
any contaminates which may have collected in the system.

Table 12 Setup functions, default values and allowable ranges

Function Default Range

Restart Time Delay 0.1

C/F Degrees

Humidity Control Rel Relative or Absolute

Valve Time 165 50 to 250 sec(s)

CW Flush 24 0 to 99 hours

°F °C or °F

0 to 9.9 min

(0 = manual restart)

3.11 Change Passwords

The display will prompt the operator to enter a three digit password when attempting to make
changes. The system includes two (2) passwords, one for setpoints and one for setup. The system
allows the password to be changed by first entering the default password set at the factory (1-2-3) for
setpoints and (3-2-1) for setup. The password function provides system security, so that only autho­rized personnel are allowed to make changes to the system. (If unauthorized changes are being made,
the passwords may be compromised and new ones should be selected). The password function can be
disabled by setting DIP switch 8 in the wallbox to OFF, then resetting power to the unit.

Microprocessor Control

3.12 Calibrate Sensors

The temperature and humidity sensors can be calibrated by selecting the CALIBRATE SENSORS
menu item. The temperature sensor can be calibrated ±5°F, while the humidity sensor can be cali­brated ±10% RH. When calibrating the humidity sensor, the value shown will always be % RH, even
though absolute humidity control may be selected. If absolute humidity control is selected, the Nor­mal Status Display will display the adjusted reading. This reading may not agree with the relative
humidity reading displayed while in calibration.

If the sensors are subject to frequent wide temperature and humidity swings, it may be necessary to
shorten the cycling by increasing the sensor response time delay. If the sensors are located too close to
the air discharge, they will likely experience rapid swings in measurement. The factory default is 30
seconds. Another method in reducing compressor cycling is to increase the temperature and/or humid­ity sensitivity.

3.13 Alarm Enable

Each alarm can be disabled or enabled. Use the UP/DOWN ARROW to select a particular alarm,
press Enter to select either enable or disable. Then press Enter again to store the change. When the
alarm is disabled it will NOT report to either the wallbox beeper or the common alarm relay. The high
water in condensate pan and high head alarms cannot be disabled.

NOTE

The high-water alarm will automatically shut the unit off.

39

3.14 Alarm Time Delay

Each individual alarm can be programmed with a time delay (Table 13), causing the unit to delay a
specified amount of time (0-255 seconds) before recognizing the alarm. The alarm condition must be
present for the full amount of the time delay before the alarm will sound. If the alarm condition is
diverted prematurely, the alarm will not be recognized and the time delay will automatically reset.

NOTE

For software alarms such as “loss of power” and “short cycle,” the time
delay should be left at the factory default of 0.

Table 13 Alarm default time delays

Default Time Delay

Alarm

Hum Prob 2

Chng Fltr 2

Custom Alarm #1 0

Custom Alarm #2 0

Custom Alarm #3 0

High Temperature 30

Low Temperature 30

High Humidity 30

Low Humidity 30

Short Cycle 1 & 2 0

Loss of Power 0

Microprocessor Control

(seconds)

3.15 Common Alarm Enable

Each individual alarm can be selected to activate/deactivate the common alarm relay. If the energize
common alarm function is set to YES, the relay is energized immediately as the alarm is enunciated,
and de-energized when the alarm condition has cleared. If the alarm is completely DISABLED, the
alarm has no effect on the common alarm relay. Use the UP/DOWN arrows to scroll to a particular
alarm, press the ENTER button to select it, then press the ENTER key again to select Yes or No.

3.16 Custom Alarms

The custom alarm messages can be selected from a list of standard alarm messages, or the operator
can write his/her own message. A MAXIMUM OF THREE (3) ALARM MESSAGES CAN BE CUS­TOMIZED.

The text for custom alarms can be changed at any time by selecting “CUSTOM ALARMS”. To change
the text for a custom alarm, select the alarm you would like to change, 1, 2 or 3. Using the UP/DOWN
arrows, step through the list of seven standard alarm messages (listed below) and two custom alarms.
Select the alarm message desired and store it by pressing ENTER.

• SMOKE DETECTED

•CUSTOM 2

•CUSTOM 3

• STANDBY GC PUMP

• WATER FLOW LOSS

• STANDBY UNIT ON

•CUSTOM 1

40

3.17 Custom Text

To modify the two custom alarm messages select “CUSTOM TEXT”. Then select “Custom Text #1,”
“Custom Text #2” or “Custom Text #3.” Text can be up to 16 characters in length and can be either a
blank space or any of the following alphanumeric characters and symbols:

• A,B,C,D,E,F,G,H,I,J,K,L,M,N,O,P,Q,R,S,T,U,V,W,X,Y,Z

• #,%,*,-

• 0,1,2,3,4,5,6,7,8 or 9

Use the UP/DOWN arrows to select a character, then press ENTER. The cursor will move to the
next space where you may once use the UP/DOWN arrows to select another character, etc. The cus­tom text alarm will be displayed only if the alarm is selected in Custom Alarms.

LCD Display Contrast

The level of contrast due to the viewing angle of the LCD display can be adjusted using a potentiome­ter screw, inside the wall box next to the display.

Nonvolatile Memory

All critical information is stored in nonvolatile memory. Setpoints and setup parameters are kept
inside the microcontroller in EEPROM.

Equipment Options Switches

Equipment options are selected and enabled using DIP switches 1 through 7. These are located on the
control board near TB3. These switches are factory set and should not require any user changes. The
setting and function of the switches can be individually read on the LCD display.

Microprocessor Control

NOTE

In order to update the DIP switch settings, power must be cycled off, then on, from the unit
disconnect switch.

Table 14 Equipment switch settings (unit control board)

Switch OFF Position ON Position

1 Step Cool Ramp Cool

2 Step Heat Ramp Heat

3 Not Used Not Used

4 No GLYCOOL GLYCOOL

5 Disable 1 stage CW Enable 1 stage CW

6 Not used Not used

7 1-stage

dehumidification

8 Disable SCR Reheat Enable SCR Reheat

2-stage
dehumidification

Table 15 Switch settings (wallbox board)

Switch OFF Position ON Position

1 Beeper Disable Beeper Enable

2 Not Used Not Used

3 Not Used Not Used

4 Enable Reheat Disable Reheat

5 Enable Hum. Disable Hum.

6 Enable Dehum. Disable Dehum.

7 Disable Setback Enable Setback

8 Enable Password Disable Password

41

3.18 Run Diagnostics

By selecting Run Diagnostics, maintenance personnel can check system inputs, outputs, and conduct
a test of the microcontroller circuit board from the wall box control. A review of the system inputs and
the microcontroller test can be done without interrupting normal operation.

Test Outputs

• When this feature is selected, the controller is effectively turned off. When stepping from one load
to the next, the previous load is automatically turned off. The loads can also be toggled on/off by
selecting “ENTER”. Once turned on, the output will remain on for five minutes unless toggled off
or the test outputs function is exited by selecting “MENU/ESC” (Compressor is limited to 15 sec­onds on to prevent damage.

CAUTION

!

Testing compressor output for more than a few seconds could damage the compressor. To
eliminate damaging the compressor during testing, DO NOT test compressor output for more
than a few seconds.

CAUTION

!

Extended unit operation in the test outputs mode for troubleshooting may cause damage to
unit. DO NOT operate unit in the test outputs mode any longer than is necessary for
troubleshooting.

Microprocessor Control

NOTE

Fan turned on with all loads.

The outputs are:

•Main Fan

• Compr1 (3-ton)

• Compr1 & HGBP1

• Compr2

• Compr2 & HGBP2

• Compr1 & Compr2

• Chill Water/Gly (if present)

• Reheat 1

• Reheat 2

• SCR Reheats (if present)

• Humidifier

• Common Alarm

Test Inputs

With the unit on and the fan running, the input states may be displayed for the following devices:

•Input Power

• High Water in Pan

• High Head Comp1

• High Head Comp2

• Air Sail Switch (requires additional factory-installed components)

•Filter Clog

• Humidifier Prob.

• Custom Alarm #1

• Custom Alarm #2

• Custom Alarm #3

42

Test Micro

By selecting this function, the microcontroller will perform a self test lasting approximately 10 sec­onds. When the test is complete, the display will show the ROM checksum, ROM part number, and
firmware revision number.

Figure 24 Control menu

Status Display

72 F 50 %RH

NO ALARMS

Menu

Setpoints

Status
Active Alarms
Alarm History

Time
Date

Setback

Setup Operation

Setpoint

Password

Setup Password

Calibrate Sensor

Alarm Enable

Alarm Time Delay

Com Alarm

Enable

Custom Alarms

Custom Text

Diagnostics

End of Menu

Setpoints

Temp Setpt

Temp Sens

Hum Setpt

Hum Sens

Hi Temp Alm

Lo Temp Alrm

Hi Hum Alm

Lo Hum Alm

Status

Dx Cool % 0
CW Valve% 0
Econo Cool % 0
Heat % 0
Dehumidify% 0
Humidify% 0

Active Alarms

No Alarms

or

Alarm 01 of 01

High Head

Time

Date

Setback

Wknd Time 1

On/Off:

Wknd Temp 1

Wknd Tsens 1

Wknd Humd 1

Wknd Hsens 1

Wknd Time 2

On/Off:

Wknd Temp 2

Wknd Tsens 2

Wknd Humd 2

Wknd Hsens 2

Wkdy Time 1

On/Off:

Wkdy Temp 1

Wkdy Humd 1

Wkdy Hsens 1

Wkdy Time 2

On/Off:

Wkdy Temp 2
Wkdy Tsens 2
Wkdy Humd 2

Wkdy Hsens 2

Setup Operation

Restart TD

C/F Degrees

Humidity Control

Lead Compr

Dipswch 00000000

Pos 12345678

Valve Time

CW Flush

Setpoint Password

Enter New PSW

Setpt PSW = 000

Setup Password

Enter New PSW

Setup PSW = 000

Calibrate sensor

Temp Cal

Hum Cal

Temp Delay

Hum Delay

Alarm Enable

Hum Prob

Chng Fltr

Loss Air
Custom #1
Custom #2
Custom #3

High Temp

Low Temp

High Hum

Low Hum
Short Cyc1
Short Cyc2

Fan Ovrld

Loss Pwr

Microprocessor Control

Alarm Time Delay

Hum Prob

Chng Filt

Loss Air
Custom #1
Custom #2
Custom #3
High Temp

Low Temp

High Hum

Low Hum
Short Cyc1
Short Cyc2

Fan Ovrld

Loss Pwr

Com Alarm Enable

Hum Prob
Hi Head 1
Hi Head 2

Chng Fltr

Loss Air
Custom #1
Custom #2
Custom #3

Hi Water

High Temp

Low Temp

High Hum

Low Hum
Short Cyc1
Short Cyc2

Fan Ovrld

Loss Pwr

Custom Alarms

Custom Alarm #1
Custom Alarm #2
Custom Alarm #3

Custom Text

Custom Text #1
Custom Text #2
Custom Text #3

Diagnostics

Test Outputs

Test Inputs

Test Microcontroller

43

Figure 25 Control board (inside evaporator)

Microprocessor Control

P32

P33

P36

P8

P34

P35

P40

P22

P38

P39

P7

P18

P1P2P3

P4

P25

TB

T+

P26

P16

P10

G2 G3G4G5

TB3-4 Connection to Terminal #4 Wallbox
TB3-3 Connection to Terminal #3 Wallbox

T­+5V

TB3-2 Connection to Terminal #2 Wallbox

GND

TB3-1 Connection to Terminal #1 Wallbox

P5

P16 Remote Sensor Connection

P43

Figure 26 Wall box board

TB3-1
TB3-2
TB3-3
TB4-4

Wall Box
DIP Switches (1-8)

44

System Performance Microprocessor Controls

4.0 SYSTEM PERFORMANCE MICROPROCESSOR CONTROLS

4.1 Control Type Response Proportional Control

The percent requirement is determined by the difference between the return air temperature and the
temperature setpoint. As the return air temperature rises above the temperature setpoint, the per­cent cooling required increases proportionally (from 0 to 100%) over a temperature band equal to the
temperature sensitivity plus 1 degree Fahrenheit. The heating requirement is determined in a simi­lar manner as the temperature decreases below the setpoint. With this control type the temperature
at which the room is controlled increases as the room load increases. At full load the room would be
controlled at a temperature equal to the setpoint plus the sensitivity.

4.2 Cooling

4.2.1 Multi-Step Cooling, Compressorized Direct Expansion (DX) Systems

The system will use the 3-ton (compressor #1) and 5-ton (compressor #2) compressors in an 8-ton sys­tem. The control will determine the average cooling requirement updated every hour and select the
lead compressor or, the user can select the lead compressor through the “Setup Operation” menu. At
startup, the 3-ton compressor will be the lead compressor. The compressors will be staged on with hot
gas bypass energized at 50 and 100% cooling requirements. The compressors will turn off at 75% and
25% requirements.

4.2.2 Chilled-Water Cooling (8 Ton)

The chilled-water control valve is adjusted proportionally as the temperature control varies the
requirement for cooling from 0% to 100%. This is based on the full valve travel time programmed in
the “Setup Operation” menu.

4.2.3 GLYCOOL Cooling (8 Ton)

When GLYCOOL is available, the temperature control will calculate a total cooling requirement of
200%. Assuming that full GLYCOOL capacity is available, the GLYCOOL valve opens proportionally
as the requirement for cooling rises from 0 to 100%. If the call for cooling continues to increase, the
control will energize the compressors as needed to match the average cooling requirement. As long as
GLYCOOL is available, the control will leave the valve 100% open. If GLYCOOL cooling is not avail­able, the temperature control will operate the compressors in the same manner as the Multi-Step
without GLYCOOL.

4.3 Reheat

4.3.1 Electric Reheat - Staged

For 2-stage electric reheat, they are activated when the temperature control calculates a requirement
of 50% and 100%. They are deactivated when the requirement decreases to 75% (reheat 2) and 25%
(reheat 1).

4.3.2 SCR Electric Reheat

The SCR (Silicon Controlled Rectifier) controller shall proportionally control the stainless steel
reheats to maintain the selected room temperature. The rapid cycling made possible by the SCR con­troller provides precise temperature control, and the more constant element temperature extends
heater life. During operation of the SCR control, the compressor(s) operate(s) continuously. The heat­ers are modulated to provide temperature control. If overcooling occurs, the compressor(s) will be
locked off when the temperature drops to the low temperature alarm. SCR reheats are 15 kW.

45

System Performance Microprocessor Controls

4.4 Dehumidification / Humidification Percent Required

The humidity control for the MM2 is based on a calculated percent requirement for dehumidification
or humidification. The percent requirement is calculated from the difference between the sensor read­ing and the humidity setpoint, divided by the sensitivity. The control method is selectable between
relative and absolute. Relative humidity control is the default.

4.4.1 Staged Dehumidification, Compressorized Direct Expansion (DX) Systems

For the 8-ton unit operation, 1 or 2 stage dehumidification is selected through DIP switch #7. For 2
stages, the 5-ton compressor is the lead compressor when dehumidifying. Dehumidification will be
staged on at 50 and 100% call. The electric reheats are turned on at 25% cooling (reheat 1) and 25%
heating (reheat 2) for improved temperature control. The reheats are deactivated at 0% and 50% cool­ing requirement, respectively. If overcooling occurs, the first stage of dehumidification is disabled at
125% call for heating. If 1 stage or 2 stage is selected, dehumidification is disabled at 200% call for
heating. Dehumidification is re-enabled at 66% call for 2 stage and 33% call for 1 stage. For optional
hot water heating, the valve is energized at its normal point, 100% heating requirement.

4.4.2 Humidification Operation

System Activation

The humidifier is activated when the humidity control calculates a requirement for 100% humidifica­tion, and is deactivated when the requirement falls below 50%.

4.4.3 Dehumidification Lockout

Dehumidification is locked out if overcooling occurs. Dehumidification on the 8-ton unit is disabled at
125% (first stage) and 200% (all stages) heating requirement. Dehumidification is re-enabled at 66%
and 33% heating requirement.

4.5 Load Control Features

The control system monitors the compressor and prevents it from turning on within a 3-minute period
of being off. If this on-off cycle occurs to often (e.g. 10 times within a one hour period) a Short Cycle
Alarm will occur.

4.6 Communications

The control system uses a two-wire, RS-422 channel to communicate with Liebert Site Products via a
proprietary protocol. A converter board (ECA2) is available to allow communications with a “dumb”
terminal or a computer using RS-232 channel. More details are provided in the Site Products and
ECA2 User Manual.

The communications channel provides both monitoring and control options, including:

• TEMPERATURE/HUMIDITY: Current temperature and humidity readings.

• STATUS (%), Cooling/heating and humidify/dehumidify operating status.

• PRESENT ALARMS: Alarms currently activated.

• SETPOINTS:

• Temperature Setpoint

• Temperature Sensitivity

•Humidity Setpoint

• Humidity Sensitivity

• High Temperature Alarm

• Low Temperature Alarm

• High Humidity Alarm

• Low Humidity Alarm

• ON/OFF STATUS and CONTROL

• SILENCE ALARM

46

5.0 ALARMS

The microprocessor control system will audibly and visually signal all ENABLED Alarms (including
two (2) custom alarms). These special alarms can be chosen from the optional alarm list and/or can
have their own fully custom text. The custom alarm inputs are contact closures wired from terminal
24 through a normally open contact to either 50 (alarm 1), 51 (alarm 2), or 56 (alarm 3). The alarms
can be enabled/disabled (refer to 3.0 - Microprocessor Control) and a time delay of 0-255 seconds
can be set. The alarms can also be programmed to either sound the alarm & activate the common
alarm relay OR to sound the alarm only.

When a new alarm occurs, it is displayed on the screen and the audible alarm is activated. (If commu­nicating with a Liebert Site Product, the alarm is also transmitted). The message “PRESS ALARM
SILENCE” will prompt the operator to silence the alarm. After the alarm is silenced, the display will
return to the Normal Status Display. Alarms can be reviewed by selecting the “ACTIVE ALARMS”
feature. The alarms can also be silenced through communications with a Liebert Site Products Unit.

Many alarms will reset automatically when the alarm condition is no longer present and only after it
has been acknowledged by being “Silenced.” The exceptions are:

1. Software alarms, i.e., Loss of Power and Short Cycle alarms will reset automatically 30 seconds
and 90 minutes respectively, after being silenced or acknowledged; and

2. Specific alarms monitoring overload or high pressure switches may require a manual reset
depending upon the model.

Alarms

5.1 Alarms: Definitions and Troubleshooting

The following list provides a definition and troubleshooting suggestions for each type of alarm. Refer
to 8.0 - Troubleshooting for additional details. If you need further assistance, contact your Liebert
supplier. THE CUSTOMER MUST SPECIFY ALARM(S) AT THE TIME OF ORDER. OTHER
DEVICES AND WIRING MAY BE REQUIRED AT THE FACTORY FOR SOME OF THE ALARMS.

5.1.1 Custom Alarms

Custom alarm(s) messages are programmed at the LCD display. The message displayed may be
included in a list of provided alarms or it may be customized text (for up to three alarms). IF CUS­TOMIZED TEXT IS USED, MAINTENANCE PERSONNEL SHOULD BE INFORMED OF THE
ALARM FUNCTION AND THE REQUIRED ACTION.

5.1.2 High Head Pressure

Compressor head pressure is monitored with a pressure switch. (One SPDT pressure switch is used).
If head pressure exceeds 360 psig, the switch turns off the compressor contactor and sends an input
signal to the control. The condition is acknowledged by pressing the alarm silence button on the wall
box, which will clear if the head pressure is alleviated. If the head pressure alarm has activated three
times, the alarm will lock until the unit is serviced. After the head-pressure problem is fixed, reset the
control by disconnecting power to the evaporator unit.

Air-Cooled Systems

Check for power shut off to the condenser, condenser fans not working, defective head pressure con­trol valves, dirty condenser coils or crimped lines.

Water/Glycol Systems

Check water regulating valves. Verify water/glycol flow (i.e., pumps operating and service valves
open). Is water tower or drycooler operating? Is the coolant temperature entering the condenser at or
below design conditions? Is AUX relay (terminals 70 & 71) operating during cooling to turn on the
drycooler?

47

5.1.3 Humidity

The humidity alarm may be activated under the following conditions:

• High: The room return air humidity exceeds the pre-set high humidity alarm setpoint. Is the unit
set up for dehumidification? Check DIP switch.

• Low: The room return air humidity decreases to the low humidity alarm setpoint. Is the unit
setup for humidification? Check DIP switch.

• High and Low Humidity (simultaneously): The simultaneous display of two alarms results in
loss of the humidity input signal. DASHES WILL BE DISPLAYED IN THE HUMIDITY READ­ING DISPLAY. Under these conditions, the control system deactivates both humidification and
dehumidification. Check for a disconnected cable or failed sensor.

NOTE

Check for proper setpoints. Does the room have a vapor barrier to seal it
from outdoor humidity? Are doors or windows open to outside air?

5.1.4 Temperature

The temperature level alarm may be activated under the following conditions:

• High: The room return air temperature increases to the high temperature alarm setpoint. Check
for proper setpoint value. Is the room load more than the unit can handle (i.e., capacity too small)?
Make sure cooling components are operating (compressor or valves).

• Low: The room return air temperature decreases to the low temperature alarm setpoint. Check
for proper setpoint value. Make sure all heating components are operating (e.g., contactors,
reheats, etc.). Are reheats drawing the proper current (refer to amp rating on nameplate).

• High and Low (simultaneously): The simultaneous display of these two alarms results in loss
of the temperature input signal (or the humidity is out of sensor range-15 to 85% RH). Dashes will
be displayed for the temperature reading. The control system will initiate 100% cooling. Check for
a disconnected cable or a failed sensor.

Alarms

5.1.5 Humidifier Problem Alarm

The Humidifier Problem Alarm will sound and display a message if any of the following humidifier
conditions occur: overcurrent detection; fill system fault or end of cylinder life.

Check fault indicator LED on humidifier control board:

• Constant LED on = Overcurrent

• 1 second LED Flash = Fill System Fault

• 1/2 second LED Flash = End of cylinder life, replace tank

5.1.6 High-Water Alarm

A float switch in the evaporator pan will shutdown the evaporator on a high water level. Clear the
drain and reset power to the unit in order to clear the alarm.

5.1.7 Loss of Power

The Loss of Power Alarm will activate (after power is restored to the unit) if the unit has lost power or
the disconnect switch was incorrectly turned off before the unit ON/OFF switch was pressed. A Lie­bert remote monitoring unit (optional) will immediately indicate loss of power.

5.1.8 Short Cycle

A Short Cycle Alarm will occur if a compressor system has exceeded 10 cooling start attempts in a
one-hour period. This can be caused by room cooling load is small compared to capacity of the unit. If
room load is low, increase temperature sensitivity to reduce cycle.

48

5.2 Optional/Custom Alarms

5.2.1 Change Filter

Periodically, the return air filters in the evaporator must be changed. The Change Filter alarm noti­fies the user that filter replacement is necessary. A differential air pressure switch closes when the
pressure drop across the filters becomes excessive. The switch is adjustable using the procedure on
the switch label.

5.2.2 Firestat

The optional firestat feature is a bi-metal operated sensing device with a closed switch under normal
conditions. Connected between pins 1-8 and 1-9, this device will shut down the entire unit.

5.2.3 Smoke Detector

The smoke detector is located in the unit, the optional smoke detector power supply is located in the
electric panel. It constantly samples return air through a tube. No adjustments are required.

Alarms

49

System Operation, Testing, and Maintenance

6.0 SYSTEM OPERATION, TESTING, AND MAINTENANCE

This section describes system testing, maintenance and replacement procedures. Use copies of the

Maintenance Inspection Checklist to record preventive maintenance inspections.

WARNING

!

Unit contains hazardous electrical voltage. Disconnect power supply before working within.
Line side of factory disconnect remains energized when disconnect is off.

6.1 System Testing

6.1.1 Environmental Control Functions

The performance of all control circuits can be tested by changing the setpoints, which activates each
of the main functions.

6.1.2 Cooling

To test the cooling function, set the setpoint to a temperature of 10°F (5°C) below room temperature.
A call for cooling should register and prompt the equipment to begin cooling cycle. (Disregard any
temperature alarms). Upon completion of testing, return setpoint to the desired temperature.

6.1.3 Heating

Reheat may be tested by setting the setpoint 10°F (5°C) above room temperature. A call for heating
should register and prompt the equipment to begin heating cycle. (Disregard any temperature
alarms). Upon completion of testing, return setpoint to the desired temperature.

6.1.4 Humidification

To check humidification, set the humidity setpoint at RH 10% above the room humidity reading. After
a short delay, the canister will fill with water and steam will be produced. Upon completion of testing,
return the humidity setpoint to the desired humidity.

6.1.5 Dehumidification

The dehumidification performance can be tested by setting the humidity setpoint at RH 10% below
room relative humidity. The compressor should turn on. Upon completion of testing, return humidity
setpoint to the desired humidity.

6.1.6 Remote Shutdown

A connection point is provided for remote shutdown devices supplied by the customer. This terminal
strip is located in the electric panel. (Terminals 37 and 38 are fitted with a jumper when no remote
shutdown device is installed).

50

6.2 Maintenance and Component Operation

6.2.1 Electric Panel

The electric panel should be inspected on a semi-annual basis for any loose electrical connections.

6.2.2 Filters

Filters are usually the most neglected item in an environmental control system. In order to maintain
efficient operation, they should be checked monthly and changed as required. ALWAYS TURN
POWER OFF BEFORE REPLACING FILTERS.

Filters are replaced by opening the hinged door on the return air filter box.

6.2.3 Blower System

Monthly inspection of the blower package includes: motor mounts, belts, fan bearings, and impellers.

Fan impellers should be thoroughly inspected and any debris removed. Check to see if they are tightly
mounted on the fan shaft and do not rub against the fan housing during rotation. Motor and fan bear­ings are permanently sealed and self-lubricating and do NOT need lubricated.

The drive belt should be checked monthly for signs of wear and proper tension. Pressing on belts mid­way between the sheave and pulley should produce from 1/2" to 1" (12 to 25 mm) of deflection. Belts
that are too tight can cause excessive bearing wear.

Belt tension can be adjusted by raising or lowering the fan motor base. Loosen nut above motor
mounting plate to remove belt. Turn nut below motor mounting plate to adjust belt tension. If belt
appears cracked or worn, it should be replaced with a matched belt (identically sized). With proper
care, a belt should last several years.

System Operation, Testing, and Maintenance

NOTE

After adjusting or changing the belt, always be certain that motor base nuts are tightened. The
bottom adjustment nut should be finger tight. The top locking nut should be tightened with a
wrench.

Air Distribution

Since all unit models are designed for constant volume air delivery, any unusual restrictions within
the air circuit must be avoided. High efficiency filters can reduce air performance and evaporator
capacity.

Blower Removal (Evaporator)

If the blower or bearings must be removed or serviced, use the following procedure.

1. Prepare the main center section of the three (3) piece electric panel by first marking and
disconnecting all power and control wiring entering the panel.

2. Remove the electric panel by removing screws from top and bottom sections

3. Remove the bottom electric panel mounting flange from unit base.

4. Remove the belt, motor, motor mounting plate, and tensioning bolt.

5. Remove the four (4) screws holding the blower mounting rails to the sled.

CAUTION

!

Protect refrigerant and water piping from damage.

6. Remove the (4) screws holding the blower mounting rails to the sled.

7. Slide the blower/rail assembly forward and rotate approximately 45 degrees and remove from
unit.

8. Replace failed parts.

51

6.2.4 Electric Reheat

Reheat element sheets and fins are manufactured with stainless steel. Regular inspections are neces­sary to assure proper cleanliness of the reheating element. Should inspection reveal corrosion parti­cles on the reheating element or adjoining surfaces (including ducts and plenums), appropriate
cleaning should be performed. Periodic replacement of the reheating element may be necessary to
meet specific application requirements.

6.2.5 Refrigeration System

Each month the components of the refrigeration system should be inspected for proper function and
signs of wear. Since in most cases evidence of malfunction is present prior to component failure, peri­odic inspections can be a major factor in the prevention of most system failures. Refrigerant lines
must be properly supported and not allowed to vibrate against ceilings, floors, or the unit frame.
Inspect all refrigerant lines every six months for signs of wear and proper support. Inspect the capil­lary and equalizer lines from the expansion valve.

Suction Pressure

Suction pressure will vary with load conditions. Suction pressure normally ranges from 58 psi to 75
psi (405 kPa to 517 kPa). When the 3-ton circuit is operating alone, the upper range of suction pres­sure may approach 100 psig. This is a function of the unit design and is acceptable for scroll compres­sors.

Discharge Pressure

The discharge pressure will vary greatly with load and ambient conditions (Table 16). The high-pres-
sure switch will shut the compressor down at its cut-out setting.

Table 16 Typical discharge pressures

System Design psig (kPa)

Air-Cooled 180-275 (1242-1895)

Water-Cooled
65ºF to 85ºF water
(18 to 29.4ºC)

Glycol-Cooled 210-275 (1445-1895)

Maximum 330 (2275)

High Pressure Cut-Out 360 (2480)

System Operation, Testing, and Maintenance

200-225 (1380-1550)

Thermostatic Expansion Valve

The thermostatic expansion valve keeps the evaporator supplied with enough refrigerant to satisfy
load conditions. Proper valve operation can be determined by measuring superheat level. If too little
refrigerant is being fed to the evaporator, then the superheat will be high. Conversely, if too much
refrigerant is being supplied, then the superheat will be low. The correct superheat setting is between
10 and 15°F (5.6 and 8.3°C). Only the 5-ton valve is adjustable.

Air-Cooled Condensing Units

Restricted airflow through the condenser coil will reduce the operating efficiency of the unit. Addi­tionally, it can result in high compressor head pressure and loss of cooling. Using compressed air or
commercial coil cleaner, clean the condenser coil of all debris that will inhibit airflow. In winter, do
not permit snow to accumulate around the side or underneath the condenser. At the same time check
for bent or damaged coil fins and repair as necessary. Check all refrigerant lines and capillaries for
vibration and support as necessary. Carefully inspect all refrigerant lines for signs of oil leaks.

Coaxial Condensers (Water/Glycol-Cooled Condensing Units)

Each water or glycol-cooled condensing unit has a coaxial condenser consisting of an exterior steel
tube and an interior copper tube. If the water supply is clean, coaxial condensers do not normally
require maintenance or replacement. Should your system begin to operate at high head pressure with
reduced capacity, and all other causes have been eliminated, the condenser may be obstructed or
fouled and should be replaced.

52

System Operation, Testing, and Maintenance

Regulating Valves (Water/Glycol Condensing Units)

The water regulating valve automatically regulate the amount of fluid necessary to remove the heat
from the refrigeration system, permitting more fluid to flow when load conditions are high and less
fluid to flow when load conditions are low.

The water regulating valve is designed to begin opening at 180 psi (1240 kPa) and be fully opened at
240 psi (1655 kPa). The valve is factory set and should not need adjustment.

Glycol Solution Maintenance

It is difficult to establish a specific schedule of inhibitor maintenance since the rate of inhibitor deple­tion depends upon local water conditions. Analysis of water samples at time of installation and every
six (6) months should help to establish a pattern of depletion. A visual inspection of the solution and
filter residue is often helpful in judging whether or not active corrosion is occurring. The complexity of
problems caused by water requires expert advice from a water treatment specialist plus a regular
maintenance program schedule. It is important to note that improper use of water treatment chemi­cals can cause severe problems.

Proper inhibitor maintenance must be performed in order to prevent corrosion of the glycol system.
Consult your glycol manufacturer for proper testing and maintenance procedures. Do not mix prod­ucts from different manufacturers.

Hot Gas Bypass (Optional)

Operation

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.

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, 25­40°F (14-22°C), may be observed at the compressor. The liquid quenching valve is internally equal­ized and superheat is not adjustable.

Adjustment

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 adjustment is necessary.

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

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

7. There may be a fluctuation 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.

53

System Operation, Testing, and Maintenance

Replacement Procedures

Compressor Replacement: Infrequently a fault in the motor insulation may result in a motor burn­out (if system is properly installed, motor burnout rarely occurs). Primarily this type of failure is due
to mechanical or lubrication problems, where the burnout is a secondary consequence.

Early detection can prevent a large percentage of the problems that can cause compressor failures.
Periodic maintenance inspections by alert service personnel (i.e., identification of abnormal opera­tion) can be a major factor in reducing maintenance costs. It is easier and more cost-effective to imple­ment the necessary preventative steps that ensure proper system operation; rather than ignore a
problem until it results in compressor failure and costly replacement. When troubleshooting a com­pressor problem, check all electrical components for proper operation:

CAUTION

!

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

• Check all fuses and circuit breakers.

• Check pressure switch operation.

• If a compressor failure has occurred, determine whether its cause is an electrical or mechanical
problem.

CAUTION

!

System contains refrigerant. Recover refrigerant before maintenance

Mechanical Failure: If you have determined that a mechanical failure has occurred, the compressor
must be replaced.

Electrical Failure: In the event of an electrical failure and subsequent burnout of the refrigeration com­pressor motor, proper procedures must be followed to thoroughly remove any acids that would cause a future
failure. There are two kits that can be used with a complete compressor burnout: Sporlan System Cleaner
and Alco Dri-Kleener. Follow the manufacturer's procedure. DAMAGE TO A REPLACEMENT COMPRES­SOR DUE TO IMPROPER SYSTEM CLEANING CONSTITUTES ABUSE UNDER THE TERMS OF THE
WARRANTY, THEREBY VOIDING THE WARRANTY.

Replacement compressors are available from your Liebert supplier and will be shipped to the job site
in a reusable crate (as required by the service contractor). If the compressor is under warranty, it
must be returned to Liebert in order to receive proper warranty credit. It should be returned in the
same container the replacement was shipped in. The possible cause(s) or condition(s) of the damage
should be legibly recorded on the provided return tag.

Proper procedures to remove and replace the failed compressor are:

1. Disconnect power

2. Attach suction and discharge gauges to access fittings.

3. Recover refrigerant using standard recovery procedures and equipment.

NOTE

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

4. Remove failed compressor.

5. Install replacement compressor and make all connections. Pressurize and leak test the system at
approximately 150 psig (1034kPa) pressure.

6. Follow manufacturer's instructions for clean out kits.

7. Evacuate the system twice to 1500 microns, and the third time to 500 microns. Break the vacuum
each time with clean, dry refrigerant to 2 psig (13.8 kPa).

8. Charge the system with refrigerant (R-22) based on requirements of the evaporator, condensing
unit, and lines. Refer to the installation manual or the unit nameplate.

9. Apply power and operate the system. Check for proper operation. Refer to Table 16 for discharge
pressure.

54

6.2.6 Steam Generating Humidifier - Operation Procedures

Steam generating humidifiers operate efficiently over a wide range of water quality conditions and
automatically adjust to changes in the conductivity of water. The system will automatically drain and
refill to maintain a current setpoint and alert the operator when the humidifier canister needs to be
replaced.

The humidifier RUN/DRAIN switch is located in the humidifier assembly. This switch should be in
the RUN position when the humidifier is in normal operation, and in the DRAIN position during ser­vice. The electronic control board for the humidifier is also located in the humidifier assembly. When
the unit is energized, power is available to humidifier. Operation involves the following steps:

1. During start-up, when the humidity control calls for humidification, the fill valve will open,
allowing water to enter the canister. When the water level reaches the electrodes, current flows
and the water will begin to warm. The canister fills until the amperage reaches the setpoint and
the fill valve closes. As the water warms, its conductivity increases and the current flow, in turn,
rises. If the amperage reaches 115% of the normal operating amperage, the drain valve opens and
flushes some of the water out of the canister. This reduces electrode contact with the water and
lowers the current flow to the amperage setpoint. Boiling soon commences and the canister
operates normally.

2. If the conductivity of the water is low, the canister fills and the water level reaches the canister
full electrode before the amperage setpoint is reached. The humidifier stops filling to prevent
overflow. Boiling should commence in time. As water is boiled off, the mineral concentration in
the canister increases and current flow also increases. The canister eventually reaches full output
and goes to normal operation. No drain is permitted until then.

3. When full output is reached the circuit board starts a time cycle which is factory set at 60 seconds.
During this repeating time cycle, the fill valve will open periodically to replenish the water being
boiled off and maintain a “steady state” output at the setpoint. The amperage variance will
depend on the conductivity of the water.

4. After a period of time, the mineral concentration in the canister becomes too high. When this
occurs, the water boils too quickly. As the water quickly boils off and less of the electrode is
exposed, the current flow decreases. When the current crosses the low threshold point (factory set
at 85%) before the end of the time cycle, the drain valve opens, draining the mineral laden water
out and replacing it with fresh water. This lowers the mineral concentration and returns the
canister to “steady state” operation and prolongs canister life. The frequency of drains depends on
water conductivity.

5. Over a period of time, the electrode surface will become coated with a layer of insulating material,
which causes a drop in current flow. As this happens, the water level in the canister will slowly
rise exposing new electrode surface to the water to maintain normal output. Eventually, the
steady state water level will reach the canister full electrode and indicate so by activating the
canister full alarm. At this point, all of electrode surface has been used up and the canister should
be replaced.

6. After the entire electrode surface has been coated, the output will slowly decrease. During these
last hours of electrode life, the mineral concentration can increase and arcing can occur. If the
electrodes start to arc, turn off the humidifier immediately and replace the canister with the
identical part.

System Operation, Testing, and Maintenance

55

System Operation, Testing, and Maintenance

Replacing the Humidifier Canister

The proper procedure to replace the humidifier canister is:

1. Turn off the humidifier by lowering the humidity setpoint below the ambient humidity level.
Record the original setpoint.

2. Turn unit off at wallbox.

3. Place the RUN/DRAIN switch in the DRAIN position to drain the water from the canister.

4. Return the RUN/DRAIN switch to the RUN position after the canister has drained.

5. Turn OFF the power at the main unit.

6. Remove the cover from the humidifier cabinet.

7. Locate the power wires to the steam canister. They are connected to the canister with 1/4" quick
connects. Make note of the wiring configuration before removing any wires. Refer to schematic on
unit. Slide the rubber boot back to expose the connections. Remove the three (3) power wires and
the canister full wire. Do not loosen the screws that secure the electrodes.

WARNING

!

Canister and steam hose may be hot! Allow time for the humidifier to cool before replacing
parts.

8. Loosen the steam outlet hose clamps and slide the steam hose away from the canister fitting.

9. Remove the canister.

10. Reverse Previous steps to re-assemble humidifier, paying special attention to the following:

WARNING

!

Hazardous voltage! use extreme caution. Circuit board adjustment should be performed by
qualified personnel only.

Power should be disconnected prior to the procedure.

6.2.7 Circuit Board Adjustments

The humidifier control board governs humidifier operation. There are three potentiometers mounted
on the board and can be used to adjust for extreme water conductivity conditions.

POT2 controls the amperage at which the drain will energize and is clearly marked in percentages.
This adjustment is factory set at 85%, which indicates that the unit will drain when the amperage
falls off to 85% of the capacity setpoint. Raising the value increases the frequency of drain cycles.
Lowering the value decreases the frequency of drain cycles.

The frequency should be increased for highly conductive water and decreased for less conductive
water. If adjustment is necessary, and a change of three to four percent in either direction does not
permit normal operation of the unit, consult your Liebert supplier.

The POT1 controls the duration of the drain cycle. This adjustment is factory set at 60 seconds
(1 VDC) and should not be readjusted without consulting your Liebert supplier.

The DIP switch settings are used to set the capacity of the humidifier. If the humidifier is replaced in
the field the DIP switches should be set to the required settings described below.

Table 17 Humidifier control board DIP switch settings

Voltage SW1 SW2 SW3 SW4 Amps

208 On On On Off 8.9

240 Off On On Off 8.5

380/415 Off Off Off Off 5.2

460 On On On Off 4.5

575 On On Off Off 3.4

56

Maintenance Inspection Checklist

7.0 MAINTENANCE INSPECTION CHECKLIST

JOB NAME: ______________________________ ROOM TEMP/HUM: ______________________________

SERIAL: ______________________________ DATE: ______________________________

UNIT MODEL: ______________________________ COND. MODEL: ______________________________

FILTERS

___ 1. Check/Replace Filters

___ 2. Check Filter Switch

___ 3. Wipe Section Clean

BLOWER SECTION

___ 1. Impellers Free of Debris & Spins Freely

___ 2. Check Belt Tension and Condition

___ 3. Check/Lube Bearings

___ 4. Check Pulleys and Motor Mounts

___ 5. Amp Draw ____ / ____ / ____

REHEAT

___ 1. Amp Draw ____ / ____ / ____

___ 2. Inspect elements for cleanliness

COMPRESSOR

___ 1. Amp Draw 1. ____ / ____ / ____

___ 2. Amp Draw 2. ____ / ____ / ____

___ 3. Check For Leaks/Oil Level

___ 4. Vibration

___ 5. Noise

___ 6. Cap Tubes (Not Rubbing)

CONTROLS

___ 1. Check/Test Changeover Panel

___ 2. Check/Test Water Detection

___ 3. Check/Test Condensate Pump

Operation

___ 4. Check/Verify Control Settings

AIR-COOLED CONDENSER/

HUMIDIFIER

___ 1. Check for Clogs

___ 2. Check Humidifier Lamps/tank

___ 3. Check for Mineral Deposits

___ 4. Check Water Make-Up Valve for Leaks

___ 5. Check Drain & Trap for Debris

___ 6. Check Amp Draw ____ / ____ / ____

REFRIGERATION CYCLE/SECTION

___ 1. Check Refrigerant Lines (rubbing)

___ 2. Suction Pressure 1.______ 2._______

___ 3. Discharge Pressure 1.______ 2.______

___ 4. Check Thermostatic Expansion Valve

___ 5. Check Superheat 1.______ 2.______

___ 6. Check Refrigerant Level (Site Glass)

ELECTRICAL PANEL

___ 1. Check Fuses

___ 2. Check Electrical Connections

___ 3. Check Operation Sequence

___ 4. Check Contactors for Pitting

DRYCOOLER

___ 1. Coil Clean

___ 2. Motor Mounts Tight

___ 3. Bearings in Good Condition

___ 4. Piping in Good Condition

___ 5. Ambient Settings ____ / ____ / ____

___ 6. Motor Amp Draws ____ / ____ / ____

___ 7. Check Electrical Connections

___ 8. Refrigerant/Glycol Level ______

___ 9. Cap. Tubes (Not Rubbing)

WATER/GLYCOL CONDENSER

___ 1. Copper Tube Clean

___ 2. Water Regulating Valve Functions

___ 3. Glycol Solution

___ 4. Check for Water/Glycol Leaks

GLYCOL PUMP

___ 1. Pump Rotation

___ 2. Glycol Leaks

___ 3. Pump Operation

___ 4. Amp Draw ____ / ____ / ____

___ 5. Pump Changeover (If Dual)

COMMENTS
_________________________________________________________________________

_________________________________________________________________________

57

8.0 TROUBLESHOOTING

Table 18 Troubleshooting

Symptom Possible Cause Check or Remedy

No power to unit Check voltage at input terminal block.

Unit will not start

No cooling

Compressor high
head pressure

Humidifier does
not operate

Reheat will not
operate

Control voltage fuses (at
transformer) open

Float switch relay has closed
due to high water in the
condensate pan.

Jumper not in place

“Cooling” is not displayed at
the control panel.

Short cycle prevention
control.

Compressor contactor not
pulling in.

Compressor high head
pressure.

Plugged filter/dryer. Replace filter/dryer.

Low refrigerant charge.

Insufficient air flow across
condenser coil

Water/Glycol-Cooled only:
No fluid flowing through
condenser.

Condenser fan not operating Check fan operation.

DIP switch not set to enable
humidifier option

“HUMIDIFY” not displayed
at control panel

Defective board

Failed humidity sensor

No water flow

Canister fill rate is not
keeping up with the steam
output

DIP switch not set to enable
reheat option

“HEAT” not displayed at the
control panel

Reheat safety open,
defective reheat contact or
defective board

Element is burned out Turn off power. Check element continuity with Ohm meter.

Locate and repair short. Replace fuses.

Check drain and line. Access through left panel. Power must be
cycled at the disconnect to reset. Check return air static pressure is
less than 0.3" wg.

Check terminal 37 and 38 for jumper or N/C contact. Check pins P39­1 and P39-2 for jumper, or N/C firestat contact. Check pins P40-12
and 1HWAR-Com for jumper or N/C smoke detector contact.

Adjust TEMP control setpoint and sensitivity to require cooling.

Control software delays compressor 3 minutes cooling, from stop to
start

Check for 24 VAC ± 2 VAC at terminals TB2 to TB1 for Compressor 1;
TB6 to TB5 for Compressor 2. If voltage, check contactor. If voltage,
check freeze stat (FR1 and FR2).

See below for cause.

Check pressure gauges. At low ambient temperatures, proper
refrigerant charge is very important on units with Lee-Temp receivers.

Remove debris from coil and air inlets.

Check fluid supply to regulating valve. Adjust valve if necessary.

See DIP switch settings Table 17.

Increase humidity control setpoint and sensitivity to require
humidification.

Check voltage at 35-1 and 35-5 on interface board for 24 VAC ±2
VAC. If no voltage, check wiring and/or replace board. Check wiring
from control panel to board.

Humidity display will indicate dashes. Check wiring from temperature/
humidity board to the control board and from the wall box to the
control board. Replace wallbox or temperature/humidity circuit board
(if remote).

Make sure switch is in Run position. Check humidifier water supply
(including filter screen) and check nylon overflow line if canister is full.

Check fill valve screen opening and capillary tube for obstructions.
Check water supply pressure (minimum 10 psig).

See DIP switch settings Table 17.

Increase temperature setpoint to require heating.

Check voltage at P34-4 or P34-6 to P34-10 on interface board for 24
VAC

± 2 VAC. If voltage, check reheat contactor and reheat safety. If

no voltage, check wiring and/or replace board.

Troubleshooting

58

Table 18 Troubleshooting (continued)

Symptom Possible Cause Check or Remedy

Cooling cycle too
short

Display freezes
and control pads
do not respond

Condensate
pump does not
operate

Continuous
Cooling

Continuous
Heating
Dehumidification
Humidification

Sensor response delay too
short

Static discharge

Open or short circuit in
wiring

Failed temperature sensor

Shorted wiring or failed
control board

Increase sensor response delay. See 3.12 - Calibrate Sensors.

During period of low humidity, static electricity can cause the control
program to freeze or display incorrect information. Although this is
unlikely, the control can be reset by cycling power from the disconnect
switch.

Find open or short circuit and repair power to pump.

Temperature display will indicate dashes. Check wiring from
temperature/humidity board (remote sensors) to the control board or
from control board to wallbox. Replace temperature/humidity circuit
board (remote sensors) or wallbox.

Check wiring and/or replace control board.

Troubleshooting

59

NOTES

Troubleshooting

60

Troubleshooting

61

Troubleshooting

62

Ensuring The High Availability
0f 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.
© 2007 Liebert Corporation
All rights reserved throughout the world. Specifications subject to change
without notice.
® Liebert and the Liebert logo are registered trademarks of Liebert
Corporation. All names referred to are trademarks
or registered trademarks of their respective owners.

Technical Support / Service

Web Site

www.liebert.com

Monitoring

800-222-5877

[e-mail]

Outside the US: 614-841-6755

Single-Phase UPS

800-222-5877

[e-mail]

Outside the US: 614-841-6755

Three-Phase UPS

800-543-2378

[e-mail]

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

7/F, Dah Sing Financial Centre

108 Gloucester Road, Wanchai

Hong Kong

852 2572220

Fax: [phone]

SL-10533_REV2_02-07

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

AC Power
Connectivity
DC Power

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

©2007 Emerson Electric Co.

Embedded Computing
Embedded Power Power Switching & Controls
Monitoring

Outside Plant

Precision Cooling

EmersonNetworkPower.com

Racks & Integrated Cabinets
Services
Surge Protection