Vaisala DS User Manual

Liebert®

DS™ ThermalManagementSystem

Installer/User Guide

35to 105kW (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.

Technical Support 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 ™ In staller/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

3 Pre-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 with a 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 on a Floor Stand 28

5 Piping 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

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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

10 Maintenance 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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Vertiv | Liebert® DS ™ In staller/User Guide

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 with Electrical Failure (MotorBurnout) 114

10.9.9 Compressor Mechanical Failure 115

10.9.10 Replacing a Compressor with Mechanical 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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Vertiv | Liebert® DS ™ In staller/User Guide

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 on the unit and in this 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! 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 over-pressurization of the refrigeration system. Can cause explosive discharge of highpressure refrigerant, loss of refrigerant, environmental pollution, equipment damage, injury, or death. This unit contains fluids and gases under high pressure. Use extreme caution when charging the refrigerant system. Do not pressurize the system higher than the design pressure marked on the unit's nameplate. For systems requiring EU CE compliance (50Hz), the system installer must provide and install a pressure relief valve in the high side refrigerant circuit that is rated same as the refrigerant high side “Max Allowable Pressure” rating that is marked on the unit serial tag. Do not install a shutoff valve between the compressor and the field installed relief valve. The pressure relief valve must be CE-certified to the EU Pressure Equipment Directive by an EU “Notified Body.”

WARNING! Risk of very heavy 125-lb (56.7-kg) fan modules dropping downward suddenly. Can cause injury or death. Support fan modules before removing mounting hardware. Use caution to keep body parts out of the fan modules pathway during repositioning. Only properly trained and qualified personnel should work on this equipment.

WARNING! Risk of improper moving. Can cause equipment damage, injury or death. Use only lifting equipment that is rated for the unit weight by an OSHA-certified rating organization. The center of gravity varies depending on the unit size and selected options. The slings must be equally spaced on either side of the center of gravity indicator. Shipping weights and unit weights are listed in the tables in Table 2.3 on page18. Use the center of gravity indicators on the unit to determine the position of the slings.

WARNING! Risk of improper piping installation, leak checking, fluid chemistry and fluid maintenance can cause equipment damage and personal injury. Installation and service of this equipment should be done only by qualified personnel who have been specially-trained in the installation of air-conditioning equipment and who are wearing appropriate, OSHA-approved PPE.

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Vertiv | Liebert® DS ™ In staller/User Guide

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! Risk of improper wiring, piping, moving, lifting and handling. Can cause equipment damage, serious injury or death. Installation and service of this equipment should be done only by qualified personnel who have been specially-trained in the installation of air-conditioning equipment and who are wearing appropriate, OSHA-approved PPE.

WARNING! Risk of improper wire sizing/rating and loose electrical connections. Can cause overheated wire and electrical connection terminals resulting in smoke, fire, equipment and building damage, injury or death. Use correctly sized copper wire only and verify that all electrical connections are tight before turning power On. Check all electrical connections periodically and tighten as necessary.

WARNING! Risk improper drive-belt removal. Can cause the spring-loaded motor base to slam down suddenly causing serious injury to hands and fingers from crushing and pinching. Read the directions in this manual and on the unit instruction labels, keep hands and fingers away from 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! Risk of explosive discharge of high-pressure refrigerant. Can cause serious injury. Neutral and service ports on the rotalock valve do not have a valve core. Front-seat the service valves and relieve pressure from the compressor before loosening a part or a component attached to the service valve. Follow local codes to properly reclaim refrigerant.

CAUTION: Risk of excessive refrigerant line pressure. Can cause tubing and component rupture resulting in equipment damage and personal injury. Do not close off the refrigerant-line isolation valve for repairs unless a pressure-relief valve is field- installed in the line between the isolation valve and the check valve. The pressure-relief valve must be rated 5% to 10% higher than the system-design pressure. An increase in ambient temperature can cause the pressure of the isolated refrigerant to rise and exceed the system-design pressure rating (marked on the unit nameplate).

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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Vertiv | Liebert® DS ™ In staller/User Guide

NOTICE

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) may arise. Take appropriate technical safety measures. Operating personnel must wear appropriate, OSHA-approved PPE and observe all appropriate hearing-protection safety requirements.

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

Risk of improper refrigerant charging. Can cause 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 can cause the compressors to operate at less than 5°F (–15°C) evaporator temperature and at less than 20psig (138kPa). Operation for extended periods at less than 20psig (138kPa) can cause premature compressor failure.

1 Important Safety Instructions

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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.

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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Vertiv | Liebert® DS ™ In staller/User Guide

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.

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.

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.

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.

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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Vertiv | Liebert® DS ™ In staller/User Guide

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

Digits 1 and 2 = Airflow Distribution

DS = Downflowstandard

VS = Upflow standard

Digit3, 4, 5 = Nominal Cooling Capacity, 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 = 10 5 kW, 30 ton

Digit6 = Cooling Type

A = Air-cooled

D = Dual-cool, air-cooled

H = Dual-cool, water-cooled

K = GLYCOOL™ (Liebert®Economizer Coil)

W = Water/Glycol-cooled

Digit7 = Compressor Type

D = Digital scroll, R-407C

S = Scroll, R-407C

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

V = Sem i-hermetic with 4-step, R-407C

(DS105 water/glycol/GLYCOOL-only)

2 Nomenclature an d Components

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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 = Fan Type

0 = Forward-curved blowers

1 = Electronically-commutated (EC) fans

Digit10 = Reheat Type

0 = None

E = 3-stage electric

Digit11 = Humidifier

0 = No humidifier

I = Infrared Humidifier

Digit12-15 = Factory Configuration Number

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 on air cooled models 035–105

• Available on water/glycol models 035–070

• Scroll compressors not available on 77- and 105-kW models for water/glycol/GLYCOOL/DualCool units

• GLYCOOL Liebert® Econ-O-Coil™ Models

• Available with digital-scroll compressors on 035 to 070 models, and with semi-hermetic compressors on 077 to 105 models

• High Pressure Water Regulating Valve

• Not available on 042, 053, 070 and 077 models with semi-hermetic and scroll compressors

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Vertiv | Liebert® DS ™ In staller/User Guide

2.2 Component Location

The unit component locations are described in the submittal documents included in the Submittal Drawings on page139

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

Table 1.3 Component-location Drawings

Docu ment Number Title

DPN003706 Component Location, Downflow Models

DPN003707 Component Location, Upflow Models

2 Nomenclature an d Components

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3 PRE-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 on page9, and submittal drawings to determine the type of system being installed and anticipate building alterations, piping and duct work needed.

The unit dimensions, pipe-connection locations, and piping schematics are described in the submittal documents included in the Submittal Drawings on page139.

• Verify that the floor is level, solid and sufficient to support the unit. See Liebert DS Downflow Unit weights and

Shipping Weights—Approximate on page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 an absolute minimum (less than 5% of total air circulated in the room).

• Do not install a Liebert® DS in an alcove or at the end of a 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 an under-floor water detection system. Contact your Vertiv representative for information.

3.1 Planning Dimensions

The unit, floor stand, and plenum dimensions are described in the submittal documents included in the Submittal Drawings on page139.

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

Table 2.1 Dimension Planning Drawings

Docu ment Number Title

Downflow Units

DPN003643 CabinetDimensional Data, 35 to 105 kW (10 to 30 Tons) All Blower Types

UpflowUnits

DPN003681 Cabinet Dimensional Data Upflow 35-105kW (10-30 Tons) Models with EC Fans

DPN003646 Cabinet Dimensional Data Upflow 35 to 105 kW (10-30 Tons) with Forward Curved Blower

Floor Stands

DPN003240 Floor Stand Dimensional Data 35kW - 42kW (10-12 Tons) with EC Fans

DPN003173 Floor Stand Dimensional Dta 53kW - 77 kW (15-22 Tons) with EC Fans

DPN003174 Floor StandDimensional Data 105 kW (30 Tons) Models withEC Fans

DPN003134

Floor Stand and Floor Planning Dimensional Data Upflow 35-42 kW (10-12 Tons)Models with Forward Curved B lowers

3 Pr e-inst allation Preparationand Guidelin es

13

Table 2.1 Dimension Planning Drawings (continued)

Docu ment Number Title

DPN003141

DPN003149

Blower Outlet, Deck and Filter Box

DPN001120 Blower Outlet a nd Deck Dimensional Data Upflow 35-42 kW (10-12 Tons) with Forward Curved Blowers

DPN001191 Blower Outlet and Deck Dimensional Data Upflow 53-77kW (15-22) Tons with Forward Curved Blowers

DPN001192 B lower Outlet a nd Deck Dimensional Data Upflow 1 05kW (30 Tons)with Forward Curved Blowers

DPN001196

DPN003974

Plenums

DPN003164 Upflow P lenum Dimensional Data 35kW-105kW (10-30 Tons)Models with Foward Curved Blowers

DPN003458 Plenum Dimensional Data Upflow35-42kW (10-12 Tons)Models with EC Fans

DPN003453 P lenum Dimensional Data Upflow 53-77kW (15-22 Tons)with EC Fans

DPN003459 Plenum Dimensional Data Upflow 105kW (30 Tons) Models with EC Fans

Floor Stand and Floor Planning Dimensional Data Upflow 53-77 kW (15-22 Tons)Models with Forward Curved B lowers

Floor Stand and Floor Planning Dimensional Data Upflow 1 05kW (30 Tons) Models with Forward Curved Blowers

Rear Return Filter Box Dimensional Data Upflow 35-105kW (10-30 Tons)All CompressorModels with ForwardCurved Blowers

Rear Return Filter Box Dimensional Data Upflow 35-105kW (10-30 Tons)with EC Fans All Compressor Models

3.2 Air 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) of clearance.

• A minimum of 24in. (610mm) is required to operate the fans when they are lowered with the factory-provided jacking mechanism.

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

• Optional plenums are available for downflow unit ducting.

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Vertiv | Liebert® DS ™ In staller/User Guide

Figure 2.1 Downflow Unit Ducting and Plenum Ducting

Item Description

1 Field-fabricated duct work.

Field service access for filter replacement.

2

Minimum height = 1 2in. (305mm)

Minimum distance from unit= 2in. (51mm)

3 Optional Liebert® plenum with service-access doorfor filter replacement.

4 Direct-to-unit ducting

5 Plenum ducting

3 Pr e-inst allation Preparationand Guidelin es

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 of the unit. Allow 25in. (635mm) on one side of the 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

1 Typical ducting

2 Straightsections must be 1.5 to 2. 5 times the longest blower dimension.

3 Front of unit

NOTE: Drain traps are qualified to a return duct static of negative 1.5 i.w.g. (-1.5i.w.g).

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Vertiv | Liebert® DS ™ In staller/User Guide

Figure 2.3 Upflow Ducting Configurations for EC Fans

Item Description

1 Typical ducting. May run to either side.

2 Straight section must be 2.5 times the depth of blower.

3 Ducting only attached to flanges onprovidedplenum.

NOTE: Follow standard practices in all duct work.

3.4 Connections 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 on page32, for details.

• Plan the routing of wiring, 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 an optional aquastat setting. See Table 9.7

on page119, and Table 9.8 on page119, through Table 9.10 on page120, for drycooler aquastat setting guidelines. Applications with the optional stat setting require field piping to be insulated to prevent condensation.

• If seismic 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.

3 Pr e-inst allation Preparationand Guidelin es

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, Humidification and 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

Cooling Type Compressor Type

035/042 053/070/077 105

LxWxH, in. (mm ) LxWxH, in. (mm ) LxWxH, in. (mm )

Air, Dual-Cool Air

Air, Dual-Cool Air Semi-hermetic —

Water/Glycol, GLYCOOL/Dual-Cool Water

Scroll or Digitalscroll

Semi-hermetic —

90x42x82

(2286x1067x2083)

90x42x82

(2286x1067x2083)

102x42x82

(2591x1067x2083

114x42x82

(2896x1 067x2083)

114x42x82

(2896x1 067x2083)

114x42x82

(2896x1 067x2083)

136x42x82

(3454x1 067x2083)

136x42x82

(3454x1 067x2083)

—

136x42x82

(3454x1 067x2083)

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

Down flow D ownflow Shippin g Weights, lb (kg)

Model Number Compressor Type Cooling Type EC Fan Unit Weight, lb (kg) Dom estic, lb (kg) Export, lb (kg)

Air-cooled 1470 (668) 1608 (730) 1778 (807)

DS035-042 Scroll or Digital-scroll

DS053 Scroll or Digital-scroll

Dual Cool Air 1620 (736) 1758 (798) 1928 (875)

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 )

Water/Glycol 2220 (1010) 2382 (1081) 2582 (1172)

GLYCOOL/Dual Cool Water 2400 (1091) 2562 (1163) 2762 (1253)

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Vertiv | Liebert® DS ™ In staller/User Guide

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

Down flow D ownflow Shippin g Weights, lb (kg)

Model Number Compressor Type Cooling Type EC Fan Unit Weight, lb (kg) Dom estic, lb (kg) Export, lb (kg)

Air-cooled 1970 (894) 2120 (962) 2310 (1048)

DS070 Scroll or Digital-scroll

Standard Scroll*

DS077

Semi-hermetic

Standard Scroll*

DS105

Semi-hermetic

Dual Cool Air 2150 (975) 2300 (1044) 2490 (1130)

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)

Dual Cool Air 2200 (998) 2350 (1066) 2540 (1153)

*Digital-scroll not available.

Air-cooled 2450 (1114) 2612 (1185) 2812 (1276)

Dual Cool Air 2630 (1196) 27 92 (1267) 2992 (1358)

Water/Glycol 2750 (1250) 2912 (1321) 31 12 (1412)

GLYCOOL/Dual Cool Water 2930 (1332) 3092 (1403) 3292 (1494)

Air-cooled 2660 (1207) 3103 (1408) 3323 (1508)

Dual Cool Air 301 5 (1368) 3463 (1571) 3683 (1671)

*Digital-scroll not available.

Air-cooled 2780 (1261) 3223 (1462) 3443 (1562)

Dual Cool Air 3135 (1422) 3583 (1626) 3803 (1726)

Water/Glycol 3150 (1429) 3593 (1630) 3813 (1730)

GLYCOOL/Dual Cool Water 3505 (1590) 3953 (1794) 4173 (1893)

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

Model Number Compressor Type Cooling Type EC Fan Unit Weight, lb (kg)

VS035-042 Scrollor Digital-scroll

VS053 Scroll or Digital-scroll

3 Pr e-inst allation Preparationand Guidelin es

Upflow

Forward-Cu rved

Unit Weight, lb (kg)

Upflow Shipping Weights, lb (kg)

w/Forward-curved Blowers

Dom estic, lb (kg) Export, lb (kg)

Air-cooled 1370 (621) 1520 (689) 1658 (753) 1828 (830)

Dual Cool Air 1520 (689) 1670 (758) 1808 (821) 1978 (898)

Water/Glycol 1680 (762) 1830 (830) 1968 (893) 2138 (970)

GLYCOOL/Dual Cool Water 1830 (830) 1 980 (898) 2118 (961) 2288 (1038)

Air-cooled 1900 (862) 2070 (939) 2220 (1007) 2410 (1094)

Dual Cool Air 2080 (943) 2250 (1021 ) 2400 (1089) 2590 (117 5)

Water/Glycol 2200 (998) 2370 (1075) 2532 (1149) 27 32 (1240)

GLYCOOL/Dual Cool Water 2380 (1080) 2550 (1157) 2712 (1231) 2912 (1321)

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)

Air-cooled 1900 (862) 2070 (939) 2220 (1007) 2410(1094)

Dual Cool Air 2080 (943) 2250 (1021 ) 2400 (1089) 2590 (117 5)

VS070 Scroll or Digital-scroll

Water/Glycol 2200 (998) 2370 (1075) 2532 (1149) 27 32 (1240)

GLYCOOL/Dual Cool Water 2380 (1080) 2550 (1157) 2712 (1231) 2912 (1321)

Air-cooled 1900 (862) 2070 (939) 2220 (1007) 2410 (1094)

Standard Scroll*

*Digital-scroll not available.

Air-cooled 2330 (1057 ) 2500 (1134) 2662 (1208) 2862 (1299)

VS077

Dual Cool Air 2510 (1139) 2680 (1216) 2842 (1290) 3042 (1380)

Semi-hermetic

Water/Glycol 2630 (1193) 2800 (1270) 2962 (1344) 3162 (1435)

GLYCOOL/Dual Cool Water 2810 (1275) 2980 (1352) 3142 (1426) 3342 (1516)

Air-cooled 2640 (11 97) 2880 (1306) 3063 (1390) 3283 (1490)

Standard Scroll*

*Digital-scroll not available.

Air-cooled 27 60 (1252) 3000 (1361) 3183 (1444) 3403 (1544)

VS105

Dual Cool Air 3090 (1402) 3330 (1510) 3513 (1594) 3733 (1694)

Semi-hermetic

Water/Glycol 3130 (1420) 337 0 (1529) 3553 (1612) 37 73 (171 2)

Forward-Cu rved

Unit Weight, lb (kg)

Dom estic, lb (kg) Export, lb (kg)

GLYCOOL/Dual Cool Water 3460 (1569) 3700 (1678) 3883 (1762) 4103 (1862)

20

Vertiv | Liebert® DS ™ In staller/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

4.1 Packaging Material

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

4 Equipment Insp ection and Hand lin g

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 than 6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.

• If the unit must be lifted higher than 6in.(152mm), all personnel not directly involved in moving the unit must be 20ft (5m) or farther from the unit.

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

Figure 3.1 Center of Gravity Indicator

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Vertiv | Liebert® DS ™ In staller/User Guide

4.3 Unpacking the Unit

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

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

1 Remove exterior wrap from unit

2 Remov e corner a nd side packaging planks

3 Leave the bag on the unit until ready to install.

4.3.1 Removing the Unit from the Skid with a 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 Insp ection and Hand lin g

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

1 Align forklift with front or rear of unit.

2 Insert tines c ompletely under base of unit.

3 Remove lag bolts and brackets

4 Lift unit and remove skid.

4.3.2 Removing the Unit from 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 in Figure 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.

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Vertiv | Liebert® DS ™ In staller/User Guide

Figure 3.4 Example Sling Placement

Item Description

1 Distance between sling and center-of-gravity marker equal to item2.

2 Distance between sling and center-of-gravity marker equal to item1.

4 Equipment Insp ection and Hand lin g

25

3. Referring to Figure 3.5 below:

• Align the slings as described previously.

• Use spreader bars or equivalent device to ensure proper protection of the unit (Item 1).

• Remove the lag bolts from each bracket located around the base, and remove the brackets (Item 2).

NOTE: Depending on final installation location, the skid may need to remain under the unit. Therefore, the lag bolts and brackets would not yet be removed.

• 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 (Item 3).

Figure 3.5 Moving Unit with Rigging

Item Description

1 Spreader bars and rigging on unit.

2 Remov e lag bolts and brackets.

3 Lift the unit and remove the skid.

4.3.3 Moving the Unit to the Installation Location Using Piano Jacks

Refer to Figure 3.6 on the facing page.

1. With the unit elevated, position piano jacks at each end of the unit.

2. Lower the unit to a height suitable for the piano jacks, place protective material between the unit and the piano jacks and straps.

26

Vertiv | Liebert® DS ™ In staller/User Guide

3. With the unit secured to the piano jacks, move the forklift away from the unit.

4. Using the piano jacks, at least two trained personnel can move the unit to the site for installation.

• For location considerations, refer to Pre-installation PreparationandGuidelines on page13.

Figure 3.6 Moving Unit with Piano Jacks

Item Description

1 Place piano jacks on each end of the unit.

2 Use padding between unit and strapsand, with the unit secured to the piano jacks, move the forklift away from the unit.

4.4 Remove Shipping Blocks fromUnitswithSemi-HermeticCompressors

The shipping blocks under all semi-hermetic compressors must be removed and the springs must be adjusted before startup.

1. Loosen nuts at each of the four compressor feet and remove the two shipping blocks.

2. Beginning with one compressor foot, re-tighten nut until the washer under the nut can no longer be rotated by finger.

3. Loosen the nut half a turn. The washer will be slightly loose.

4. Repeat for remaining feet and recheck all when done

4 Equipment Insp ection and Hand lin g

27

4.5 Placing the Unit on a Floor Stand

Refer to the floor-stand installation sheet, located inside the floor-stand package. Lower the unit onto the floor stand. Refer to Figure 3.7 below. Be sure to align the welded tabs on top of the floor stand with the inside of the unit frame base.

NOTE: The floor stand for the units equipped with EC fans is not symmetrical. Its orientation to the unit is critical for lowering the EC fans. Unless the floor stand is installed in the correct position, the fans will not lower into the floor stand.

Figure 3.7 Welded Tabs on Floor Stand

Item Description

1 Front of unit

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Vertiv | Liebert® DS ™ In staller/User Guide

5 PIPING AND REFRIGERANT REQUIREMENTS

All fluid and refrigeration connections to the unit, with the exception of the condensate drain, are sweat copper. Factoryinstalled piping brackets must not be removed. Field-installed piping must be installed in accordance with local codes and must be properly assembled, supported, isolated and insulated. Avoid piping runs through noise-sensitive areas, such as office walls and conference rooms.

Refer to specific text and detailed diagrams in this manual for other unit-specific piping requirements.

All piping below the elevated floor must be located so that it offers the least resistance to air flow. Careful planning of the piping layout under the raised floor is required to prevent the air flow from being blocked. When installing piping on the subfloor, we recommend that the pipes be mounted in a horizontal plane rather than stacked one above the other. Whenever possible, the pipes should be run parallel to the air flow.

The following pipe connections are required:

• A drain line from the unit.

• A water-supply line to the optional humidifier (if applicable).

• On air-cooled systems: refrigerant piping connections between the unit and the condenser. See Refrigerant

Piping and Charging on page34.

• On water-glycol systems: connections to a water or glycol loop.

The pipe connection locations, piping general arrangement and schematics are described in the submittal documents included in the Submittal Drawings on page139.

The following tables list the relevant documents by number and title.

Table 4.1 Piping General Arrangement Drawings

Docu ment Number Title

Air Cooled Units

DPN003954 Air Cooled Piping Schematic Condenser Above Indoor Unit

DPN003730 Piping Schema tic withLiebert MC Condenser Air Cooled Scroll or Digital Scroll Compressor

Water/Glycol Cooled Units

NOTE: For systems with drycoolers, s ee Drycooler A quastat Settings on page119.

DPN000896 PipingSchematic Water/Glycol Scroll Compressor Models

DPN001430 Piping Schematic Water Glycol Digital Scroll Compressor Models

DPN000895 Piping Schematic Water/Glycol 77kW-105kW Semi-Hermetic Compressor Models

GLYCOOL™ Units

NOTE: For systems with drycoolers, s ee Drycooler A quastat Settings on page119.

DPN000897 Piping Schematic GLYCOOL™ 7 7kW -105kW Semi-Hermetic Compressor Models

DPN000898 Piping Schematic GLYCOOL™ Scroll Compressor Models

DPN001432 Piping Schematic GLYCOOL™ Digital Scroll Compressor Models

Econ-O-Coil™ Option

DPN000805 Optional Piping Schematic Econ-O-Coil Models

5 Pi pin g and Refrigeran t Requirements

29

Table 4.2 Piping Connection Drawings

Docu ment Number Title

Downflow, Air Cooled Models with EC Fans

DPN003239

DPN002182

Primary Connection Locations DownflowAir Cooled 35-42kW (10-12 Tons)Scroll or Digital Scroll Compressor Models

Primary Connection Locations DownflowAir Cooled 53-77kW Scroll or Digital Scroll CompressorModels with EC Fans

DPN00217 9 Primary Connections Downflow Air Cooled77kW (22 Tons) Semi-Hermetic Compressor Models

DPN002154 Primary Connection Locations Downflow Air Cooled 105kW (30 Tons) All Compressor Models

Downflow, Water/Glycol/GLYCOOL Models with EC Fans

DPN003530

DPN002183

Primary Connection Locations DownflowWater/Glycol/GLYCOOL™ 35-42kW (10-12 Tons) All Compressor Models

Primary Connection Locations DownflowWater/Glycol/GLYCOOL™ 53-77 kW (15-22 Tons)All Compressor Models

DPN002153 Primary Connection Locations Downflow Water/Glycol/GLYCOOL™ (30 Tons) All Compressor Models

Upflow, Air Cooled Models with EC Fans

DPN002740

DPN002742

DPN002743

Primary Connection Locations Upflow Air Cooled 35-42kW (10-12 Tons)Scroll or Digital Scroll Compressor Models with EC Fans

Primary Connection Locations Upflow Air Cooled 77kW (22 Tons) Semi-Hermetic Compressor Models with EC Fans

Primary Connection Locations Upflow Air Cooled 53-77kW (15-22 Tons) Scroll or Digital Scroll Compressor Models

DPN002745 Primary Connection Locations Upflow Air Cooled 105kW (30 Tons)All Compressor Models

Upflow, Water/Glycol/GLYCOOL Models with EC Fans

DPN002741

DPN002744

Primary Connection Locations Upflow Water/Glycol/GLYCOOL ™ 35-42kW (10-12 Tons)Scroll and Digital Scroll CompressorModels with EC Fans

Primary Connection Locations Upflow Water/Glycol/GLYCOOL™ 53-77kW (15-22 Tons)All Compressor Models with EC Fans

DPN002746 P rimary Connection LocationsUpflow Water/Glycol/GLYCOOL ™ 105kW (30 Tons) All Compressor Models

Upflow, Air Cooled Models with Forward Curved Blowers

DPN001119

DPN00121 2

Primary Connection Locations Upflow Air Cooled 35-42kW (10-12 Tons)Scroll or Digital Scroll Compressor Models with Forward Curved Blowers

Primary Connection Locations Upflow Air Cooled 77kW (22 Tons) Semi-Hermetic Compressor Models with ForwardCurved Blowers

DPN00121 3 Primary Connection Locations Upflow Air Cooled 53-77 kW 15-22 Tons Scroll or Digital Scroll Compressors

DPN001257 Primary Connection Locations Upflow Air Cooled 105kW (30 Tons) All Compressor Models

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Vertiv | Liebert® DS ™ In staller/User Guide

Table 4.2 Piping Connection Drawings (continued)

Docu ment Number Title

Upflow, Water/Glycol/GLYCOOL™ Models with Forward Curved Blowers

DPN001179

DPN00121 4

DPN001258 Primary Connection Locations Upflow Water/Glycol/GLYCOOL™ 1 05kW (30 Tons) All CompressorModels

Primary Connection Locations Upflow Water/Glycol/GLYCOOL™ 35-42 kW (10-12 Tons) Scroll and Digital Scroll CompressorModels with Forward Curved B lower

Primary Connection Locations Upflow Water/Glycol/GLYCOOL™ 53-77kW (15-22 Tons)All Compressor Models with Forward Curved Blowers

5.1 Drain and Humidifier Fluid Piping

NOTICE

Risk of water leakage. Can cause severe property damage and loss of critical data center equipment.

The Liebert®DS requires a water drain connection. Improper installation, application and service practices can result in water leakage from the unit.

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

We recommend installing monitored leak detection equipment for the water supply lines and the internal unit water lines.

5 Pi pin g and Refrigeran t Requirements

31

5.1.1 Field-installed, Gravity Fed Drain Line Requirements

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 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.

A 3/4-in. NPT-Female drain connection is provided on units without an optional condensate pump.

Observe the following requirements and refer to Figure 4.1 on the facing page, when installing and routing the drain line:

• The drain line must be sized for 2 gpm (7.6 l/m) flow.

• 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 drain line must slope continuously away from the unit. Pitch drain line toward drain a minimum of 1/8in. (3mm) per 1ft (305mm) of length.

• Drain is trapped internally. Do not externally-trap the drain line.

• The drain line must be rigid enough that it does not sag between supports, which unintentionally creates traps.

• The drain line must comply with all applicable codes.

• On units with the optional, factory-installed condensate pump, see Factory Installed Condensate Pump on page34 and Condensate Pump Drain Line Requirements on page34.

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Vertiv | Liebert® DS ™ In staller/User Guide

Figure 4.1 Correct and Incorrect Gravity Drains for Downflow and Upflow Units

5 Pi pin g and Refrigeran t Requirements

Table 4.3 Gravity Fed Drain Line Figure Descriptions

Item Description

1 For downflow units

2 For upflow units

3 Correct drain installation

4 Incorrect drain installation

5 Internal drain

6 External drain

7 Continuousdownward slope

33

Table 4.3 Gravity Fed Drain Line Figure Descriptions (continued)

Item Description

8 External trap. Do nottrap externally.

9 External traps, althoughunintentional. Lines m ust be rigid enough not to bowover top of other objects.

10 Internal drain

11 DS unit

5.1.2 Condensate Pump Drain Line Requirements

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.

Observe the following requirements when installing and routing the drain line:

• The drain line must be located so it will not be exposed to freezing temperatures.

• Size the piping based on the available condensate head.

• Drain is trapped internally. Do not externally-trap the drain line.

• The drain line must be rigid enough that it does not sag between supports, which unintentionally creates traps.

• We recommend installing monitored, under-floor leak-detection equipment.

Factory Installed Condensate Pump

If your unit includes an optional condensate pump, the pump is factory-installed inside the unit and a 1/2-in. copper sweat connection is provided on the unit.

5.1.3 Water Supply Line Requirements for the Optional Humidifier

The unit may have an optional humidifier. Refer to the appropriate supply-line piping requirements if a humidifier is included on your unit:

Infrared Humidifier:

• 1/4-in. supply line, maximum water pressure is 150 psi (1034kPa).

• Size supply line for 1 gpm (3.8 l/m), with a minimum water pressure of 20psi(138kPa).

• Do not supply de-ionized water to the humidifier.

5.2 Refrigerant Piping and Charging

WARNING! Risk of over-pressurization of the refrigeration system. Can cause explosive discharge of highpressure refrigerant, loss of refrigerant, environmental pollution, equipment damage, injury, or death. This unit contains fluids and gases under high pressure. Use extreme caution when charging the refrigerant system. Do not pressurize the system higher than the design pressure marked on the unit's nameplate.

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Vertiv | Liebert® DS ™ In staller/User Guide

Consult local building and plumbing codes for installation requirements of additional pressure-relief devices when isolation valves are field installed. Do not isolate any refrigerant circuits from over-pressurization protection.

NOTICE

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

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

5.2.1 Refrigerant Piping Guidelines forAir CooledSystems

• Air cooled units ship with a nitrogen holding charge. Do not vent the charge until all refrigerant piping is in place, ready for connection to the unit and condenser.

• Use copper piping with a brazing alloy with a minimum temperature of 1350°F (732°C), such as Sil-Fos. Avoid soft solders, such as 50/50 or 95/5.

• Use a flow of dry nitrogen through the piping during brazing to prevent formation of copper oxide scale inside the piping. When copper is heated in the presence of air, copper oxide forms. POE oils will dissolve these oxides from inside the copper pipes and deposit them throughout the system, clogging filter driers and affecting other system components.

• A pure dry nitrogen flow of 1-3 ft3/min (0.5-1.5 l/s) inside the pipe during brazing is sufficient to displace the air. Control the flow using a suitable measuring device.

• Ensure that the tubing surfaces to be brazed are clean and that all burrs have been removed from the ends of the tubes.

• Ensure that all loose material has been cleaned from inside the tubing before brazing.

• Protect all refrigerant line components within 18in. (460mm) of the brazing site by wrapping them with a wet cloth or with a suitable heat-sink compound.

• Isolate piping from building using vibration-isolating supports.

• Condenser with receiver:

• Cannot be installed below the evaporator.

• The bottom of the receiver on the outdoor, MC condenser must be higher than the elevation of the thermal expansion valve (TXV) inside the indoor unit.

• The vertical height of the bottom of the receiver must not exceed 60 ft. (18.3m) above the TXV.

• Consult factory before installing units, condensers, and receivers outside these parameters.

• Refer to DPN003954 and DPN003993 included in the Submittal Drawings on page139.

• Condenser without receiver:

• The bottom of the condenser coil must be less than 15 feet below the location of the TXV inside the indoor unit.

• The vertical height of the bottom of the condenser coil must not exceed 60 ft. (18.3m) above the TXV inside of the indoor unit.

5 Pi pin g and Refrigeran t Requirements

35

• Consult factory before installing units and condensers outside of these parameters.

• Refer to DPN003954 ncluded in the Submittal Drawings on page139.

• Consult factory if piping run exceeds 150ft(46m) equivalent length.

• Install traps on hot-gas (discharge) lines at the base of vertical risers over 5ft(1.5m) and then for vertical rises over 25 ft (7.6m), install a trap in 20-ft (6-m) increments or evenly-divided over the vertical rise.

• Pitch horizontal hot-gas piping down at a minimum rate of 1/2in.per 10ft (42mm per 10m) so that gravity will aid in moving oil in the direction of refrigerant/oil flow.

• Keep piping clean and dry, especially on units with R-407C refrigerant.

• Avoid piping runs through noise-sensitive areas.

• Do not run piping directly in front of discharge air stream.

• Refrigerant oil. Do not mix oil types (see Compressor Oil on page111).

Refer to ASHRAE Refrigeration Handbook for general, good-practice refrigeration piping.

• Refer to Table 4.4 below,, for recommended refrigerant piping sizes based on equivalent pipe lengths.

• Refer to Refrigerant Charge Requirements for Air Cooled Systems on the facing page,, for the refrigerantcharge requirements of the system.

• Refer to Charging Air Cooled Systems withLiebertLee-Temp Receiver on page47, for charging information.

5.2.2 Refrigerant Line Sizes and Equivalent Lengths

Table 4.4 Recommended Refrigerant Line sizes for Standard Scroll Models (Non-Digital Scroll) - OD Copper (Inches)

Model: 035 04 2 053 070 077 105

Hot

Equivalent Length

50 ft (15m) 7/8 1/2 7/8 1/2 7/8 5/8 1-1/8 7/8 1-1/8 7/8 1-3/8 7/8

100 ft (30m) 7/8 5/8 7/8 5/8 1-1/8 7/8 1 -1/8 7/8 1 -1/8 7/8 1-3/8 7/8

150 ft (45m) 7/8 5/8 7/8 5/8 1-1/8 7/8 1 -1/8 7/8 1 -1/8 7/8 1-3/8 1-1/8

Consultfactory for proper line sizing for runslonger than max imum equivalent length shown.

1. Downsize vertical riser one trade size (1-1/8” to 7/8”)

Source: DPN000788, Rev 13

Gas

Line

Liquid

Line

Hot

Gas

Line

Liquid

Line

Hot

Gas

Line

Liquid

Line

Hot

Gas

Line

Liquid

Line

Hot

Gas

Line

Liquid

Line

Hot

Gas

Line

Liquid

Line

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Vertiv | Liebert® DS ™ In staller/User Guide

Table 4.5 Recommended Refrigerant Line Sizes for 4 Step Semi-Hermetic and Digital Scroll Models - OD Copper

(Inches)

Model: 035 042 053 070 077

2

105

2

Hot

Equivalent Length

Gas

Line

Liquid

Line

50 ft (15m) 3/4 1 /2 7 /8 5/8 7/8 5/8 1-1/8

100 ft (30 m) 7/8 5/8 7 /8 5/8 1 -1/8

150 ft (45m) 7/8 5/8 1-1/8

Hot

Gas

Line

1

Liquid

Line

5/8 1 -1/8

Hot

Gas

Line

1

Liquid

Line

7/8 1-1/8

Hot

Gas

Line

Liquid

Line

1

7/8 1-1/8 7/8 1-3/8 7 /8

1

7/8 1-1/8 7/8 1-3/8 7 /8

1

7/8 1-1/8 7/8 1-3/8 1-1/8

Hot

Gas

Line

Liquid

Line

Hot

Gas

Line

Consultfactory for proper line sizing for runslonger than max imum equivalent length shown.

1. Downsize vertical riser one trade size (1-1/8” to 7/8”)

2. Digital-scroll not available on 077 or 105 models.

Source: DPN000788, Rev 13

5.2.3 Refrigerant Charge Requirements for Air Cooled Systems

The following tables provide the refrigerant charge requirements for the Liebert® DS, connected piping, and condenser options.

Table 4.6 Approximate R-407C Refrigerant Charge forAir Cooled Liebert DS

System Type Mo del

035, 042 5.5 (2.5)

Air-cooled

053, 07 0, 077 8.0 (3.6)

Charge per C ircuit,

lb (kg)

Liquid

Line

105 9.5 (4.3)

Table 4.7 Interconnecting Piping Refrigerant Charge for R-407C, lbper 100ft (kgper30m)

Line Size, O.D ., in. Liquid Lin e Hot G as L ine

1/2 6.7 (3.0) 0.5 (0.2)

5/8 10. 8 (4.8) 0.8 (0.4)

3/4 1 6.1 (7.2) 1. 2 (0.5)

7/8 22.3 (10.0) 1.7 (0.8)

1-1/8 38.0 (17. 0) 2.9 (1. 3)

1-3/8 57.9 (25.9) 4.4 (2.0)

Source: DPN003099, Rev. 1

5 Pi pin g and Refrigeran t Requirements

37

Table 4.8 Approximate R-407C Refrigerant Required per Circuit for Liebert MC Condenser

Condenser Model

MCS056 2.2 (1.0) 21. 0 (9.5)

MCM080 3.0 (1.4) 23.9 (10.8)

MCM160 7.5 (3.4) 44.5 (20.2)

MCL110 5.1 (2.3) 2 6.0 (11. 8)

MCL220 12.2 (5.6) 53.8 (24.4)

Source: DPN002411, Rev. 8

Per Circuit witho utLiebertLee-Temp,

lb (kg)

Per Circuit withL iebertLee-Temp,

lb (kg)

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Vertiv | Liebert® DS ™ In staller/User Guide

5.2.4 Additional Oil Requirements forScrollandDigital ScrollCompressors

NOTICE

Risk of improper compressor lubrication. Can cause compressor and refrigerant system damage.

Failure to use oil types, viscosities and quantities recommended by the compressor manufacturer may reduce compressor life and void the compressor warranty.

• Do not mix polyolester (POE) and mineral-based oils.

• Do not mix oils of different viscosities.

• Consult your Vertiv sales representative, visit https://www.Vertiv.com/en-us/support/, or contact the compressor manufacturer if questions arise.

System charges may require additional oil charge to be added. See Additional Oil Requirements forScrollandDigital

ScrollCompressors above, for the amount required for various system charge levels.

In addition to oil added based on system charge, additional oil is required for discharge-line field-installed traps. Standardformed tube traps are required, see Standard Formed Tube Trap Versus Straight Tubes and Fittings Trap on page41 and

Volume of Oil in Standard Form Trap by Pipe Diameter on page41, because straight tubes and fittings used as traps

require much more oil and the length of the straight tube can vary.

After the system has been fully charged with refrigerant, use a hand pump to add the additional oil at the suction side of the system while the system is running.

5 Pi pin g and Refrigeran t Requirements

39

On the tag marked “Oil Added Field Service Record,” attached to each compressor, record the date the oil was added and the amount of oil added by field service, including oil added for traps and for system charge per Additional Oil

Requirements forScrollandDigital ScrollCompressors on the previous page.

Table 4.9 Additional Oil Required per Circuit by System Refrigerant Charge per Circuit

Refrigerant

System C harge

Per Circuit,

lb (kg) *

DS035 DS042

<40 (18. 1) 0 0 0 0 0 0 0

40 (18.1) 0 0 8 (240) 5 (150) 5 (150) 5 (150) 5 (150)

50 (22.7) 2 (60) 2 (60) 12 (350) 9 (270) 9(270) 9 (270) 9(270)

60 (27.2) 4 (120) 4 (120) 16 (470) 13 (380) 13 (380) 1 3 (380) 1 3 (380)

70 (31.8) 5. 5 (160) 5.5 (160) 20 (590) 1 7 (500) 1 7 (500) 1 7 (500) 17 (500)

80 (36.3) 7 (210) 7 (210) 24 (710) 21 (620) 21 (620) 21 (620) 21 (620)

90 (40.8) 8,5 (250) 8,5 (250) 28 (830) 25 (740) 25 (740) 25 (740) 25 (740)

100 (45.4) 10 (300) 1 0 (300) 32 (950) 29 (860) 29 (860) 29 (860) 29 (860)

110 (49,9) 11.5 (340) 11 .5 (340) 36 (1060) 33 (980) 33 (980) 33 (980) 33 (980)

120 (54.4) 13 (380) 13 (380) 40 (1180) 37 (1090) 37 (1090) 37 (1090) 37 (1090)

DS053

60-Hz

Additional Oil Required Per Circuit, oz (ml)

DS053

50-Hz

DS070 DS077 DS105

130 (59.0) 14.5 (430) 14.5 (430) 44 (1300) 14.5 (430) 1 4.5 (430) 14.5 (430) 14.5 (430)

140 (63.5) 16 (470) 16 (470) 48 (1420) 45 (1330) 45 (1330) 45 (1330) 45 (1330)

150 (68.0) 18 (530) 18 (530) 52 (1540) 49 (1450) 49 (1450) 49 (1450) 49 (1450)

160 (72.6) 20 (590) 20 (590) 56 (1660) 53 (1570) 53 (1570) 53 (1570) 53 (1570)

170 (77.1 ) 21.5 (640) 21. 5 (640) 60 (1770) 57 (1690) 57 (1690) 57 (1690) 57 (1690)

180 (81.6) 23 (680) 23 (680) 64 (1890) 61 (1800) 61 (1800) 61 (1800) 61 (1800)

190 (86.2) 24.5 (720) 24.5 (720) 68 (2010) 65 (1920) 65 (1920) 65 (1920) 65 (1920)

200 (90.7) 26 (770) 26 (770) 72 (2130) 69 (2040) 69 (2040) 69 (2040) 69 (2040)

*System Charge = indoor unit + condenser + refrigerant receiver +refrigerant lines. For system charges over 200 lb. (91.7kg), consult your Vertiv representative.

Use Copeland POE Oil ULTRA 32-3MAF or other Copeland-approved oils,

Source:DPN003950 Rev. 5

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Vertiv | Liebert® DS ™ In staller/User Guide

Figure 4.2 Standard Formed Tube Trap Versus Straight Tubes and Fittings Trap

Item Description

1 Standard-formed tube trap

2 Straighttubes and fittings trap

Table 4.10 Volume of Oil in Standard Form Trap by Pipe Diameter

Pipe d iameter, in. Oil volume, oz

Source: DPN003950, Rev. 5

1/2 0.2 (5.9)

5/8 0.4 (11.8)

3/4 0.6 (17.7 )

7/8 0.9 (26.6)

1-1/8 1.8 (53.2 )

1-3/8 3.3 (97.6)

1-5/8 5.5 (162.7 )

5 Pi pin g and Refrigeran t Requirements

41

5.2.5 Evacuation, Leak Testing, and Charging Air CooledSystems withoutLiebertLee-Temp™ Receivers

Two discharge lines and two liquid lines must be field-installed between the indoor unit and the outdoor condenser. See the appropriate piping schematic, listed in Piping General Arrangement Drawings on page29.

Evacuation and Leak Testing Air Cooled SystemswithoutLiebertLee-Temp™

For proper leak-check and evacuation, you must open all system valves and account for all check valves.

NOTE: The system includes a factory-installed check valve and an additional downstream Schrader valve with core in the compressor discharge line. Proper evacuation of the condenser side of the compressor can be accomplished only using the downstream Schrader valve. See the appropriate piping schematic for your system in the submittaldrawings appendix.

1. If unit power is available, open the unit liquid-line solenoid valves using the evacuation function for System #1 and System #2 in the diagnostic section of the Liebert® iCOM™ controller. – or – If unit power is not available, connect a field supplied 24-VAC/75-VA power source directly to the unit solenoid valve.

2. Connect refrigerant gauges to the suction rotalock valves and discharge-line Schrader valves on both compressors.

3. Starting with Circuit #1, open the service valves and place a 150 PSIG (1034kPa) of dry nitrogen with a tracer of refrigerant. Check system for leaks with a suitable leak detector.

4. With pressure still in Circuit #1, open the compressor service valves in Circuit#2.

• If pressure increases in Circuit#2, the system is cross-circuited and must be re-checked for proper piping.

• If there is no pressure increase, repeat step3 on Circuit#2.

5. After completion of leak testing, release the test pressure, (observe local code) and pull an initial deep vacuum of 500 microns on the system with a suitable pump.

6. After 4hours, check the pressure readings and, if they have not changed, break vacuum with dry nitrogen. Pull a second and third vacuum to 500 microns or less. Re-check the pressure after 2hours.

7. When the 3 checks are complete, proceed to ChargingAir Cooled Systems without LiebertLee-Temp below.

ChargingAir Cooled Systems without LiebertLee-Temp

NOTICE

Risk of improper refrigerant charging. Can cause equipment damage.

R-407C is a blended refrigerant and must be introduced and charged from the cylinder only as a liquid.

When adding liquid refrigerant to an operating system, it may be necessary to add the refrigerant through the compressor suction service valve. Care must be exercised to avoid damage to the compressor. We recommend connecting a sight glass between the charging hose and the compressor suction service valve. This will permit adjustment of the cylinder hand valve so that liquid can leave the cylinder while allowing vapor to enter the compressor.

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Vertiv | Liebert® DS ™ In staller/User Guide

NOTICE

Risk of refrigerant overcharge. Can cause equipment damage.

Do not use the sight glass as an indicator when charging Liebert®condenser systems.

NOTE: A digital scroll compressor can have a clear unit sight glass on the liquid line only when operating at 100% capacity. When operating below 100%, the unit sight glass may show bubbles with each 15 second unloading cycle.

The system must be fully piped and evacuated before it can be charged. See Evacuation and Leak Testing Air Cooled

SystemswithoutLiebertLee-Temp™ on the previous page.

Liebert® MC condensers are charge-sensitive and require accurate calculation of the system charge to avoid overcharging. To avoid overcharge, the following additional guidelines are recommended to ensure trouble-free operation.

• When charging system in an outdoor ambient below 50°F (10°C), recheck the subcooling against Table 4.11 on the next page, when the ambient is above 60°F (15.6°C)

• The indoor space should be maintained at 70 to 80°F (21 to 26.7°C) return air before final charge adjustments are made.

• Charging unit at greater than 80°F (26.7°C) return air and low outdoor ambient temperature may result in the unit being overcharged.

• Charge by subcooling measurement at the indoor unit. See Table 4.11 on the next page, for target subcooling temperatures.

• Pressure and temperature measuring instruments should be capable of measuring to ±10psig (68.9kPa) and ± 2°F (1.1°C) for best subcooling measurement.

To charge the system:

1. Check the nameplate on the indoor unit for refrigerant type to be used. Unit control configurations differ depending on refrigerant type.

2. The unit must be operating. Refer to the following if necessary:

• Checklist for Completed Installation on page83 to operate the system.

• The operating manual for the Liebert® MC Condenser.

Manuals are available at https://www.Vertiv.com/en-us/support/.

3. Calculate the amount of charge for the system. See Refrigerant Charge Requirements for Air Cooled Systems on page37.

4. Accurately weigh in as much of the system charge as possible before starting the unit. Do not exceed the calculated charge by more than 0.5 lb (0.23kg).

5. Close the Liebert® MC disconnect switch.

6. Close the Liebert® DS disconnect switch.

5 Pi pin g and Refrigeran t Requirements

43

7. In the Service menu of the Liebert® iCOM controller, select Diagnostics/Service > Diagnostics:

a. Enable Manual Mode.

NOTE: Manual Mode will time out after 30 minutes.

b. In Evaporator Fan options set Motors to On to operate the fan during Manual Mode.

c. In Compressor Circuit 1 options, set Compressor Mode to Charge to operate the compressor at full

capacity, energize the liquid-line solenoid valve, and disable reheat and humidifier.

d. Reset the charge function as many times as needed to complete unit charging.

NOTE: You must establish and maintain a minimum 20psig (138kPa) for the compressor to operate.

8. Attach pressure and temperature instruments to the liquid-line of the indoor unit, measure the initial subcooling, and continue to add charge until the recommended subcooling for the current outdoor ambient temperature is reached. See Table 4.11 below. Read the outdoor ambient temperature from the Liebert® MC condenser control menu ID F02.

NOTE: To determine subcooling measurement, you must measure the liquid-line pressure reading (at the factoryinstalled Schrader tap) and obtain a temperature reading on the liquid line. Convert the liquid-line pressure reading into a liquid temperature using a Pressure-Temperature Guide or Table 4.12 on the facing page. Subtract the measured temperature from the saturated-liquid temperature. The difference is subcooling. Make sure to use the saturated liquid temperature to calculate subcooling.

9. As head pressure builds, the variable-fan-speed controlled condenser fan begins rotating. The fan will run at full speed when sufficient head pressure is developed.

Table 4.11 Target Subcooling forAmbientOutdoor

Temperature

Ambient Temp, °F(°C) Subcoo ling, °F(°C)

0 (-17.8) 22 (12.0 )

10 (-12.2) 22 (12.0 )

20 (-6.7) 22 (12.0)

30 (-1. 1) 22 (12.0)

40 (4.4) 22 (12.0)

50 (10.0) 21 (11.7)

60 (15. 6) 19 (10. 8)

70 (21.1) 17 (9.3)

80 (26.7) 13 (7.2)

90 (32. 2) 9 (5.0)

95 (35.0) 7 (3.9)

100 (37. 8) 5 (2.9)

105 (40.6) 3 (1.8)

110 (43.3) 1 (0.7 )

125 (51.7) 0

DPN002411, Rev. 8

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Vertiv | Liebert® DS ™ In staller/User Guide

Table 4.12 Liquid Pressure andTemperature Chart—R-407C

Pressure Temperature* Temperature*

PSIG BarG °F °C

170 1 1. 7 81.5 27.5

180 1 2.4 85.1 29.5

190 13.1 88.6 31.5

200 13.8 92.0 33.3

210 14.5 95.2 35.1

220 15.2 98.3 36.8

230 15. 9 101.4 38.5

240 16.6 104.3 40. 2

250 17.2 107.2 41.8

260 17. 9 1 09.9 43.3

270 18.6 11 2. 6 44.8

280 19.3 115.3 46.3

290 20.0 117.8 47. 7

300 20. 7 120. 3 49.1

310 21. 4 122. 8 50.4

320 22. 1 125.2 51.8

330 22.8 127.5 53.1

340 23.4 129.8 54.3

350 24.1 132.1 55.6

360 24.8 1 34.3 56.8

370 25.5 136.4 58.0

380 26.2 1 38.6 59.2

390 26.9 140. 6 60.3

400 27.6 142.7 61.5

500 34.5 161. 3 71. 8

600 41.4 177.4 80.8

* Values are for saturated liquid

Source: DPN002411, Rev. 8

5 Pi pin g and Refrigeran t Requirements

45

5.2.6 Evacuation, Leak Testing, and Charging Air Cooled Systems withLiebertLee-Temp™ “Flooded Condenser” Head PressureControlSystem

The Liebert® Lee-Temp system consists of a modulating-type head-pressure control valve and insulated receiver with heater pad to ensure operation at ambient temperatures as low as -30°F (-34.4°C).

Two discharge lines and two liquid lines must be field-installed between the indoor unit and the outdoor condenser. See the appropriate piping schematic, listed in Piping General Arrangement Drawings on page29.

Liebert® Lee-Temp Controlled Materials Supplied

• Built-in, pre-wired condenser control box

• Air-cooled condenser

• Piping access cover

• Bolts—4per leg (3/8in. x 5/8in.)

• Terminal block for 2 wire, 24V interlock connection between unit and condenser

• Terminal blocks for shielded, CANbus-cable connection between unit and condenser

• Condenser legs—6with 2 fan units, 8 with 2 , 3, and 4 fan units

• Bolts—6per receiver (3/8in. x 1in.)

• Liebert® Lee-Temp system:

• Insulated storage receiver with (2) liquid-level sight glasses—1 per circuit

• Head-pressure control-valve piping assembly with (2) integral check valves—1 per circuit

• Service valve—1 per receiver

• Pressure-relief valve—1 per receiver

NOTE: The Lee-Temp heater pad requires a separate, continuous electrical source. See nameplate on receiver for proper voltage.

Evacuation and Leak Testing Air Cooled Systems withLiebertLee-Temp Receiver

For proper leak check and evacuation, you must open all system valves and account for all check valves.

NOTE: The system includes a factory-installed check valve and an additional downstream Schrader valve with core in the compressor discharge line. Proper evacuation of the condenser side of the compressor can be accomplished only using the downstream Schrader valve. See the appropriate piping schematic for your system in Submittal Drawings on page139.

1. If unit power is available, open the unit liquid-line solenoid valve using the evacuation function in the diagnostic section of the Liebert® iCOM® control. – or – If unit power is not available, connect a field-supplied 24-VAC/75-VA power source directly to the unit solenoid valve.

2. Connect a jumper hose from the service-valve fitting on the outlet of the receiver and the Schrader fitting on the discharge header of the condenser. Seat the service valve approximately twoturns from the fully backseated position.

3. On both compressors, connect refrigerant gauges to the suction rotalock valves and discharge-line Schrader valves.

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4. Starting with Circuit #1, open the service valves and place a 150 PSIG (1034kPa) of dry nitrogen with a tracer of refrigerant. Check system for leaks with a suitable leak detector.

5. With pressure still in Circuit #1, open the compressor service valves in Circuit#2.

• If pressure increases in Circuit#2, the system is cross-circuited and must be re-checked for proper piping.

• If there is no pressure increase, repeat step4 on Circuit#2.

6. After completion of leak testing, release the test pressure, (observe local code) and pull an initial deep vacuum of 500microns on the system with a suitable pump.

7. After 4hours, check the pressure readings and, if they have not changed, break vacuum with dry nitrogen. Pull a second and third vacuum to 500 microns or less. Re-check the pressure after 2hours. When the 3 checks are complete, remove the jumper hose from the service-valve fitting and the condenser, and proceed to Charging Air Cooled Systems withLiebertLee-Temp Receiver below.

Charging Air Cooled Systems withLiebertLee-Temp Receiver

NOTICE

Risk of improper refrigerant charging. Can cause equipment damage.

R-407C is a blended refrigerant and must be introduced and charged from the cylinder only as a liquid.

When adding liquid refrigerant to an operating system, it may be necessary to add the refrigerant through the compressor suction service valve. Care must be exercised to avoid damage to the compressor. We recommend connecting a sight glass between the charging hose and the compressor suction service valve. This will permit adjustment of the cylinder hand valve so that liquid can leave the cylinder while allowing vapor to enter the compressor.

To charge the system:

1. Check the nameplate on the indoor unit for refrigerant type to be used. Unit control configurations differ depending on refrigerant type.

2. The unit must be operating during charging, refer to Checklist for Completed Installation on page83.

3. Calculate the amount of charge for the system. See Refrigerant Charge Requirements for Air Cooled Systems on page37.

4. Accurately weigh in as much of the system charge as possible before starting the unit.

5. Close the Liebert® MC disconnect switch.

6. Close the Liebert® DS disconnect switch.

7. In the Service menu of the Liebert® iCOM controller, select Diagnostics/Service > Diagnostics:

a. Enable Manual Mode.

NOTE: Manual Mode will time out after 30 minutes.

b. In Evaporator Fan options set Motors to On to operate the fan during Manual Mode.

c. In Compressor Circuit 1 options, set Compressor Mode to Charge to operate the compressor at full

capacity, energize the liquid-line solenoid valve, and disable reheat and humidifier.

d. Reset the charge function as many times as needed to complete unit charging.

NOTE: You must establish and maintain a minimum 20psig (138kPa) for the compressor to operate.

e. Repeat step 7 for Compressor Circuit 2.

5 Pi pin g and Refrigeran t Requirements

47

8. Check the refrigerant level in the refrigerant-level sight glass on each Lee-Temp receiver after the unit has been operating for at least 15minutes.

NOTE: Each receiver at the condenser has 2 sight glasses and the refrigerant level varies with outside temperature.

9. Adjust the refrigerant level in each circuit to meet the level shown in Target Refrigerant Level in Sight Glasses

at Outdoor Temperatures below.

10. After adjusting the refrigerant, allow the system to operate an additional 15minutes before checking for the need of further adjustment.

NOTE: A digital-scroll compressor can have a clear unit sight glass on the liquid line only when operating at 100% capacity. When operating with a receiver, the unit sight glass might not become clear even when operating at 100% capacity. When operating below 100%, the unit sight glass may show bubbles with each 15-second unloading cycle.

Target Refrigerant Level in Sight Glasses at Outdoor Temperatures

• 40°F (4.5°C) and lower—bottom sight glass is 3/4 full

• 40 to 60°F (4.5 to 15.5°C)—bottom sight glass is full

• 60°F (15.5°C) and higher—top sight glass is 3/4 full

5.3 Refrigerant Charge for Water/Glycol Cooled Systems

The water/glycol cooled system is factory-charged and includes and includes a Paradenser™ condenser and control valves.

Table 4.13 Approximate R-407C Refrigerant Factory Charge forWater/Glycol Cooled Liebert DS

System Type Model

Charge per C ircuit,

lb (kg)

035, 042 12.2 (5.6)

Water, Glycol/GLYCOOL

053, 07 0, 077 1 7. 0 (7.8)

105 22.5 (10.3)

Table 4.14 Water/Glycol Cooled and GLYCOOL Suction Pressure Transducer Settings

Fun ction

Gauge (Sea Level) psiG (kPa) Abso lute psiA (kPa)

Minimum to Start-Cooling 50 (345) 65 (448)

Freeze P rotection (DX w/Econ-O-Coil) 52 (358) 67 (461)

R-407C

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5.4 Water/Glycol Loop Piping Guidelines

WARNING! Risk of improper piping installation, leak checking, fluid chemistry and fluid maintenance can cause equipment damage and personal injury. Installation and service of this equipment should be done only by qualified personnel who have been specially-trained in the installation of air-conditioning equipment and who are wearing appropriate, OSHA-approved PPE.

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 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.

5 Pi pin g and Refrigeran t Requirements

49

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.

Refer to the appropriate piping general-arrangement schematics for your system for the recommended, field-installed hardware such as shut-off valves. See Table 4.1 on page29.

• Use copper piping with a brazing alloy with a minimum temperature of 1350°F (732°C), such as Sil-Fos. Avoid soft solders, such as 50/50 or 95/5.

• Follow local piping codes and safety codes.

• Qualified personnel must install and inspect system piping.

• The water/glycol-cooled system will operate in conjunction with a cooling tower, city water or drycooler.

• Contact a local water consultant regarding water quality, corrosion protection and freeze-protection requirements.

• Install manual shut-off valves at the supply and return line to each indoor unit and drycooler to permit routine service and emergency isolation of the unit.

• Install a monitored, fluid-detection system that is wired to activate the automatic closure 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 coolantfluid system pressure in case of a catastrophic fluid leak.

5.4.1 Leak Checking for Unit and Field Installed Piping

The fluid systems in the Liebert® DS are factory-checked for leaks and may be shipped with an inert-gas holding charge. At installation, check all fluid circuits for leaks.

NOTE: We recommend isolating the unit with field-installed shutoff valves during leak checking of field-installed piping. When the units are included in a leak test, use of fluid for pressure testing is recommended. When pressurized gas is used for leak testing the unit, the maximum recommended pressure is 30 psig (207kPa) and tightness of the unit should be verified by pressure decay over time, (<2 psig/hour [13.8kPa/hour]) or sensing a tracer gas with suitable instrumentation. Dry seals in fluid valves and pumps may not hold a high gas pressure.

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6 ELECTRICAL CONNECTIONS

Three-phase electrical service is required for all models. Electrical service must conform to national and local electrical codes. Refer to equipment nameplate regarding wire size and circuit protection requirements. Refer to electrical schematic when making connections. Refer the appropriate submittal drawing, listed in Electrical Field-connection Drawings on the next page, for electrical service entrances into unit.

A manual electrical disconnect switch should be installed in accordance with local codes and distribution system. Consult local codes for external disconnect requirements.

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 improper wiring, piping, moving, lifting and handling. Can cause equipment damage, serious injury or death. Installation and service of this equipment should be done only by qualified personnel who have been specially-trained in the installation of air-conditioning equipment and who are wearing appropriate, OSHA-approved PPE.

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

WARNING! Risk of improper wire sizing/rating and loose electrical connections. Can cause overheated wire and electrical connection terminals resulting in smoke, fire, equipment and building damage, injury or death. Use correctly sized copper wire only and verify that all electrical connections are tight before turning power On. Check all electrical connections periodically and tighten as necessary.

NOTICE

Risk of improper electrical connection of three-phase input power. Can cause backward compressor rotation and unit damage. Service technicians should use a gauge set on the system during the initial start up to verify that the three-phase power is connected properly. The EC fans are not a reliable indicator of proper connection. The blowers will rotate the same direction, regardless of the three-phase power input. Three-phase power must be connected to the unit line voltage terminals in the proper sequence so that the compressors rotate in the proper direction. Incoming power must be properly phased to prevent compressors from running backward. We recommend checking the unit’s phasing with proper instrumentation to ensure that power connections were made correctly. We also recommend verifying discharge and suction pressures during start up to ensure that the compressors are running in the correct direction.

6 Electrical Connections

51

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.

See transformer label for primary tap connections. Installer will need to change transformer primary taps if applied unit voltage is other than pre-wired tap voltage.

The electrical connections are described in the submittal documents included in the Submittal Drawings on page139.

The following tables list the relevant documents by number and title.

Table 5.1 Electrical Field-connection Drawings

Docu ment Number Title

DPN004352 Electrical Field Connection Description Upflow and Downflow Models

DPN003267 CANbus and Interlock Connections between Liebert DSa nd Liebert MC Condenser (Premium)

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7 EC FANS AND PLENUMS

Depending on the air-distribution options of your unit, you may have EC fans and/or plenums to install.

7.1 Downflow Units with EC Fans

DS downflow models are equipped with EC fans that may operate in the fully-raised position or lowered into the floor stand for increased efficiency from reduced air resistance.

WARNING! Risk of very heavy 125-lb (56.7-kg) fan modules dropping downward suddenly. Can cause injury or death. Support fan modules before removing mounting hardware. Use caution to keep body parts out of the fan modules pathway during repositioning. Only properly trained and qualified personnel should work on this equipment.

CAUTION: Risk of improper handling of 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.

NOTE: Use fans either in their original raised position or with the fans in their fully-lowered position. Suspension of fans in an intermediate position will directly affect product performance and is not recommended.

7.1.1 Lowering the EC Fans into the Floor Stand on Downflow Models

NOTE: If your floor-stand height is between 9in.(228.6mm) and 21in. (533.5mm), please contact the factory before attempting to lower the fans into the floor stand. If the floor-stand height is 24in. (609.6mm) up to 48in. (1219.2mm), the fans can be installed and lowered into the floor stand.

Tools Needed

• 1/2-in. hex socket and wrench

• Factory-supplied jack, crank and jack support

• Cable tie cutter

To lower the fans:

1. Remove the middle and bottom panels from the front of the unit.

2. For ease of fan lowering, We recommend removing the infrared humidifier.

3. Position the factory-supplied jack and jack support under the fan to be lowered.

4. Raise the jack to safely support the fan before removing any hardware.

NOTE: The jack should be centered between the first and second set of tabs on the jack support (see Detail A in Figure 6.1 on the next page).

7 EC Fans and Plen ums

53

5. Cut and remove the cable tie that holds the wiring loop to the blower mounting plate. All other cable ties that route the fan wiring should remain intact.

6. Remove the six 1/2” hex head screws. Retain the hardware for later use.

Figure 6.1 Lowering EC Fans into Floor Stand, Steps 1 through 6

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7. Using the jack, lower the fan module slowly until it rests on the frame of the unit.

NOTICE

Risk of equipment snagging cables and wiring. Can damage the unit wiring and components.

Carefully monitor the position of the EC-fan wire harnesses and other parts while lowering the fan to be sure that they are not caught or pinched.

8. Secure the fan module in the fully lowered position by reinstalling the hex head screws directly to the frame. Screw clearance holes are provided in the fan module.

NOTE: Not all hardware retained will be used to secure the fans in the lowered positioned.

9. Repeat steps 3 through 8 to lower remaining fan modules.

Figure 6.2 Lowering EC fans into floor, steps 7 through 8

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55

7.2 Upflow Unit Plenums with EC Fans

EC fans on upflow units are mounted external to the unit in a factory-provided plenum. The plenum distributes air to the conditioned space through adjustable, double-deflection grilles, or connects with field-supplied duct work.

Read all instructions before installing plenums and EC fans.

WARNING! Risk of electric shock and contact with high-speed moving parts. Open all local and remote electric power-supply disconnect switches, verify with a voltmeter that power is off, and visually verify that all fans have stopped rotating before opening doors, removing panels, and working within the unit cabinet. This unit may start and stop operating automatically. Do not assume that electric power is off when the unit is not operating.

WARNING! Risk of contact with sharp edges, exposed fasteners, and improper handling of very heavy parts. Can cause equipment damage, injury or death. Use extreme caution, wear appropriate, OSHA-approved PPE, and install the EC fan(s) and plenum to the unit only as described in these instructions.

More than one person may be required to complete the assembly and installation. Installer(s) must be properly trained and qualified to lift, move and manipulate very heavy equipment from floor level to the top of the unit.

Wear appropriate, OSHA-approved PPE when moving, lifting and installing the fan(s) and plenum.

Equipment used in moving, lifting and installing the fan(s) and plenum must meet OSHA requirements and be rated for the weight of the fan(s) and plenum. If ladders are used, verify that they are rated for the combined weight of the fan(s), plenum and installer(s) as loaded. EC Fan and plenum weights are specified in Table 6.1 on the facing page and Table 6.2 on the facing page.

Read and follow the lifting equipment and/or ladder manufacturer's operating instructions and safety requirements.

NOTE: Grilled plenums are intended for use in upflow configurations only. Non-grilled plenums provide service access on upflow units with duct work.

NOTE: We recommend using a duct lift or scissors lift when installing the EC-fan assemblies on top of the unit.

Figure 6.3 Equipment recommended to install the upflow plenum and EC fans

• Ladders

• Over-head winch or crane

• Duct lift

• Lift chains with hooks

• Scissor lift

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7.2.1 Assembly Inspection

1. Inspect all items for visible or concealed damage. Immediately report any damage to the carrier and file a damage claim, sending a copy of the claim to your local sales representative.

2. Move to the installation location, remove items from packaging and verify that the assembly number is correct:

• Refer to Table 6.1 below to verify plenum number by unit length, plenum height, quantity, and grille size.

• If a compressor-section plenum is included, refer to Table 6.4 on page60 to verify plenum number by size.

• Refer to Table 6.2 below to verify EC fan number by unit voltage.

• Verify that the fan-motor voltage rating is appropriate for the marked voltage rating of the cooling unit.

3. Verify that all assembly contents are present:

• Refer to Figure 6.4 on the next page and Table 6.3 on page59 to verify plenum parts.

• If a compressor-section plenum is included, refer to Figure 6.5 on page60 and Table 6.4 on page60 to verify plenum parts.

• Refer to on page61 to verify EC-fan parts.

Table 6.1 Plenum Assembly Numbers, Plenum Heights, Plenum Weights andUnitLengths

Plenum Height: 24 in . (610 mm) 30 in. (762 mm) 36 in. (917 mm )

Unit Description Assembly Number and Weight

VS105, Unit Length 1 32 in. (3353 mm)

Non-grilled plenum, length 1 05 in. (2673mm) 311666G1 - 1 31 lb (59kg) 31 1666G2 - 162 lb (74 kg) 311666G3 - 188 lb (85 kg)

Front discharge, length 105 in. (2673mm) 3117 76G1 - 206 lb (93 kg) — —

Rear discharge, length105 in. (2673mm) 31230G1 - 220 lb (100 kg) — —

VS053–077, Unit Length 109 in. (2769 mm)/98 in. (2489 mm )

Non-grilled plenum, length 82 in. (2089mm) 312208G1 - 112 lb (51 kg) 312208G2 - 136 lb (62 kg) 3122 08G3 - 156 lb (71 kg)

Front discharge, length 82 in. (2089mm) 31298G1 - 160 lb (73 kg) — —

Rear discharge, length82 in. (2089mm) 312411 G1 - 1 73 lb (79 kg) — —

VS028–042, Unit Length 73 in. (1854 mm)/86 in. (2184 mm)

Non-grilled plenum, length 59 in. (1505mm) 31 307 7G1 - 85 lb (39kg) 31 3077G2 - 105 lb (48 kg) 31307 7G3 - 123 lb (56 kg)

Front discharge, length 59 in. (1505mm) 312980G1 - 126 lb (57 kg) — —

Rear discharge, length59 in. (1505mm) 313025G1 - 129 lb (59 kg) — —

Table 6.2 EC-fan Assembly Numbers, Weights and Voltage

Assembly no. andweight Fan size (No minal) Vo ltage / kW Unit Size

312583G1 - 93 lb (42 kg)

20 in. (500 mm)

312583G2 -93 lb (42 kg) 208 V / 2.7 kW VS105

460 V / 2 .5 kW VS105

312583G3 - 102 lb (46 kg)

312583G4 - 102 lb (46 kg) 208 V / 2.9 kW

7 EC Fans and Plen ums

22 in. (560 mm)

460 V / 3.1 kW

VS053 / 070/ 077

57

Table 6.2 EC-fan Assembly Numbers, Weights and Voltage (continued)

Assembly no. andweight Fan size (No minal) Vo ltage / kW Unit Size

312583G5 - 119 lb (54 kg)

312583G6 - 119 lb (54 kg) 208 V / 2. 9 kW

312583G7 - 141 lb (64 kg) 460 V / 4.0 kW VS042

25 in. (630 mm)

460 V / 2 .8 kW

VS028 / 035

Plenum Parts Identification

Figure 6.4 Plenum Parts Identification

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NOTE: Not all parts are used in all models:

NOTE: Units shorter than 132 in. (3353 mm) do not include short front and rear grilled panels or channel panels.

NOTE: Only non-grilled plenums on 132-in. (3353-mm) units include a plenum brace.

NOTE: Units shorter than 132 in. (3353 mm) have only 1 top panel (with holes).

NOTE: Front-discharge units do not include a top frame or channel frames. 86-in. (2184mm) and 73-in. (1854mm) units do not include channel frames or panel-mounting brackets.

Table 6.3 Plenum Parts and Quantities

Item Description Quantity

1 Top panel (with holes) 1

2 Top panel (plain) 1

3 Side panel 2

4 Top-panel brace (Non-grilled plenum) 1

5 Angle bracket, 59-in. - 105-in. 1

6 Front/Rear solidpanel 1

7 Top-panel brace (Rear-discharge plenum) 1

8 P anel mounting bracket 1 or 2

9 Channel frame varies

10 Front solid panel 1

11 Top frame 1

12 Short front grilled panel 1

13 Front grilled panel 1

14 Channel panel 1 or 2

15 Assembly v iew of long and short front/rear grilledpanels N/A

16 Assembly view of front solid panel. N/A

Not shown Angle bracket varies

Not shown Washer 1/4 varies

Not shown B olt 1/4-20 x 1 varies

Not shown Sheet-metal screw #8-18 x 1 /2 varies

Not shown Insulation tape varies

7 EC Fans and Plen ums

59

Compressor Plenum Parts Identification

Table 6.4 Compressor Plenum Assembly Numbers, Weights and Size

Assembly no. andweight Plenum size, in. (mm)

313202G1 - 33 lb (15 kg) 26 x 24 (660 x 610)

313202G2 - 37 lb (17 kg) 26 x 30 (660 x 7 62)

313202G3 - 42 lb (19 kg) 26 x 36 (660 x 914)

313202G4 -26 lb (12 kg) 15 x 24 (381 x 610)

313202G5 - 29 lb (13 kg) 1 5 x 30 (381 x 762)

313202G6 -31 lb (14 kg) 1 5 x 36 (381 x 914)

313202G7 - 24 lb (11 kg) 13 x 24 (330 x 610)

313202G8 - 26 lb (12 kg) 1 3 x 30 (330 x 762)

313202G9 -29 lb (13 kg) 13 x 36 (330 x 914)

313202G10 - 27 lb (11 kg) 17 x 24 (432 x 610)

313202G11 - 30 lb (14 kg) 17 x 30 (432 x 762)

313202G12 - 33 lb (15 kg) 17 x 36 (432 x 914)

Figure 6.5 Compressor Plenum Parts Identification

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NOTE: Not all parts are used in all plenum sizes: 26 in. (660mm) wide compressor plenums include 3 angle-mounting brackets and a front panel with quarter-turn fasteners.

NOTE: Compressor plenums shorter than 26 in. (660mm) include 2angle mounting brackets and do not include a front panel with quarter-turn fasteners.

Table 6.5 Compressor plenum parts and

quantities

Item Description Quantity

1 Front/Rear panel 1 or 2

2 Angle-mounting channel 2 or 3

3 Angle-mounting bracket 2

4 Front panel with quarter-turn fasteners 1

5 Side panel 1

Not shown Sheet-metal screw varies

EC Fan Parts Identification

Figure 6.6 EC Fan Assembly

7 EC Fans and Plen ums

Item Description Quantity

Not shown Washer 6

Not shown B olt 6

Not shown Spacer 6

61

7.2.2 Assemble Plenum Rear and Side Panels

NOTE: Grilles can be installed on different sides of the plenum depending on discharge configuration. Verify grill location and install according to facility-layout plans.

NOTE: Electrical connections and some piping connections are made through the plenum. Plan accordingly.

1. Apply factory-supplied gasket/insulation tape to plenum panels, Figure 6.7 on the facing page:

• On front solid panels install the gasketing on the inner edge of the sides, and along the top and bottom edges.

• On front and rear grilled panels, install the gasketing on the inner edge of the sides, and along the top and bottom edges, except on 105-in. (2673-mm) plenums, do not install gasketing along the edges where the short and long panel connect.

• On rear solid panels, install the gasketing on the inner edge of the sides and along the bottom edge only.

• On side panels, install the gasketing along the bottom edge.

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Figure 6.7 Apply Gasket/Insulation Tape

7 EC Fans and Plen ums

Item Description

1 Gasketing/Insulationtape

2 Frontsolid panel, Front and Rear grilled panels

3 Rear solid panel

4 Side panel

63

2. If assembling a solid rear plenum or a grilled rear plenum shorter than 105in. (2673mm), skip tostep 3. – or – If assembling a 105-in. (2676mm) grilled, rear plenum, attach the long and short panel together using the channel panel and sheet-metal screws as shown inFigure 6.8 below.

Figure 6.8 105-in. Grilled Rear Panel Assembly

Item Description

1 Short rear panel

2 Channel panel

3 Long rea r panel

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3. Attach the 2 side panels to each end of the rear-panel assembly using 10 sheet-metal screws as shown in Figure

6.9 below.

NOTE: Figure 6.9 below, shows a non-grilled rear plenum as an example. If your unit is rear-discharge, the rear plenum panels have grilles.

Figure 6.9 Attach Side Panels to Rear Panel

7 EC Fans and Plen ums

Item Description

1 Side panel

65

7.2.3 Place Assembled Panels and EC Fans on Top of Unit

1. Lift the assembled plenum panels and place on top of the unit, Figure 6.10 below.

2. If assembling a solid rear plenum or a grilled rear plenum shorter than 105in. (2673mm), attach the rear-panel assembly using the angle bracket as shown in Figure 6.10 below. – or – If assembling a 105 in. (2676mm) grilled, attach the rear-panel assembly using two angle brackets and sheetmetal screws as shown in Figure 6.10 below.

Figure 6.10 Rear Panel Assembly Attached to Top of Unit

Item Description

1 Solid rear-panel attachment

2 Grilled rear-panel attachment

3 Sheet-metal screw

4 Angle bracket, 59-in. – 105-in.

5 Angle bracket

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3. Refer to Figure 6.11 below, for the recommended clearance from bottom of the unit to the top of the plenum for access to install the fan(s).

• Place an EC-fan assembly on the lifting device. (Figure 6.11 below, shows a duct lift as one option to lift the EC-fan assembly.)

• Position the lifting device so that it lines-up with the installation location of the EC-fan assembly.

• Use the device to lift the EC-fan assembly just above the top of the unit.

Figure 6.11 EC Fan Assembly Positioned for Lifting

Item Description

1 Access clearance area of 36 in. (914mm) fromtopto bottom of unit

4. Using the handles on the EC-fan assembly, carefully lift the assembly over the hinge along the top of the unit, and slide the assembly onto the top of the unit.

5. Align the mounting holes on the base of the assembly with the threaded holes on top of the unit depending on the size of the unit:

• For all unit sizes except for 73 in. and 85 in. single-fan units, skip to step 7.

• For 73 in. and 85 in. single-fan units, continue with step 6.

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67

6. Refer to Figure 6.12 below. The single-fan 73-in. and 85-in. units have 2 sets of mounting holes depending on discharge direction:

• On rear-discharge plenums, align the mounting holes on the EC-fan assembly with threaded holes on the unit labeled 2 in Figure 6.12 below.

• On top-discharge and front-discharge plenums, align the mounting holes with the threaded holes on the unit labeled 1 in Figure 6.12 below.

Figure 6.12 EC Fan mounting Hole Alignment for 73 in. and 85 in. Units

Item Description

1 Threaded mounting holes for top-discharge and front-discharge plenums.

2 Threaded mounting holesfor rear-discharge plenums.

3 Front of the unit.

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7. Align the mounting holes on the base of the assembly with the threaded holes on top of the unit, Figure 6.13 below.

Figure 6.13 Assembly in Place on the Unit

Item Description

1 Mounting holes

8. Use the bolts, washers and spacers, Figure 6.14 below, to attach the assembly to the unit.

9. Repeat steps 3 to 8 for each EC-fan assembly.

Figure 6.14 Attach EC Fan Assembly to Top of Unit (6 Places)

7 EC Fans and Plen ums

Item Description

1 B olt

2 Washer

3 Spacer

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7.2.4 Wire the EC Fans

WARNING! Risk of cut insulation and damaged wires. Can cause short circuits, overheated wiring, smoke, fire, activation of fire suppression systems and EMS personnel, equipment damage, loss of power to fans, injury or death. Verify that all wiring connections are tight and that all wiring is contained within the junction box prior to closing and securing the cover.

Black-sleeved harness contains fan-control wires. Grey-sleeved harness contains motor high-volt connection.

1. Refer to Figure 6.15 below, Figure 6.16 on the facing page, and Figure 6.17 on page72, to route the wire harnesses and insert them into the indicated openings on the junction boxes.

• You may need to remove existing wire ties that hold the harness to the fan cage.

NOTE: Do not route the wiring over the handles on the EC-fan assembly.

2. Connect the wires inside the junction box:

• Between fan 1 and 2 on 2- and 3-fan units, refer to Figure 6.16 on the facing page.

• On single-fan or fan 3 of 3-fan units, refer to Figure 6.17 on page72.

3. Use provided wire ties to secure the wire harnesses to the fan cage to prevent harness movement when fans are running.

Figure 6.15 EC Fan Junction Boxes

Item Description

1 Junction box between fans 1 and 2 on2-and3-fan unit

2 Junction box for 1- or 3-fan unit

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Figure 6.16 Junction Box between Fans 1 and 2

NOTE: For the high-volt terminal blocks, the wire-termination torque is 16-20in-lbs.

Item Description

1 Fan (low-volt)wiring

2 Motor (high-volt)wiring

3 Green/Yellow ground wire

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Figure 6.17 Junction Box for Single Fan or Fan 3

NOTE: For the high-volt terminal blocks, the wire-termination torque is 16-20in lbs.

Item Description

1 SHLDwire from unit harness

2 Fan (low-volt) wiring

3 Motor (high-volt)wiring

4 Green/Yellow ground wire

7.2.5 Install Front Panels on Plenum

Non-grilled plenum front panels require assembly and attachment before mounting the panels, see Non-Grilled and Rear

Discharge Front Panel Assembly on the facing page.

Grilled plenums do not require a frame assembly, see Front Discharge Front Panel Assembly on page80.

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Non-Grilled and Rear Discharge Front Panel Assembly

1. Attach the panel-mounting bracket(s), Figure 6.18 below:

• Attach the right-side panel-mounting bracket to the top of the unit using 2 bolts and 2washers and to the side panel using 2 sheet-metal screws as shown in the detail view in Figure 6.18 below.

• If a second panel-mounting bracket is included, attach in the center location using 2 bolts and 2washers.

Figure 6.18 Panel Mounting Bracket Attachment

7 EC Fans and Plen ums

Item Description

1 Panel mounting bracket

2 Sheet-metal screws

3 Bolt and Washer

4 Pa nel mounting bracket

5 Detail view of right-side bracket installation. Shown from inside the plenum.

73

2. Attach the channel frame(s) to the top frame using 3 sheet-metal screws:

• For non-grilled plenums, make sure the dimple shown in Figure 6.19 below, is on the bottom flange of the top frame.

• For rear-discharge plenums, make sure the dimple shown in Figure 6.19 below, is on the top flange of the top frame.

NOTE: The number of channel frames varies depending on the size of plenum.

Figure 6.19 Channel Frame Top Attachment

Item Description

1 Sheet-metal screws

2 Top frame

3 Channel frame

4 Dimple

5 Attachment on non-grilled plenum. Shown from bottom.

6 Attachment on rear-discharge plenum. Shown from bottom.

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3. Attach the assembled top/channel frame to the side panels on top of the unit:

• For non-grilled plenums, refer to Figure 6.20 below. and use 2 sheet-metal screws on each end.

• For rear-discharge, refer to Top Frame Attachment to Sides below, and attach the smaller flange to the side panel using 2sheet-metal screws on each end.

Figure 6.20 Top Frame Attachment to Sides

7 EC Fans and Plen ums

Item Description

1 Side panel

2 Sheet-metal screws

3 Top frame

4 Attachment for non-grilled plenums. Shown from inside the plenum.

5 Attachment for rea r-discharge plenum. Shown from inside the plenum.

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4. Attach the bottom of the channel frame(s) to the top of the unit using 1 washer and 1 bolt for each, Figure 6.21 below.

Figure 6.21 Channel Frame Bottom Attachment

Item Description

1 Channel frame

2 Bolt

3 Washer

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5. For non-grilled plenums, refer to Figure 6.22 below, and attach the plenum brace to the top frame and the rear panel using 2 sheet-metal screws on each end.

Figure 6.22 Non-Grilled Plenum Plenum-Brace Attachment

7 EC Fans and Plen ums

Item Description

1 Top frame on front of plenum. Shown from inside.

2 Sheet-metal screws

3 Plenum brace

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6. For non-grilled plenums, skip to step 7. – or – For rear-discharge plenums, assemble and attach the top panels:

• If a top-panel brace and plain top panel is included, attach them to the top panel with holes using 3sheet-metal screws as shown in Figure 6.23 below.

• Attach the top panel to the side and rear panels using 18 sheet-metal screws, Figure 6.23 below.

• Attach the top panel to the top frame using 6 sheet-metal screws, Figure 6.23 below.

Figure 6.23 Rear Discharge Top Panel Assembly and Attachment

Item Description

1 Top panel (with holes)

2 Sheet-metal screws

3 Top panel (plain)

4 Top-panel brace

5 Topframe

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7. Attach the solid front panel using the quarter-turn fasteners in the panels, Figure 6.24 below.

Figure 6.24 Front Panel Attachment

Item Description

1 Front panel

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79

Front Discharge Front Panel Assembly

1. Using the channel panel and 10 sheet-metal screws, attach the grilled front panel and the short, grilled front panel, Figure 6.25 below.

2. Attach the assembled front panels to the plenum sides using 10 sheet-metal screws, 5 on each end.

Figure 6.25 Front Discharge Front Panel Attachment

Item Description

1 Channel panel

2 Short front panel

3 Front panel

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3. Assemble and attach the top panels:

• If a top-panel brace and plain top panel is included, attach them to the top panel with holes using 3sheet-metal screws as shown in Figure 6.25 on the previous page.

• Attach the top panel and to top of the plenum assembly using 39sheet-metal screws, Figure 6.26 below.

Figure 6.26 Front Discharge Top Panel Assembly and Attachment

7 EC Fans and Plen ums

Item Description

1 Top panel (withholes)

2 Sheet-metal screws

3 Top panel (plain)

4 Top-panel brace

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8 CHECKLIST FOR COMPLETED INSTALLATION

8.1 Moving and Placing Equipment

1. Unpack and check received material.

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

3. Equipment is level and mounting fasteners are tight.

4. If equipment has been disassembled for installation, unit must be reassembled per instructions.

8.2 Electrical Installation Checks

1. Supply voltage and phase matches equipment nameplate.

2. Power wiring connections completed to the disconnect switch, evaporator unit and heat rejection equipment.

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

4. Control wiring connections completed between indoor evaporator and heat-rejection equipment.

5. All internal and external high- and low-voltage wiring connections are tight.

6. Confirm that unit is properly grounded to an earth ground.

7. Control transformer setting matches incoming power.

8. Electrical service conforms to national and local codes.

9. Check blowers and compressors for proper rotation.

10. For upflow units only: Field installed low-voltage wiring routed with loop to allow electric box to swing.

8.3 Piping Installation Checks

1. Piping completed to refrigerant or coolant loop (if required).

2. Piping has been leak-checked, evacuated and charged (if required).

3. Additional oil has been added for system charges over 40 pounds (18.1kg) per circuit. See Additional Oil

Requirements forScrollandDigital ScrollCompressors on page39.

4. Piping is properly sized, sloped and trapped as shown in the piping schematics.

5. Check piping inside and outside of equipment for proper support and adequate spacing to prevent rubthrough.

6. Ensure that factory clamps have been reinstalled.

7. Drain line connected, not obstructed, and pitched per local code.

8. Water supply line connected to humidifier and not leaking.

9. Condensate drain line piping has no leaks or visible damage.

8.4 Other Installation Checks

1. Ducting or plenum assembly complete (if required), maintain access to filters.

2. Filters installed.

3. Check fasteners that secure , reheats, humidifier and motors—some may have become loose during shipment.

4. Verify water detection is properly installed around all units (recommended).

5. Humidifier control panel DIP switches are set based on user requirements.

6. Compressor shipping blocks removed and springs adjusted (see Remove Shipping Blocks

fromUnitswithSemi-HermeticCompressors on page27).

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83

7. Blower drive system rotates freely and belts are properly aligned and tensioned.

8. All fans are free of debris.

9. Remove rubber band from float in optional infrared humidifier.

10. Seal openings around piping and electrical connections.

11. Installation materials and tools have been removed from equipment (literature, shipping materials, construction materials, tools, etc.).

12. Review and complete installation checklists for heat-rejection units (condenser(s)/drycooler(s), ifincluded.

13. Locate blank start-up sheet, ready for completion by installer or start-up technician.

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9 INITIAL START UP CHECKS ANDCOMMISSIONING PROCEDUREFORWARRANTYINSPECTION

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 improper wiring, piping, moving, lifting and handling. Can cause equipment damage, serious injury or death. Installation and service of this equipment should be done only by qualified personnel who have been specially-trained in the installation of air-conditioning equipment and who are wearing appropriate, OSHA-approved PPE.

NOTICE

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.

Risk of improper electrical connection of three-phase input power. Can cause backward compressor rotation and unit damage. Service technicians should use a gauge set on the system during the initial start up to verify that the three-phase power is connected properly. The EC fans are not a reliable indicator of proper connection. The blowers will rotate the same direction, regardless of the three-phase power input. Three-phase power must be connected to the unit line voltage terminals in the proper sequence so that the compressors rotate in the proper direction. Incoming power must be properly phased to prevent compressors from running backward. We recommend checking the unit’s phasing with proper instrumentation to ensure that power connections were made correctly. We also recommend verifying discharge and suction pressures during start up to ensure that the compressors are running in the correct direction.

9 Initial Start up Checks an dCommissionin g ProcedureforWarrantyInsp ection

85

• Confirm that all items on Checklist for Completed Installation on page83 have been done.

• Locate “Liebert® DS Warranty Inspection Check Sheet” in the unit’s electric panel. (PSWI-8542-405-CO).

• Complete “Liebert® DS Warranty Inspection Check Sheet” during start-up. (PSWI-8542-405-CO).

• Forward the completed “Liebert® DS Warranty Inspection Check Sheet” to your local sales office. This information must be completed and forwarded to validate warranty.

• Contact your local sales representative or technical support if you have any questions or problems during unit start-up and commissioning. Visit https://www.Vertiv.com/en-us/support/ or call 1-800-543-2778 for contacts.

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10 MAINTENANCE

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 improper wiring, piping, moving, lifting and handling. Can cause equipment damage, serious injury or death. Installation and service of this equipment should be done only by qualified personnel who have been specially-trained in the installation of air-conditioning equipment and who are wearing appropriate, OSHA-approved PPE.

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.

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The Liebert® DS is a single component in the facility heat-removal system. The system includes air distribution (raised floors, duct systems), outdoor heat rejection (condensers, pumps, drycoolers) and indoor cooling and humidity loads (equipment load, location, outside air infiltration). Proper application and maintenance of the entire system is critical to the life and reliability of the thermal-management units.

• Good maintenance practices are essential to minimizing operation costs and maximizing product life.

• Read and follow monthly and semi-annual maintenance schedules included in this manual. These MINIMUM maintenance intervals may need to be more frequent based on site-specific conditions.

• See the Liebert®iCOM™ user manual, SL-31075, available at www.Vertiv.com, for instructions on using the controller to predict some service maintenance intervals.

• We recommend the use of trained and authorized service personnel, extended service contracts and factoryspecified replacement parts. Contact your Vertiv sales representative.

10.1 Filters

NOTICE

Risk of improper filter installation. Can cause filter collapse and airflow reduction.

Pleat direction is non-standard. Use only short-pleat filters (see Figure 9.2 on page90). Long-pleat filters are subject to collapse at high airflows.

To maximize the performance and reliability of the equipment, use only Vertiv filters. Contact your Vertiv representative to order replacement filters.

Verify that filters are installed and positioned so the air-flow direction marked on the filter is the same direction as unit air flow.

Table 9.1 Filter Quantities

035 042 053 070 077 105

Downflow Models

Quantity 3 3 4 4 4 4

Nominal Size, inches

UpflowModels (Front & Rear return)Filters located in separate filter box on rear return, located on lower unit panel

Quantity 4 4 6 6 6 8

Nominal Size, inches 25x 20 25x20 25x20 25x20 25x20 25x20

Disposable Type -Nominal Sizes and Quantities, Standard MERV 8 or Optional MERV 11; (filter types ca nnot be mixed, must be allMERV8or all MERV 11)

2 @ 25x20

1 @ 25x16

2 @ 25x20

1 @ 25x16

4 @ 25x20 4 @ 25x20 4 @ 25x20

2 @ 25x20

4 @ 25x1 6

10.1.1 Filter Replacement for Downflow Units

1. Disconnect power from the unit.

2. Open the front access panel, locate the filter above the electric panel, and slide the filter out the front of the unit.

3. Replace with new filter—install the filter in the proper direction of the airflow.

4. Test the operation of the filter clog switch. The unit panels must be in place and closed to find this point.

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5. Start the blower and turn the switch counterclockwise until the alarm is energized.

6. Turn the adjusting knob one turn clockwise or to the desired filter change point.

Figure 9.1 Proper Filter Pleat Direction

Item Description

1 Short pleat construction

2 Longpleat construction

10.1.2 Filter Replacement for Upflow Units

1. Disconnect power from the unit.

2. Open the front access panel and remove the filter(s).

• For upflow front return units, remove the lower front access panels, lift filters to the top of the filter rack and tilt forward for removal.

• For upflow rear return units, remove filters using filter access door in rear return filter box.

3. Replace with new filter—install the filters in the proper direction of the airflow. The proper direction is marked on the filter.

4. Test the operation of the filter clog switch. The unit panels must be in place and closed to find this point.

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5. Start the blower and turn the switch counterclockwise until the alarm is energized.

6. Turn the adjusting knob one turn clockwise or to the desired filter change point.

Figure 9.2 Proper Filter Pleat Direction

Item Description

1 Short pleat construction

2 Longpleat construction

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10.2 Blower Drive System—EC Fans

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.

CAUTION: 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, ductwork of gaurd 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.

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.

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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 improper installation. Can cause equipment damage.

Only a properly trained and qualified technician should install or open this motor.

Use 60/75°C Class 1 copper wire only.

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10.2.1 Protective Features

Monitoring functions protect the motor against overtemperature of electronics, overtemperature of motor and incorrect rotor position detection. With any of these failures, an alarm will display through the Liebert® iCOM controller and the motor stops electronically. There is no automatic restart. The power must be switched off for a minimum of 20 seconds once the motor is at a standstill.

The motor also provides locked rotor protection, undervoltage/phase failure detection and motor current limitation. These conditions will display an alarm through the Liebert® iCOM.

10.2.2 Fan Impellers and Bearings Maintenance

Fan impellers should be periodically inspected and any debris removed. Check to ensure that the impellers can rotate freely and that the fan guards are still properly mounted for sufficient protection against accidentally contacting the impeller. Bearings used on the units are maintenance-free. Consult the factory for more information.

10.2.3 Fan Assembly Troubleshooting

Any safety hazards stemming from the device must be re-evaluated once it is installed in the end device.

Do not make any modifications, additions or conversions to the fan assembly without the approval of Vertiv.

WARNING! Risk of electric shock. Can cause serious injury or death. Open all local and remote electric powersupply disconnect switches and verify with a voltmeter that power is off before opening the fan motor electric-connection enclosure. Use only fully-trained and qualified HVAC technicians to replace or perform maintenance on the EC fans.

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.

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) may arise. Take appropriate technical safety measures. Operating personnel must wear appropriate, OSHA-approved PPE and observe all appropriate hearing-protection safety requirements.

CAUTION: Risk of contact with hot surfaces. Can cause injury. The 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, OSHAapproved PPE when working on or near hot components.

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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.

NOTE: Do not assume that the fan blades will not start to spin. If the motor is in a fault condition, it will safely shut down. Once the fault condition is cleared, there are certain conditions in which the motor will automatically resume operation.

EC Fan Fault Conditions

Table 9.2 EC-fan Fault Conditions

Fault

Condition

Phase Failure Automatic

Locked/Blocked Rotor

Hall Effect Sensor Error

Motor O ver Temperature

Electronics Ov er Temperature

Line Under-Voltage

Reset Trigger Description

Automatic The rotoris blocked. Once the locking mechanism has been remov ed, the motor will automatically restart.

Manual (Mains/Software)

Automatic Once the line v oltage returns within permitted operating range, the fan willautomatically restart.

EC Fan High Voltage Tests

1. Check Fuses. If fuses are okay, perform the following:

• Check all connections.

• Make sure connections are on the wire strand and not on the wire insulation.

• Cycle Power. Disconnect mains voltage to power down the motor and then re-apply power.

• Check mains voltage at each phase (phase to ground) at the KL1 connector. Confirm phase failure not present.

• Check that the voltage is within the acceptable voltage range at the KL1 connector. Confirm line under-voltage is not present.

One phase is missing. In this case the motor will come to a stop and then automatically restart when all phases are present.

The Hall Effect Sensor is used to monitor fan speed. If there is a hall sensor communication failure withthe electronics, the motor will stop. In this case there has to be a manual restart (either with the ma ins power or software).

The motor will stop in the event there is a motor over temperature condition. In this case there has to be a manual restart (either with the ma ins power or software).

The motor will stop in the event there is an electronics over temperature condition. In this case there has to be a manual restart (either with the mains power or software).

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2. Check fuses. If fuses are blown, perform the following:

• Check resistances across the phases at the KL1 connector and note them in the following table..

NOTE: Power wires must be removed from the motor for resistance test.

Table 9.3 Resistances at KL1 Connector

L1 - L2 Figure 9.3 Ohm

L2 -L3 Ohm

L1 - L3 Ohm

• Resistances should be similar for all 3 readings.

• Resistance readings should be greater than 2Ohm.

• Check all connections. Make sure connections are on the wire strand and not on the wire insulation.

• Replace fuses.

• Check mains voltage at each phase (phase to ground) at the KL1 connector. Confirms phase failure not present.

Figure 9.4 KL1 Connector

• Check that the voltage is within the acceptable voltage range at the KL1 connector. Confirmsline under-voltage is not present.

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Vertiv | Liebert® DS ™ In staller/User Guide

Vaisala DS User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1 IMPORTANT SAFETY INSTRUCTIONS

2 NOMENCLATURE AND COMPONENTS

2.1 Liebert DS Model Number Nomenclature

2.2 Component Location

3.1 Planning Dimensions

3.2 Air Distribution Considerations for Downflow Units

3.3 Air Distribution Considerations for Upflow Units

3.4 Connections and System Setup

3.5 Operating Conditions

3.5.1 Cooling, Humidification and Dehumidification

3.5.2 Heating

4 EQUIPMENT INSPECTION AND HANDLING

4.1 Packaging Material

4.2 Handling the Unit while Packaged

4.3 Unpacking the Unit

4.3.1 Removing the Unit from the Skid with a Forklift

4.3.3 Moving the Unit to the Installation Location Using Piano Jacks

4.5 Placing the Unit on a Floor Stand

5 PIPING AND REFRIGERANT REQUIREMENTS

5.1 Drain and Humidifier Fluid Piping

5.1.1 Field-installed, Gravity Fed Drain Line Requirements

5.1.2 Condensate Pump Drain Line Requirements

5.1.3 Water Supply Line Requirements for the Optional Humidifier

5.2 Refrigerant Piping and Charging

5.2.2 Refrigerant Line Sizes and Equivalent Lengths

5.2.3 Refrigerant Charge Requirements for Air Cooled Systems

5.3 Refrigerant Charge for Water/Glycol Cooled Systems

5.4 Water/Glycol Loop Piping Guidelines

5.4.1 Leak Checking for Unit and Field Installed Piping

6 ELECTRICAL CONNECTIONS

7 EC FANS AND PLENUMS

7.1 Downflow Units with EC Fans

7.1.1 Lowering the EC Fans into the Floor Stand on Downflow Models

7.2 Upflow Unit Plenums with EC Fans

7.2.1 Assembly Inspection

7.2.2 Assemble Plenum Rear and Side Panels

7.2.3 Place Assembled Panels and EC Fans on Top of Unit

7.2.4 Wire the EC Fans

7.2.5 Install Front Panels on Plenum

8 CHECKLIST FOR COMPLETED INSTALLATION

8.1 Moving and Placing Equipment

8.2 Electrical Installation Checks

8.3 Piping Installation Checks

8.4 Other Installation Checks

10 MAINTENANCE

10.1 Filters

10.1.1 Filter Replacement for Downflow Units

10.1.2 Filter Replacement for Upflow Units

10.2 Blower Drive System—EC Fans

10.2.1 Protective Features

10.2.2 Fan Impellers and Bearings Maintenance

10.2.3 Fan Assembly Troubleshooting