Vaisala DS User Manual

Liebert®

DS™Thermal Management System

Installer/UserGuide

35to 105kW(10 to 30 ton)Capacity,Upflow and Downflow,50 and 60 Hz,Air-cooled,

Water/Glycol-cooled,GLYCOOL™ Economizer Coil,

Dual-Cool DX with Secondary Chilled-water Coil

The information contained in this document is subject to change without notice and may not be suitable for all applications. While every precaution has been taken to ensure the accuracy and completeness of this document, Vertiv assumes no responsibility and disclaims all liability for damages resulting from use of this information or for any errors or omissions. Refer to other local practices or building codes as applicable for the correct methods, tools, and materials to be used in performing procedures not specifically described in this document.

The products covered by this instruction manual are manufactured and/or sold by Vertiv. This document is the property of Vertiv and contains confidential and proprietary information owned by Vertiv. Any copying, use or disclosure of it without the written permission of Vertiv is strictly prohibited.

Names of companies and products are trademarks or registered trademarks of the respective companies. Any questions regarding usage of trademark names should be directed to the original manufacturer.

TechnicalSupport Site

If you encounter any installation or operational issues with your product, check the pertinent section of this manual to see if the issue can be resolved by following outlined procedures.

Visit https://www.Vertiv.com/en-us/support/ for additional assistance.

Vertiv | Liebert® DS™ Installer/User Guide

TABLE OF CONTENTS

1 Important Safety Instructions		1
2 Nomenclature and Components		9
2.1 Liebert DS Model Number Nomenclature		9
2.2 Component Location		11
3Pre-installation Preparation and Guidelines		13
3.1 Planning Dimensions		13
3.2	Air Distribution Considerations for Downflow Units	14
3.3	Air Distribution Considerations for Upflow Units	16
3.4	Connections and System Setup	17
3.5 Operating Conditions		18
	3.5.1 Cooling, Humidification and Dehumidification	18
	3.5.2 Heating	18
3.6	Shipping Dimensions and Unit Weights	18
4 Equipment Inspection and Handling		21
4.1 Packaging Material		21
4.2 Handling the Unit while Packaged		22
4.3 Unpacking the Unit		23
	4.3.1 Removing the Unit from the Skid witha Forklift	23
	4.3.2 Removing the Unit from the Skid Using Rigging	24
	4.3.3 Moving the Unit to the Installation Location Using Piano Jacks	26
4.4 Remove Shipping Blocks from Units with Semi-Hermetic Compressors		27
4.5 Placing the Unit ona Floor Stand		28
5Piping and Refrigerant Requirements		29
5.1 Drain and Humidifier Fluid Piping		31
	5.1.1 Field-installed, Gravity Fed Drain Line Requirements	32
	5.1.2 Condensate Pump Drain Line Requirements	34
	5.1.3 Water Supply Line Requirements for the Optional Humidifier	34
5.2	Refrigerant Piping and Charging	34
	5.2.1 Refrigerant Piping Guidelines for Air Cooled Systems	35
	5.2.2 Refrigerant Line Sizes and Equivalent Lengths	36
	5.2.3 Refrigerant Charge Requirements for Air Cooled Systems	37
	5.2.4 Additional Oil Requirements for Scroll and Digital Scroll Compressors	39
	5.2.5 Evacuation, Leak Testing, and Charging Air Cooled Systems without Liebert Lee-Temp™ Receivers	42
	5.2.6 Evacuation, Leak Testing, and Charging Air Cooled Systems with Liebert Lee-Temp™ “Flooded
	Condenser” Head Pressure Control System	46
5.3 Refrigerant Charge for Water/Glycol Cooled Systems		48
5.4	Water/Glycol Loop Piping Guidelines	49
	5.4.1 Leak Checking for Unit and Field Installed Piping	50

i

6 Electrical Connections			51
7 EC Fans and Plenums			53
7.1 Downflow Units with EC Fans			53
	7.1.1 Lowering the EC Fans into the Floor Stand on Downflow Models		53
7.2 Upflow Unit Plenums with EC Fans			56
	7.2.1 Assembly Inspection		57
	7.2.2 Assemble Plenum Rear and Side Panels		62
	7.2.3 Place Assembled Panels and EC Fans on Top of Unit		66
	7.2.4	Wire the EC Fans	70
	7.2.5	Install Front Panels on Plenum	72
8 Checklist for Completed Installation			83
8.1 Moving and Placing Equipment			83
8.2	Electrical Installation Checks		83
8.3	Piping Installation Checks		83
8.4	Other Installation Checks		83
9 Initial Start up Checks and Commissioning Procedure for Warranty Inspection			85
10Maintenance			87
10.1	Filters		88
	10.1.1 Filter Replacement for Downflow Units		88
	10.1.2	Filter Replacement for Upflow Units	89
10.2 Blower Drive System—EC Fans			91
	10.2.1 Protective Features		92
	10.2.2 Fan Impellers and Bearings Maintenance		92
	10.2.3 Fan Assembly Troubleshooting		92
	10.2.4 Removing EC Fans from Downflow Units		96
	10.2.5 Removing EC Fans from Upflow Units		100
10.3 Blower Drive System—Forward Curved Blowers			103
	10.3.1 Upflow Motor Access		104
	10.3.2	Belt Removal	104
	10.3.3	Belt Installation and Tensioning	105
	10.3.4	Blower Bearing Maintenance	106
	10.3.5	Blower Bearing Inspection	106
	10.3.6	Blower Bearing Replacement	106
	10.3.7	Blower Motor	106
	10.3.8 Blower Motor Lubrication		106
	10.3.9	Blower Wheel	106
10.4	Infrared Humidifier Maintenance		107
	10.4.1 Cleaning Humidifier Pan and Float Switch		107
	10.4.2 Changing Humidifier Lamps		108
10.5 Condensate Drain and Condensate Pump System Maintenance			109

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	10.5.1 Condensate Drain		109
	10.5.2 Condensate Pump		109
10.6	Air Cooled Condenser and Drycooler Maintenance		110
10.7	Electric Reheat Maintenance		110
10.8 Thermostatic Expansion Valve (TXV) Maintenance			110
	10.8.1 Determining Suction Superheat		110
	10.8.2	Adjusting Superheat Setting with the TXV	110
10.9	Compressor Maintenance		111
	10.9.1 Compressor Oil		111
	10.9.2	Scroll and Digital Scroll Compressor Maintenance	111
	10.9.3 Semi-Hermetic Compressor Maintenance		112
	10.9.4	Replacement Compressors	112
	10.9.5	Rotalock Valve on Scroll and Digital-Scroll Compressors	112
	10.9.6	Unloading Solenoids on a Digital Scroll Compressor	113
	10.9.7	Compressor Electrical Failure (Motor Burnout)	113
	10.9.8 Replacing a Compressor withElectrical Failure (Motor Burnout)		114
	10.9.9	Compressor Mechanical Failure	115
	10.9.10 Replacing a Compressor withMechanical Failure		115
10.10 Motorized Ball Valve (MBV) Maintenance (Digital Scroll Compressors)			115
	10.10.1 MBV Control		116
	10.10.2 MBV Control Method		116
	10.10.3 MBV Adjustment		116
	10.10.4	MBV Start-up	116
	10.10.5 MBV Location		116
	10.10.6	MBV Manual Control	116
10.11 Facility Fluid and Piping Maintenance for Water and Glycol Systems			116
10.12	Glycol Solution Maintenance		117
10.13 Paradenser™—Water Cooled Condenser Maintenance			117
	10.13.1 Cleaning the Paradenser		117
	10.13.2 Water Regulating Valves Maintenance for Semi-Hermetic and Standard Scroll Compressors		118
10.14	Drycooler Aquastat Settings		119
11 Preventive Maintenance Checklist			121
Appendices			127
Appendix A: Technical Support and Contacts			127
Appendix B: Disassembling the DS for Transport			129
Appendix C: Submittal Drawings			139

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1 IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS

This manual contains important safety instructions that should be followed during the installation and maintenance of the Liebert® DS. Read this manual thoroughly before attempting to install or operate this unit.

Only qualified personnel should move, install or service this equipment.

Adhere to all warnings, cautions, notices and installation, operating and safety instructions onthe unit and inthis manual. Follow all installation, operation and maintenance instructions and all applicable national and local building, electrical and plumbing codes.

WARNING! Arc flash and electric shock hazard. Open all local and remote electric power-supply disconnect switches, verify with a voltmeter that power is Off and wear appropriate, OSHA-approved personal protective equipment (PPE) per NFPA 70E before working within the electric control enclosure. Failure to comply can cause serious injury or death. Customer must provide earth ground to unit, per NEC, CEC and local codes, as applicable. Before proceeding with installation, read all instructions, verify that all the parts are included and check the nameplate to be sure the voltage matches available utility power. The Liebert® controller does not isolate power from the unit, even in the “Unit Off” mode. Some internal components require and receive power even during the “Unit Off” mode of the controller. The factory-supplied, optional disconnect switch is inside the unit. The line side of this switch contains live high-voltage. The only way to ensure that there is NO voltage inside the unit is to install and open a remote disconnect switch. Refer to unit electrical schematic. Follow all local codes.

WARNING! Risk of electric shock. Can cause equipment damage, injury or death. Open all local and remote electric power supply disconnect switches and verify with a voltmeter that power is off before working within any electric connection enclosures. Service and maintenance work must be performed only by properly trained and qualified personnel and in accordance with applicable regulations and manufacturers’ specifications. Opening or removing the covers to any equipment may expose personnel to lethal voltages within the unit even when it is apparently not operating and the input wiring is disconnected from the electrical source.

WARNING! Risk of electric shock. Can cause serious injury or death. The Liebert® iCOM microprocessor does not isolate power from the unit, even in the "Unit Off" mode. Some internal components require and receive power even during the "unit off" mode of the Liebert® iCOM control. Open all local and remote electric power disconnect switches and verify with a voltmeter that power is Off before working on any component of the system.

WARNING! Risk of electric shock. Can cause serious injury or death. Open all local and remote electric power supply disconnect switches and verify with a voltmeter that power is off before working within the fan-motor electric-connection enclosures. Fan-motor controls can maintain an electric charge for 10 minutes after power is disconnected. Wait 10 minutes after power is verified as off before working within the electric control/connection enclosures. Use only fully-trained and qualified HVAC technicians to perform maintenance on the fans.

1 Important Safety Instructions	1

WARNING! Risk of electric shock. Can cause injury or death. Open all local and remote electric power-supply disconnect switches and verify that power is Off with a voltmeter before working within the condensate pump electrical connection enclosure. The Liebert® iCOM™ does not isolate power from the unit, even in the “Unit Off” mode. Some internal components require and receive power even during the “Unit Off” mode of the Liebert® iCOM.

WARNING! Riskof electric shock. Can cause serious injuryor death. The Liebert®iCOM microprocessor does notisolate power from the unit, even in the "UnitOff" mode. Some internal components require and receive power even during the "unitoff" mode of the Liebert®iCOM control. Open all local and remote electric power disconnectswitches and verifywith a voltmeter thatpower is Off before working on anycomponentof the system.

WARNING! Riskof over-pressurization of the refrigeration system. Can cause explosive discharge of highpressure refrigerant, loss of refrigerant, environmental pollution, equipmentdamage, injury, or death. This unitcontains fluids and gases under high pressure. Use extreme caution when charging the refrigerant system. Donotpressurize the system higher than the design pressure marked on the unit's nameplate. For systems requiring EU CE compliance (50 Hz), the system installer mustprovide and install a pressure relief valve in the high side refrigerantcircuitthatis rated same as the refrigeranthigh side “Max Allowable Pressure” rating thatis marked on the unitserial tag. Donotinstall a shutoff valve between the compressor and the field installed relief valve. The pressure relief valve mustbe CE-certified tothe EU Pressure EquipmentDirective byan EU “Notified Body.”

WARNING! Riskof veryheavy125-lb (56.7-kg) fan modules dropping downward suddenly. Can cause injuryor death.

Supportfan modules before removing mounting hardware. Use caution tokeep bodyparts outof the fan modules pathwayduring repositioning. Onlyproperlytrained and qualified personnel should workon this equipment.

WARNING! Riskof improper moving. Can cause equipmentdamage, injuryor death. Use onlylifting equipmentthatis rated for the unitweightbyan OSHA-certified rating organization. The center of gravity varies depending on the unitsize and selected options. The slings mustbe equallyspaced on either side of the center of gravityindicator. Shipping weights and unitweights are listed in the tables in Table 2.3 on page 18. Use the center of gravityindicators on the unittodetermine the position of the slings.

WARNING! Riskof improper piping installation, leakchecking, fluid chemistryand fluid maintenance can cause equipmentdamage and personal injury. Installation and service of this equipmentshould be done only byqualified personnel whohave been specially-trained in the installation of air-conditioning equipmentand whoare wearing appropriate, OSHA-approved PPE.

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WARNING! Risk of contact with high-speed rotating fan blades. Can cause serious injury or death. Open all local and remote electric power-supply disconnect switches, verify with a voltmeter that power is off, and verify that all fan blades have stopped rotating before working in the unit cabinet or on the fan assembly. If control voltage is applied, the fan motor can restart without warning after a power failure. Do not operate the unit with any or all cabinet panels removed. Do not operate upflow units without installing a plenum, duct work or guard over the blower opening(s) on the top surface of the unit cabinet. Ductwork must be connected to the blower(s), or a plenum must be installed on the blower deck for protection from rotating blower wheel(s) on upflow units.

WARNING! Risk of top-heavy unit falling over. Improper handling can cause equipment damage, injury or death. Read all of the following instructions and verify that all lifting and moving equipment is rated for the weight of the unit before attempting to move, lift, remove packaging from or prepare the unit for installation. Unit weights are specified in Table 2.3 on page 18

WARNING! Riskof improper wiring, piping, moving, lifting and handling. Can cause equipmentdamage, serious injuryor death. Installation and service of this equipmentshould be done onlybyqualified personnel whohave been specially-trained in the installation of air-conditioning equipmentand whoare wearing appropriate, OSHA-approved PPE.

WARNING! Riskof improper wire sizing/rating and loose electrical connections. Can cause overheated wire and electrical connection terminals resulting in smoke, fire, equipmentand building damage, injuryor death. Use correctlysized copper wire onlyand verifythatall electrical connections are tightbefore turning power On. Checkall electrical connections periodicallyand tighten as necessary.

WARNING! Riskimproper drive-beltremoval. Can cause the spring-loaded motor base toslam down suddenly causing serious injurytohands and fingers from crushing and pinching. Read the directions in this manual and on the unitinstruction labels, keep hands and fingers awayfrom pinch points, and wear appropriate, OSHA-approved PPE when performing maintenance on the belts, motors or pulleys. Follow all directions when servicing the unit.

WARNING! Riskof explosive discharge of high-pressure refrigerant. Can cause serious injury. Neutral and service ports on the rotalockvalve donothave a valve core. Front-seatthe service valves and relieve pressure from the compressor before loosening a partor a componentattached tothe service valve. Follow local codes toproperlyreclaim refrigerant.

CAUTION: Riskof excessive refrigerantline pressure. Can cause tubing and componentrupture resulting in equipmentdamage and personal injury. Donotclose off the refrigerant-line isolation valve for repairs unless a pressure-relief valve is fieldinstalled in the line between the isolation valve and the checkvalve. The pressure-relief valve mustbe rated 5% to10% higher than the system-design pressure. An increase in ambienttemperature can cause the pressure of the isolated refrigeranttorise and exceed the system-design pressure rating (marked on the unitnameplate).

1 Important Safety Instructions	3

CAUTION: Risk of improper moving, lifting and handling. Can cause equipment damage or injury. Only properly trained and qualified personnel should work on this equipment. Evaporator fan modules weigh in excess of 125-lb (56.7-kg). Use proper lifting techniques and wear appropriate, OSHA-approved PPE to avoid injury and dropping the fan module during removal. Equipment used in handling/lifting, and/or installing the fan assembly must meet OSHA requirements. Use handling/lifting equipment rated for the weight of the fan assembly. Use ladders rated for the weight of the fan assembly and technicians if used during installation. Refer to handling/lifting, and/or installation equipment operating manual for manufacturer's safety requirements and operating procedures.

CAUTION: Risk of improper moving, lifting and handling. Can cause equipment damage or injury. Only properly trained and qualified personnel should work on this equipment. Condenser fan modules weigh in excess of 125-lb (56.7-kg). Use proper lifting techniques and wear appropriate, OSHA-approved PPE to avoid injury and dropping the fan module during removal. Equipment used in handling/lifting, and/or installing the fan assembly must meet OSHA requirements. Use handling/lifting equipment rated for the weight of the fan assembly. Use ladders rated for the weight of the fan assembly and technicians if used during installation. Refer to handling/lifting, and/or installation equipment operating manual for manufacturer's safety requirements and operating procedures.

CAUTION: Risk of contact with sharp edges, splinters, and exposed fasteners. Can cause injury. Only properly trained and qualified personnel wearing appropriate, OSHA-approved PPE should attempt to move, lift, remove packaging from or prepare the unit for installation.

CAUTION: Risk of contact with hot surfaces. Can cause injury. The electronics housing, humidifier components, compressor, refrigerant discharge lines, fan motor, and some electrical components are extremely hot during unit operation. Allow sufficient time for them to cool to a touch-safe temperature before working within the unit cabinet. Use extreme caution and wear appropriate, OSHA-approved PPE when working on or near hot components.

CAUTION: Risk of contact with extremely hot water and part surfaces. Can cause burn injury. The infrared humidifier bulbs, metal enclosure, humidifier water, water reservoir pan and drain tubing are very hot during and shortly after operation. Allow sufficient time for these parts to cool to a touch-safe temperature before handling. Use extreme caution, and wear appropriate, OSHA-approved PPE when performing maintenance on the infrared humidifier.

CAUTION: Risk of handling heavy and lengthy parts. Can cause personal injury and equipment damage. Cabinet panels can exceed 5 ft. (1.5 m) in length and weigh more than 35 lb. (15.9 kg). Follow relevant OSHA lifting recommendations and consider using a two-person lift for safe and comfortable removal and installation of cabinet panels. Only properly trained and qualified personnel wearing appropriate, OSHAapproved PPE should attempt to remove or install cabinet panels.

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CAUTION: Risk of handling heavy unit and component parts. Can cause injury and equipment damage. Use OSHA-recommended safe lifting techniques and/or lifting equipment rated for the weight of the unit.

CAUTION: Risk of smoke generation. Can cause fire suppression and alarm system activation, resulting in injury during building evacuation and mobilization of emergency fire and rescue services. Start-up operation of optional electric reheat elements can create smoke or fumes that can activate the facility alarm and fire suppression system. Prepare and take appropriate steps to manage this possibility. Activating reheat during initial start-up may burn off particulates from electric reheat elements. Before beginning initial start-up checks, make certain that unit was installed according to the instructions in this manual. All exterior panels must be in place.

CAUTION: Risk of exposure to harmful noise levels. Can cause hearing injury or loss. Depending on the installation and operating conditions, a sound pressure level greater than 70 dB(A) mayarise. Take appropriate technical safetymeasures. Operating personnel mustwear appropriate, OSHA-approved PPE and observe all appropriate hearing-protection safetyrequirements.

NOTICE

Risk of improper power-supply connection. Can cause equipment damage and loss of warranty coverage.

Prior to connecting any equipment to a main or alternate power source (for example: back-up generator systems) for start-up, commissioning, testing, or normal operation, ensure that these sources are correctly adjusted to the nameplate voltage and frequency of all equipment to be connected. In general, power-source voltages should be stabilized and regulated to within ±10% of the load nameplate nominal voltage. Also, ensure that no three-phase sources are single-phased at any time.

NOTICE

Risk of oil contamination with water. Can cause equipment damage.

Liebert® DS systems require the use ofPOE (polyolester) oil. POE oil absorbs water at a much faster rate when exposed to air thanpreviously used oils. Because water is the enemy ofa reliable refrigeration system, extreme care must be used when opening systems during installation or service. Ifwater is absorbed into the POE oil, it will not be easily removed and will not be removed through the normal evacuation process. Ifthe oil is too wet, it may require anoil change. POE oils also have a property that makes them act as a solvent ina refrigeration system. Maintaining system cleanliness is extremely important because the oil will tend to bring any foreign matter back to the compressor.

NOTICE

Risk ofimproper refrigerant charging. Cancause equipment damage.

Refrigerant charge must be weighed into air-cooled compressorized systems before they are started. Starting scroll and digital scroll compressors without proper refrigerant charging cancause the compressors to operate at less than5°F (–15°C) evaporator temperature and at less than20 psig (138 kPa). Operation for extended periods at less than20 psig (138 kPa) cancause premature compressor failure.

1 Important Safety Instructions	5

NOTICE

Risk of clogged or leaking drain lines and leaking water-supply lines. Can cause equipment and building damage.

This unit requires a water drain connection. Drain lines must be inspected at start-up and periodically, and maintenance must be performed to ensure that drain water runs freely through the drain system and that lines are clear and free of obstructions and in good condition with no visible sign of damage or leaks. This unit may also require an external water supply to operate.

Improper installation, application and service practices can result in water leakage from the unit. Water leakage can result in catastrophic and expensive building and equipment damage and loss of critical data center equipment.

Do not locate unit directly above any equipment that could sustain water damage.

We recommend installing a monitored fluid-detection system to immediately discover and report coolant-fluid system and condensate drain-line leaks.

NOTICE

Risk of piping-system corrosion and freezing fluids. Can cause leaks resulting in equipment and expensive building damage. Cooling coils, heat exchangers and piping systems are at high risk of freezing and premature corrosion. Fluids in these systems must contain an inhibitor to prevent premature corrosion.

The system coolant fluid must be analyzed by a competent fluid-treatment specialist before start up to establish the inhibitor level and evaluated at regularly scheduled intervals throughout the life of the system to determine the pattern of inhibitor depletion. The fluid complexity and variations of required treatment programs make it extremely important to obtain the advice of a competent and experienced fluid-treatment specialist and follow a regularly scheduled coolant-fluid system-maintenance program.

Fluid chemistry varies greatly as do the required additives, called inhibitors, that reduce the corrosive effect of the fluids on the piping systems and components.

The chemistry of the coolant fluid used must be considered, because some sources may contain corrosive elements that reduce the effectiveness of the inhibited formulation. Sediment deposits prevent the formation of a protective oxide layer on the inside of the coolant system components and piping. The coolant fluid must be treated and circulating through the system continuously to prevent the buildup of deposits and/or growth of bacteria. Proper inhibitor maintenance must be performed to prevent corrosion of the system.

Consult fluid manufacturer for testing and maintenance of inhibitors.

Commercial-grade coolant fluid is generally less corrosive to the common metals of construction than water itself. It will, however, assume the corrosivity of the coolant fluid from which it is prepared and may become increasingly corrosive with use if not properly inhibited.

Vertiv recommends installing a monitored fluid-detection system that is wired to activate the automaticclosure of field-installed coolant-fluid supply and return shut-off valves to reduce the amount of coolant-fluid leakage and consequential equipment and building damage. The shut-off valves must be sized to close-off against the maximum coolant-fluid system pressure in case of a catastrophic fluid leak.

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NOTICE

Risk of frozen pipes and corrosion from improper coolant mixture. Can cause water leaks resulting in equipment and building damage.

When the cooling unit or piping may be exposed to freezing temperatures, charge the system with the proper percentage of glycol and water for the coldest design ambient temperature. Automotive antifreeze is unacceptable and must NOT be used in any glycol fluid system. Use only HVAC glycol solution that meets the requirements of recommended industry practices. Do not use galvanized pipe.

NOTICE

Risk of a catastrophic water circuit rupture. Can cause expensive building and equipment damage.

Install an overflow drain pan under the unit with a monitored leak detection system in the pan and shutoff valves in the supply and return water lines that automatically close if water is detected by the leak detection system. The shutoff valves should be spring return and must be rated for a close-off pressure that is the same as or higher than the supply water pressure. If it is not possible to install an overflow drain pan, then a monitored leak detection system should be installed in the base of the unit or under the unit to actuate the shutoff valves immediately on a leak detection signal.

The overflow drain pan should have a drain line connected to it that flows to a floor drain or maintenance sink in case of a shutoff valve or leak detection system malfunction.

NOTICE

Risk of no-flow condition. Can cause equipment damage. Do not leave the water/coolant fluid-supply circuit in a no-flow condition. Idle fluid allows the collection of sediment that prevents the formation of a protective oxide layer on the inside of tubes. Keep unit switched On and water/coolant fluid-supply circuit system operating continuously.

NOTICE

Risk of improper water supply. Can reduce humidifier efficiency or obstruct humidifier plumbing.

Do not use a hot water source. It will cause deposits that will eventually block the fill-valve opening.

NOTICE

Risk of water backing up in the drain line. Leaking and overflowing water can cause equipment and building damage.

Do not install an external trap in the drain line. This line already has a factory-installed trap inside the cabinet. Installation of a second trap will prevent drain-water flow and will cause the water to overflow the drain pan.

Sagging condensate drain lines may inadvertently create an external trap.

NOTICE

Risk of doorway/hallway interference. Can cause unit and/or structure damage. The unit may be too large to fit through a doorway or hallway while on the skid. Measure the unit and passageway dimensions, and refer to the installation plans prior to moving the unit to verify clearances.

1 Important Safety Instructions	7

NOTICE

Risk of damage from forklift. Can cause unit damage. Keep tines of the forklift level and at a height suitable to fit below the skid and/or unit to prevent exterior and/or underside damage.

NOTICE

Risk of improper storage. Can cause unit damage.

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

NOTE: The Liebert® indoor cooling unit has a factory-installed, high-pressure safety switch in the high-side refrigerant circuit. Each refrigerant receiver contains a fusible plug for fire-safety purposes. Consult your local building code to determine whether the refrigerant piping will require additional, field-provided pressure-relief devices.

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2 NOMENCLATURE AND COMPONENTS

This section describes the model number for Liebert® DS units and components.

2.1

Liebert DS Model Number Nomenclature

Table 1.2 below describes each digit of the model number.

Table 1.1 DS Model Number Example

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

D

S

0

3

5

A

D

A

1

E

I

*

*

*

*

Table 1.2 DS Model Number Digit Definitions

Digit

Description

Digits1 and2 = AirflowDistribution

DS= Downflowstandard

VS= Upflowstandard

Digit3, 4, 5 = Nominal CoolingCapacity, kW

035 = 35 kW, 10 ton

042 = 42 kW, 12 ton

053 = 53 kW, 15 ton

070 = 70 kW, 20 ton

077 = 77 kW, 22 ton

105 = 105 kW, 30 ton

Digit6= CoolingType

A= Air-cooled

D= Dual-cool, air-cooled

H = Dual-cool, water-cooled

K = GLYCOOL™ (Liebert®EconomizerCoil)

W = Water/Glycol-cooled

Digit7 = CompressorType

D= Digital scroll, R-407C

S= Scroll, R-407C

U= Semi-hermetic with 4-step, R-407C

V = Semi-hermetic with 4-step, R-407C

(DS105 water/glycol/GLYCOOL-only)

2 Nomenclature and Components	9

Table 1.2 DS Model Number Digit Definitions (continued)

Digit

Description

Digit8 = Voltage

A= 460 V -3 ph -60 Hz B = 575 V-3 ph -60 Hz C= 208 V -3 ph -60 Hz D= 230 V -3 ph -60 Hz 2 = 380 V -3 ph -60 Hz

Digit9= FanType

0 = Forward-curvedblowers

1 = Electronically-commutated(EC)fans

Digit10 = ReheatType

0 = None

E= 3-stage electric

Digit11 = Humidifier

0 = Nohumidifier

I= InfraredHumidifier

Digit12-15 = Factory ConfigurationNumber

Not all combinations of options are available on all units:

•Digital Scroll Compressors

•Not available on VS042A with forward-curved blower

•Not available on 077 and 105 models

•575-V available only on 035, 053 and 070 models

•Scroll Compressors

•Available onair cooled models 035 – 105

•Available onwater/glycol models 035 – 070

•Scroll compressors not available on77and 105-kW models for water/glycol/GLYCOOL/Dual Cool units

•GLYCOOL Liebert® Econ-O-Coil™ Models

•Available withdigital-scroll compressors on035 to 070 models, and withsemi-hermetic compressors on 077 to 105 models

•High Pressure Water Regulating Valve

•Not available on042, 053, 070 and 077 models withsemi-hermetic and scroll compressors

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2.2 Component Location

The unit component locations are described in the submittal documents included in the Submittal Drawings onpage 139 The following table lists the relevant documents by number and title.

Table 1.3 Component-location Drawings

Document Number	Title
DPN003706	ComponentLocation, DownflowModels
DPN003707	ComponentLocation, UpflowModels

2 Nomenclature and Components	11

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3PRE-INSTALLATION PREPARATION AND GUIDELINES

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

Refer to DS Model Number Digit Definitions onpage 9, and submittal drawings to determine the type ofsystem being installed and anticipate building alterations, piping and duct work needed.

The unit dimensions, pipe-connection locations, and piping schematics are described inthe submittal documents included inthe Submittal Drawings onpage 139.

•Verify that the floor is level, solid and sufficient to support the unit. See Liebert DS Downflow Unit weights and Shipping Weights—Approximate onpage 18 for unit weights.

•Confirm that the room is properly insulated and has a sealed vapor barrier.

•For proper humidity control, keep outside or fresh air to anabsolute minimum (less than5% oftotal air circulated inthe room).

•Do not install a Liebert® DS inanalcove or at the end ofa long, narrow room.

•Install the units as close as possible to the largest heat load.

•Allow at least the minimum recommended clearances for maintenance and service. See the appropriate submittal drawings for dimensions.

•We recommend installing anunder-floor water detection system. Contact your Vertiv representative for information.

3.1Planning Dimensions

The unit, floor stand, and plenum dimensions are described inthe submittal documents included inthe Submittal Drawings onpage 139.

The following table lists the relevant documents by number and title.

Table 2.1 Dimension Planning Drawings

	Document Number	Title
	DownflowUnits
	DPN003643	CabinetDimensional Data, 35 to 105 kW (10 to 30 Tons)All BlowerTypes
	UpflowUnits
	DPN003681	CabinetDimensional Data Upflow35-105kW (10-30 Tons)Modelswith EC Fans
	DPN003646	CabinetDimensional Data Upflow35 to 105 kW (10-30 Tons)with ForwardCurvedBlower
	FloorStands
	DPN003240	FloorStandDimensional Data 35kW -42kW (10-12 Tons)with EC Fans
	DPN003173	FloorStandDimensional Dta 53kW -77 kW (15-22 Tons)with EC Fans
	DPN003174	FloorStandDimensional Data 105 kW (30 Tons)Modelswith EC Fans
	DPN003134	FloorStandandFloorPlanningDimensional Data Upflow35-42 kW (10-12 Tons)Modelswith Forward
		CurvedBlowers

3Pre-installation Preparation and Guidelines	13

Table 2.1 Dimension Planning Drawings (continued)

	Document Number	Title
	DPN003141	FloorStandandFloorPlanningDimensional Data Upflow53-77 kW (15-22 Tons)Modelswith Forward
		CurvedBlowers
	DPN003149	FloorStandandFloorPlanningDimensional Data Upflow105kW (30 Tons)Modelswith ForwardCurved
		Blowers
	BlowerOutlet, Deck andFilterBox
	DPN001120	BlowerOutletandDeck Dimensional Data Upflow35-42 kW (10-12 Tons)with ForwardCurvedBlowers
	DPN001191	BlowerOutletandDeck Dimensional Data Upflow53-77kW (15-22)Tonswith ForwardCurvedBlowers
	DPN001192	BlowerOutletandDeck Dimensional Data Upflow105kW (30 Tons)with ForwardCurvedBlowers
	DPN001196	RearReturn FilterBox Dimensional Data Upflow35-105kW (10-30 Tons)All CompressorModelswith
		ForwardCurvedBlowers
	DPN003974	RearReturn FilterBox Dimensional Data Upflow35-105kW (10-30 Tons)with EC FansAll Compressor
		Models
	Plenums
	DPN003164	UpflowPlenum Dimensional Data 35kW-105kW (10-30 Tons)Modelswith FowardCurvedBlowers
	DPN003458	Plenum Dimensional Data Upflow35-42kW (10-12 Tons)Modelswith EC Fans
	DPN003453	Plenum Dimensional Data Upflow53-77kW (15-22 Tons)with EC Fans
	DPN003459	Plenum Dimensional Data Upflow105kW (30 Tons)Modelswith EC Fans

3.2Air Distribution Considerations for Downflow Units

•Verify that the raised floor has been properly sized for the unit’s airflow and the room is free of airflow restrictions.

•Perforated floor tiles in the raised floor should ensure minimal pressure loss.

•The raised floor must provide 7-1/2 in. (191 mm) ofclearance.

•A minimum of24 in. (610 mm) is required to operate the fans when they are lowered withthe factory-provided jacking mechanism.

•Ensure that there is adequate clearance above the unit for service, suchas replacing filters.

•Optional plenums are available for downflow unit ducting.

14	Vertiv | Liebert® DS™ Installer/User Guide

Figure 2.1 Downflow Unit Ducting and Plenum Ducting

Item Description

1Field-fabricatedductwork.

Fieldservice accessforfilterreplacement.

2Minimum height= 12 in. (305 mm) Minimum distance from unit= 2 in. (51 mm)

3OptionalLiebert®plenum withservice-accessdoorforfilterreplacement.

4Direct-to-unitducting

5Plenum ducting

3Pre-installation Preparation and Guidelines	15

3.3 Air Distribution Considerations for Upflow Units

Various configurations are available:

•Front return

•Rear return

•Top-front supply (forward-curved blowers)

•Top-rear supply (forward-curved blowers)

•Top, rear, and front supply with plenum (EC fans)

For in-room applications with supply and return grilles, several feet of clearance must be maintained at the intake and discharge of the unit.

Upflow rear-return configurations use a filter box attached to the back ofthe unit. Allow 25 in. (635 mm) onone side ofthe unit for access to the rear-return filter box. Refer to the rear-return installation sheet, inside the rear-return filter box package.

Figure 2.2 Upflow Ducting Configurations (Forward Curved Blowers)

Item Description

1Typical ducting

2Straightsectionsmustbe 1.5 to 2.5 timesthe longestblowerdimension.

3Frontof unit

NOTE: Drain traps are qualified toa return ductstatic of negative 1.5i.w.g. (-1.5 i.w.g).

16	Vertiv | Liebert® DS™ Installer/User Guide

Figure 2.3 Upflow Ducting Configurations for EC Fans

Item Description

1Typical ducting. May run to eitherside.

2Straightsectionmustbe 2.5 timesthe depth of blower.

3Ductingonly attachedtoflangeson providedplenum.

NOTE: Follow standard practices in all duct work.

3.4Connections and System Setup

•Three-phase electrical service is required for all models. Electrical service must conform to national and local electrical codes. See equipment nameplate for details.

•The unit requires a drain, which must comply with all applicable codes. See Field-installed, Gravity Fed Drain Line Requirements onpage 32, for details.

•Planthe routing ofwiring, piping and duct work to the unit. Refer to the appropriate piping connection location drawings, piping schematics, and electrical-connection drawings for your system in Submittal Drawings on page 139.

•Water/glycol and GLYCOOL units utilizing a drycooler may require anoptional aquastat setting. See Table 9.7

onpage 119, and Table 9.8 onpage 119, through Table 9.10 onpage 120, for drycooler aquastat setting guidelines. Applications withthe optional stat setting require field piping to be insulated to prevent condensation.

•Ifseismic requirements apply, consult your Vertiv representative for information about a seismic-rated floor stand.

NOTE: Seal openings around piping and electrical connection to prevent air leakage. Failure to do so could reduce the unit’s cooling performance.

3Pre-installation Preparation and Guidelines	17

3.5 Operating Conditions

The Liebert® DS must be operated in a conditioned space within the operating envelope that ASHRAE recommends for data centers. Operating the DS outside of this envelope can decrease equipment reliability. Refer to ASHRAE’s publication, “Thermal Guidelines for Data Processing Environments.”

3.5.1 Cooling, Humidificationand Dehumidification

Return air to the unit must be no cooler than the ASHRAE recommendation of 68°F (20°C) DB and 40% RH or minimum WB of 54°F (12.2°C) for proper unit operation. Operating below this can decrease equipment reliability.

3.5.2 Heating

The Liebert® DS is qualified for heating-only operation at temperatures not exceeding 80°F (27°C).

3.6 Shipping Dimensions and Unit Weights

Table 2.2 Liebert DS Shipping Dimensions—Domestic and Export

			035/042	053/070/077	105
	Cooling Type	Compressor Type
			LxWxH, in. (mm)	LxWxH, in. (mm)	LxWxH, in. (mm)
	Air, Dual-Cool Air	Scroll orDigital-	90x42x82	102x42x82	136x42x82
		scroll	(2286x1067x2083)	(2591x1067x2083	(3454x1067x2083)
	Air, Dual-Cool Air	Semi-hermetic	—	114x42x82	136x42x82
				(2896x1067x2083)	(3454x1067x2083)
	Water/Glycol, GLYCOOL/Dual-Cool	Scroll orDigital-	90x42x82	114x42x82
					—
	Water	scroll	(2286x1067x2083)	(2896x1067x2083)
	Water/Glycol, GLYCOOL/Dual-Cool	Semi-hermetic	—	114x42x82	136x42x82
	Water			(2896x1067x2083)	(3454x1067x2083)

Table 2.3 Liebert DS Downflow Unit weights and Shipping Weights—Approximate

			Downflow	Downflow Shipping Weights, lb (kg)
Model Number	Compressor Type	Cooling Type	EC Fan Unit Weight, lb (kg)	Domestic, lb (kg)	Export, lb (kg)
		Air-cooled	1470 (668)	1608 (730)	1778 (807)
		Dual Cool Air	1620 (736)	1758 (798)	1928 (875)
DS035-042	Scroll orDigital-scroll
		Water/Glycol	1780 (809)	1918 (870)	2088 (948)
		GLYCOOL/Dual Cool Water	1930 (877)	2068 (939)	2238	(1016)
		Air-cooled	1920 (871)	2070 (939)	2260	(1026)
		Dual Cool Air	2100 (953)	2250 (1021)	2440	(1107)
DS053	Scroll orDigital-scroll
		Water/Glycol	2220 (1010)	2382 (1081)	2582	(1172)
		GLYCOOL/Dual Cool Water	2400 (1091)	2562 (1163)	2762	(1253)

18	Vertiv | Liebert® DS™ Installer/User Guide

Table 2.3 Liebert DS Downflow Unit weights and Shipping Weights—Approximate (continued)

			Downflow		Downflow Shipping Weights, lb (kg)
Model Number	Compressor Type	Cooling Type	EC Fan Unit Weight, lb (kg)		Domestic, lb (kg)		Export, lb (kg)
		Air-cooled	1970 (894)		2120 (962)		2310	(1048)
		Dual Cool Air	2150 (975)		2300 (1044)		2490 (1130)
DS070	Scroll orDigital-scroll
		Water/Glycol	2270	(1032)	2432	(1104)	2632 (1194)
		GLYCOOL/Dual Cool Water	2450 (1114)		2612	(1185)	2812	(1276)
		Air-cooled	2020 (916)		2170(985)		2360 (1071)
	StandardScroll*	DualCoolAir	2200 (998)		2350 (1066)		2540 (1153)
		*Digital-scrollnotavailable.
DS077		Air-cooled	2450 (1114)		2612	(1185)	2812	(1276)
		DualCoolAir	2630 (1196)		2792	(1267)	2992 (1358)
	Semi-hermetic
		Water/Glycol	2750	(1250)	2912	(1321)	3112	(1412)
		GLYCOOL/DualCoolWater	2930 (1332)		3092	(1403)	3292 (1494)
		Air-cooled	2660	(1207)	3103 (1408)		3323	(1508)
	StandardScroll*	DualCoolAir	3015	(1368)	3463 (1571)		3683 (1671)
		*Digital-scrollnotavailable.
DS105
		Air-cooled	2780 (1261)		3223	(1462)	3443 (1562)
		DualCoolAir	3135 (1422)		3583	(1626)	3803 (1726)
	Semi-hermetic
		Water/Glycol	3150	(1429)	3593 (1630)		3813 (1730)
		GLYCOOL/DualCoolWater	3505	(1590)	3953	(1794)	4173	(1893)

Table 2.4 Liebert DS Upflow Unit Weights and Shipping Weights—Approximate

				Upflow		Upflow Shipping Weights, lb (kg)
						w/Forward-curved Blowers
	Model Number	Compressor Type	Cooling Type	EC Fan Unit Weight, lb (kg)	Forward-Curved	Domestic, lb (kg)	Export, lb (kg)
					Unit Weight, lb (kg)
			Air-cooled	1370 (621)	1520 (689)	1658(753)	1828(830)
			DualCoolAir	1520 (689)	1670 (758)	1808(821)	1978(898)
	VS035-042	ScrollorDigital-scroll
			Water/Glycol	1680 (762)	1830 (830)	1968(893)	2138(970)
			GLYCOOL/DualCoolWater	1830 (830)	1980 (898)	2118(961)	2288(1038)
			Air-cooled	1900 (862)	2070 (939)	2220 (1007)	2410 (1094)
			DualCoolAir	2080 (943)	2250 (1021)	2400 (1089)	2590 (1175)
	VS053	ScrollorDigital-scroll
			Water/Glycol	2200 (998)	2370 (1075)	2532 (1149)	2732 (1240)
			GLYCOOL/DualCoolWater	2380 (1080)	2550 (1157)	2712 (1231)	2912 (1321)

3Pre-installation Preparation and Guidelines	19

Table 2.4 Liebert DS Upflow Unit Weights and Shipping Weights—Approximate (continued)

				Upflow		Upflow Shipping Weights, lb (kg)
						w/Forward-curved Blowers
	Model Number	Compressor Type	Cooling Type	EC Fan Unit Weight, lb (kg)	Forward-Curved	Domestic, lb (kg)		Export, lb (kg)
					Unit Weight, lb (kg)
			Air-cooled	1900 (862)	2070 (939)	2220	(1007)	2410(1094)
			Dual Cool Air	2080 (943)	2250 (1021)	2400 (1089)		2590 (1175)
	VS070	Scroll orDigital-scroll
			Water/Glycol	2200 (998)	2370 (1075)	2532 (1149)		2732 (1240)
			GLYCOOL/Dual Cool Water	2380 (1080)	2550 (1157)	2712 (1231)		2912 (1321)
			Air-cooled	1900 (862)	2070 (939)	2220	(1007)	2410 (1094)
		StandardScroll*	*Digital-scrollnotavailable.
			Air-cooled	2330 (1057)	2500 (1134)	2662	(1208)	2862 (1299)
	VS077
			DualCoolAir	2510 (1139)	2680 (1216)	2842	(1290)	3042 (1380)
		Semi-hermetic
			Water/Glycol	2630 (1193)	2800 (1270)	2962 (1344)		3162 (1435)
			GLYCOOL/DualCoolWater	2810 (1275)	2980 (1352)	3142	(1426)	3342 (1516)
			Air-cooled	2640 (1197)	2880 (1306)	3063 (1390)		3283 (1490)
		StandardScroll*	*Digital-scrollnotavailable.
			Air-cooled	2760 (1252)	3000 (1361)	3183	(1444)	3403 (1544)
	VS105
			DualCoolAir	3090 (1402)	3330 (1510)	3513	(1594)	3733 (1694)
		Semi-hermetic
			Water/Glycol	3130 (1420)	3370 (1529)	3553 (1612)		3773 (1712)
			GLYCOOL/DualCoolWater	3460 (1569)	3700 (1678)	3883 (1762)		4103 (1862)

20	Vertiv | Liebert® DS™ Installer/User Guide

4 EQUIPMENT INSPECTION AND HANDLING

WARNING! Risk of top-heavy unit falling over. Improper handling can cause equipment damage, injury or death. Read all of the following instructions and verify that all lifting and moving equipment is rated for the weight of the unit before attempting to move, lift, remove packaging from or prepare the unit for installation.

WARNING! Risk of contact with sharp edges, splinters, and exposed fasteners. Can cause injury. Only properly trained and qualified personnel wearing appropriate, OSHA-approved PPE should attempt to move, lift, remove packaging from or prepare the unit for installation.

NOTICE

Risk of passageway interference. Can cause unit and/or structure damage. The unit may be too large to fit through a passageway while on or off the skid. Measure the unit and passageway dimensions, and refer to the installation plans prior to moving the unit to verify clearances.

NOTICE

Risk of damage from forklift. Can cause unit damage. Keep tines of the forklift level and at a height suitable to fit below the skid and/or unit to prevent exterior and/or underside damage.

NOTICE

Risk of improper storage. Keep the unit upright, indoors and protected from dampness, freezing temperatures and contact damage.

Upon arrival of the unit and before unpacking:

•Verify that the labeled equipment matches the bill of lading.

•Carefully inspect all items for visible or concealed damage.

•Report damage immediately to the carrier and file a damage claim with a copy sent to Vertiv or to your sales representative.

Equipment Recommended for Handling the Unit:

•Forklift

•Pallet jack

•Piano jacks

•Lift beam

•Slings

•Spreader bars

4.1Packaging Material

All material used to package this unit is recyclable. Please save for future use or dispose of the material appropriately.

4 Equipment Inspection and Handling	21

4.2 Handling the Unit while Packaged

If possible, transport the unit with a forklift or pallet jack. If that is not possible, use a crane with slings and spreader bars that are rated for the weight of the unit.

When using a forklift or pallet jack:

•Ensure that the fork length is suitable for the unit length and, if adjustable, spread to the widest allowable distance that will fit under the skid.

•When moving the packaged unit, lift the unit from the "HEAVY SIDE" of the unit, and do not lift the unit any higher than6 in. (152 mm). All personnel except those moving the unit must be kept 12 ft (3.7 m) or more from the unit while it is being moved.

•Ifthe unit must be lifted higher than6 in. (152 mm), all personnel not directly involved inmoving the unit must be 20 ft (5 m) or farther from the unit.

• Always refer to the location ofthe center-of-gravity indicators when lifting the unit, see Figure 3.1 below.

Figure 3.1 Center of Gravity Indicator

22	Vertiv | Liebert® DS™ Installer/User Guide

4.3Unpacking the Unit

1.Remove the exterior stretch wrap packaging and two V-shaped boards from around the unit, as shown inFigure 3.2 below.

2.Remove the corner and side packaging planks, exposing the bag over the unit.

NOTE: The bag may remain in place to protect from dust and to protect the unit panels, or it may be removed for immediate installation.

3.Remove the bag from the unit when ready to remove the skid and install the unit.

Figure 3.2 Unpacking the Unit

Item Description

1Remove exteriorwrapfrom unit

2Remove cornerandside packagingplanks

3Leave the bagon the unituntil ready to install.

4.3.1 Removing the Unit from the Skid witha Forklift

Refer to Figure 3.3 on the next page.

1.Align a forklift with either the front or rear side of the unit.

•Ensure that the tines of the fork lift are locked to the widest location.

•Use the center of gravity indicators on the unit panels when determining the entry points for the tines. Center of gravity varies per unit size and selected options.

•The tines shall be equally spaced on either side of the center of gravity indicator.

2.Insert the tines of the forklift completely under the base of the unit.

•Ensure that the tines are level, not angled in an upward direction.

•The tines are to be at a height that will allow proper clearance under the unit.

•Ensure that the tines extend beyond the opposite side of the unit.

NOTE: If these steps are not followed, damage may occur to the panels and/or base of the unit.

4 Equipment Inspection and Handling	23

3.Remove the lag bolts from each bracket located around the base, and remove the brackets.

4.Lift the unit off the skid to an elevation point where the skid is not supporting the weight of the unit and remove the skid from under the unit.

Figure 3.3 Removing From Skid with a Forklift

Item Description

1Align forkliftwith frontorrearof unit.

2Inserttinescompletely underbase of unit.

3Remove lagboltsandbrackets

4Liftunitandremove skid.

4.3.2Removing the Unitfrom the Skid Using Rigging

1.Use the center-of-gravity indicators on the unit panels to determine the position of the slings.

•The slings shall be equally-spaced on either side of the center-of-gravity indicator

2. Place the slings and between the bottom rails of the unit and the skid as shown inFigure 3.4 on the facing page.

NOTE: Unit is shown without packaging. These instructions may be followed with or without the outer packaging in place.

24	Vertiv | Liebert® DS™ Installer/User Guide