Vertiv Liebert PFD Installer/user Manual

Liebert®

PFD™ Prop Fan Digital Condensing Unit
ThermalManagementSystems

Installer/User Guide

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.VertivCo.com/en-us/support/ for additional assistance.

Vertiv | Liebert® PFD™ Installer/User G uide

TABLE OF CONTENTS

1 Important Safety Instructions 5

1.1 Agency Listed 6

2 Nomenclature and Components 7

2.1 PFD Model Number Nomenclature 7

2.2 Component Location 8

3 Pre-installation PreparationandGuidelines 9

3.1 Planning Dimensions 9

3.1.1 Location Considerations for Outdoor Condensing Unit 9

3.2 Connections and System Setup 10

3.3 PFD Unit Weights 10

3.4 Equipment Inspection and Handling 10

4 Piping and Refrigerant Requirements 11

4.1 Refrigerant Piping 11

4.1.1 Refrigerant Piping Guidelines forAir-cooledSystems 12

4.1.2 Piping when Condensing Unit is Above or Below Evaporator 13

4.2 Refrigerant-line Sizes and Equivalent Lengths 14

4.2.1 Refrigerant Charge Requirements 14

4.2.2 Additional Oil Requirements for Digital-scroll Compressors 19

5 Electrical Connection Requirements 21

5.1 Low-voltage, Control Connections 22

6 Checklist for Completed Installation 23
7 Initial Start-up Checks andCommissioning ProcedureforWarrantyInspection 25
8 Maintenance 27

8.1 General Maintenance 28

8.2 Compressor Maintenance 28

8.2.1 Compressor Oil 28

8.2.2 Replacement Compressors 28

8.2.3 Compressor Motor Burnout 29

8.2.4 Unloading Solenoid(s) on a Digital-scroll Compressor 29

8.2.5 Replacing the Compressor 29

8.3 Condensing Unit Maintenance 30

9 Troubleshooting 31
Appendices 33

Appendix A: Technical Support and Contacts 33
Appendix B: Submittal Drawings 35

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Vertiv | Liebert® PFD™ Installer/User Guide | 4

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®PFD. 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 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 over-pressurization of the refrigeration system. Can cause explosive
discharge of high-pressure 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. Relieve pressure before cutting into or
making connections/disconnections to the piping system.
Do not close off any field-installed, refrigerant-line isolation valves 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).

WARNING! Risk of contact with high-speed, rotating fan impeller blades. Can cause 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 impellers have stopped rotating before
working in the unit cabinet.

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.

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.

1 Important Safety Instructions 5

NOTICE

NOTICE

CAUTION: Risk of contact with hot surfaces. Can cause injury. The 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.

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

Liebert®PFD 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 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
55psig (379kPa). Operation for extended periods at less than 55psig (379kPa) can cause
premature compressor failure.

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.

1.1 Agency Listed

Standard 60-Hz units are CSA Certified to the harmonized U.S. and Canadian product safety standard
CSA C22.2 No 236/UL 1995 for “Heating and Cooling Equipment” and are marked with the CSA c-us logo.

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2 NOMENCLATURE AND COMPONENTS

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

2.1 PFD Model Number Nomenclature

Table 2.2 below describes each digit of the model number.

Table 2.1 Prop-fan Condensing Unit Model-number Example

1 2 3 4 5 6 7 8 9 10 11

P F D 0 6 7 A — A L 1

Table 2.2 Model-number Digit Definitions for Outdoor, Prop-fan Condensing Units

Digit and Description

Digits 1, 2 = The base unit

PF = Prop-fan condensing unit

Digit 3 = Compressor type

D = Digital-scrollcompressor

Digit 4= Sound level

0 = Standard

Z = Quiet-Line (067 models only)

Digits 5 and 6 = Nominal Capacity, 1,000 BTU/hr

Digit 7= Unit type

A = Air-cooled

Digit 8 = Coil type

— = Standard coil

C = Coated coil

Digit 9= Supplypower

A = 460V / 3ph / 60Hz

B = 575V/ 3ph/ 60Hz(054 and067 models only)

P = 208-230 V / 1 ph / 60 Hz (037 model only)

Y = 208-230 V / 3ph/ 60Hz

Digit 10 = Head-pressure control

L = 95°F Ambient, Liebert® Lee-Temp™

H = 105°F Ambient, Liebert® Lee-Temp™ (not available on 048 model)

Digit 11= Refrigerant

1 = R-410A, field-supplied

2 Nomenclature and Components 7

2.2 Component Location

The unit component locations are described in the submittal documents included in the Submittal

Drawings on page35.

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

Table 2.3 Component-location Drawings

Document Number Title

DPN004180 PFDCondensing Unit, 3-, 4-, and 5-ton

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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 ductwork. Follow all unit dimensional drawings and refer to the submittal engineering
dimensional drawings of individual units for proper clearances.

Refer to PFD Model Number Nomenclature on page7, and submittal drawings to determine the type of
system being installed and anticipate building alterations, piping and ductwork needed.

The unit dimensions, pipe-connection locations, and piping schematics are described in the submittal
documents included in the Submittal Drawings on page35.

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

• Be mindful of the placement of the PFD in relation to the connected evaporator unit, other
outside units, barriers, and walls for air flow clearance, equivalent piping distances, and
differences in elevation between the PFD and connected evaporator unit.

• When applications do not meet or exceed any of these specifications, contact your Vertiv
representative.

3.1 Planning Dimensions

The unit dimensions described in the submittal documents included in the Submittal Drawings on
page35.

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

Table 3.1 Dimension Planning Drawings

Document Number Title

Outdoor Condensing Unit

DPN004058 Cabinet dimensions, 5-ton, top discharge

DPN004063 Cabinet dimensions, 3-, 4-, and 5-ton, horizontaldischarge

DPN004066 Optional anchoring plan, 3-, 4-, and 5-ton, horizontaldischarge

3.1.1 Location Considerations for Outdoor Condensing Unit

Observe the following when planning the installation of the outdoor unit:

• To ensure a satisfactory air supply, locate air-cooled condensing units in an environment with
clear air, away from loose dirt and foreign matter that may clog the coil.

• Condensing units must not be located in the vicinity of steam, hot air or fume exhausts or
closer than 18 inches from a wall, obstruction or adjacent unit.

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

• Avoid areas where heavy snow will accumulate at air inlet and discharge locations.

• The condensing unit should be located for maximum security and maintenance accessibility.
Avoid ground-level sites with public access. Install a solid base, capable of supporting the
weight of the condensing unit.

• The base should be at least 2in. (51mm) higher than the surrounding grade and 2 in. (51mm)
larger than the dimensions of the condensing-unit base. For snowy areas, a base of sufficient
height to clear snow accumulation must be installed.

Before beginning, refer to Piping and Refrigerant Requirements on page11 for unit placement, piping
guidelines, and refrigerant-charge requirements for your system.

The condensing unit must be located within the maximum distance from evaporator per the guidelines
listed in Pipe length and condenser elevation relative to evaporator.

3 Pre-installation PreparationandGuidelines 9

3.2 Connections and System Setup

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

• Plan the routing of wiring, piping and ductwork to the unit. Refer to the appropriate piping
connection location drawings, piping schematics, and electrical-connection drawings for your
system in .

3.3 PFD Unit Weights

Table 3.2 PFD Unit weights

Model # Weight, lb (kg)

PFD037A-L 244 (111)

PFD037A-H 351 (159)

PFD054A-L 351 (159)

PFD067A-L 351 (159)

PFD067A-H 488 (222)

PFDZ67A-L 488 (222)

3.4 Equipment Inspection and Handling

SAFETY INFORMATION

WARNING! Risk of improper moving, lifting, or handling of the unit. 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 3.2
above.

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.

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.

When the unit arrives, inspect all items for any visible or concealed damage. Report any damage to the
carrier immediately and file a damage claim. Send a copy of the claim to your Vertiv representative.

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

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4 PIPING AND REFRIGERANT REQUIREMENTS

All refrigeration connections to the unit are sweat copper. Factory-installed 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.

The pipe connection locations, piping general arrangement and schematics are described in the
submittal documents included in the Submittal Drawings on page35.

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

Table 4.1 Piping General-arrangment Drawings

Document Number Title

DPN004060 Piping arrangement, 3-, 4- and 5-ton split-system

Table 4.2 Piping Connection Drawings

Document Number Title

DPN004059 Primary connection locations, top discharge

DPN004064 Primaryconnection locations, horizontaldischarge

4.1 Refrigerant Piping

WARNING! Risk of over-pressurization of the refrigeration system. Can cause explosive
discharge of high-pressure 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. Relieve pressure before cutting into or
making connections/disconnections to the piping system.
Do not close off any field-installed, refrigerant-line isolation valves 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).

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 over­pressurization protection. The PFD condensing unit includes a factory-installed pressure-relief valve
mounted on top of the receiver. The valve is rated for a maximum working pressure of 675psig.

4 Piping and Refrigerant Requirements 11

NOTICE

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

Liebert®PFD 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.

NOTICE

Risk of improper refrigerant charging. Can cause equipment damage.

Refrigerant charge must be weighed into air-cooled compressorized systems before they are
started. Starting 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
55psig (379kPa). Operation for extended periods at less than 55psig (379kPa) can cause
premature compressor failure.

4.1.1 Refrigerant Piping Guidelines forAir-cooledSystems

• Evaporators and condensing units ship with an inert-gas holding charge. Do not vent the
evaporator and condensing unit until all refrigerant piping is in place, ready for connection to
the unit and condensing unit.

• 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.

• When sealing openings in walls and to reduce vibration transmission, use a soft, flexible
material to pack around the tubes to prevent tube damage.

• When installing remote condensing units above the evaporator, the suction gas lines should be
trapped at the evaporator. These traps will retain refrigerant oil in the off cycle. When the unit
starts, oil in the traps is carried up the vertical risers and returns to the compressors. For rises
over 25ft (7.6m), trap every 20ft (6m)or evenly-divided.

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

• Keep piping clean and dry, especially on units with R-410A 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.

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

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NOTE: All indoor and outdoor suction-line piping must have 1/2 in. minimum of insulation. All outdoor
insulation must be UV and ozone resistant.

NOTE: Proper safety equipment and proper refrigeration tools are required when working with R-410A
refrigerant. Check unit serial tag for correct refrigerant type before topping-off or recharging a system.

NOTE: Refrigerant R-410A uses a POE (polyolester) lubricant. The refrigerant must be introduced and
charged from the cylinder only as a liquid.

NOTE: When installing field piping, you must take care to protect all refrigerant lines from the
atmosphere especially when using refrigerants with POE oils. Do not allow the piping to stand open to
air for more than 15minutes. Units designed for R-410A have a compressor that contains POEoil,
which quickly absorbs water from the air. The longer that the refrigerant piping is left open to air, the
harder it will be to fully evacuate the system. If left open too long, the POE oil may require replacement
to achieve the required vacuum level.

• Refer to Refrigerant-line Sizes and Equivalent Lengths on the next page,for recommended
refrigerant piping sizes based on equivalent pipe lengths.

• Refer to Refrigerant Charge Requirements on the next page, for the refrigerant-charge
requirements of the system.

4.1.2 Piping when Condensing Unit is Above or Below Evaporator

Refer to Table 4.3 below for the maximum vertical rise/fall between condensing unit and evaporator.

When installing remote condensing units above the evaporator, trap the suction gas line at the
evaporator as shown in Figure 4.1 on the next page. This trap will retain refrigerant oil during the "Off"
cycle. When the unit starts, oil in the trap is carried up the vertical riser and returns to the compressor.

When installing remote condensing units below the evaporator, trap the suction gas line with an inverted
trap the height of the evaporator as shown in the following figure. This prevents refrigerant migration to
the compressor during "Off" cycles.

Table 4.3 Pipe length and condensing unit elevation relative to
evaporator

Maximum Equivalent Pipe Length, ft (m)

150 (45) 50 (15) 15 (4.6)

Maximum

Condensing-unit Level

Above Evaporator, ft (m)

Maximum

Condensing-unit Level

BelowEvaporator, ft (m)

4 Piping and Refrigerant Requirements 13

Figure 4.1 Refrigerant piping when condensing unit is above or below evaporator

Item Description

1 Condensing unit above evaporator

2 Condensing unit below evaporator

3 Evaporator

4 Condensing unit

4.2 Refrigerant-line Sizes and Equivalent Lengths

The following tables list the information required to field-install the refrigerant piping for the system.

Table 4.4 Recommended refrigerant line sizes, O.D.cubyequivalentlength

Equivalent Length, ft (m)

System Models

50 (15) 75 (23) 100 (30) 125 (38) 150 (45)

MT036E/PFD037A-*L or PFD037A-*H

MT048HE/PFD054A-*L

MT060HE/PFD067A-*L

MT060HE/PFDZ67A-*L or PFD067A-*H

Consult factory for proper line sizing for runs longer than maximum equivalent length shown.

1.Use one line size smaller on suction lines for vertical risers.

Suction line, in. 7/8 7/8 7/8 7/8 7/8

Liquid line, in. 1/2 1/2 1/2 1/2 1/2

Suction line, in. 7/8 1-1/8

Liquid line, in. 1/2 1/2 5/8 5/8 5/8

Suction line, in. 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8

Liquid line, in. 1/2 5/8 5/8 5/8 5/8

Suction line, in. 1-1/8 1-1/8 1-1/8 1-1/8 1-1/8

Liquid line, in. 1/2 5/8 5/8 5/8 5/8

1

4.2.1 Refrigerant Charge Requirements

To calculate the charge requirements:

1. Determine the charge for your units by model number from the following tables.

2. Determine the charge for the piping by line size and length.

3. Add these all together to obtain the total refrigerant charge for your system.

1-1/8

1

1-1/8

1

1-1/8

1

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Table 4.5 Indoor Evaporator Approximate R-410Arefrigerant charge

Model # Charge, lb (kg)

MT036HE 1 (0.45)

MT048HE 2.2 (1.0)

MT060HE 2.2 (1.0)

Table 4.6 Interconnecting piping refrigerant charge for R-410A, lbper 100ft (kgper30m)

Line Size,

O.D., in.

3/8 3.2 (1.4) —

1/2 5.9 (2.7) 0.2 (0.1)

5/8 9.6 (4.3) 0.4 (0.2)

3/4 14.3 (6.4) 0.6 (0.3)

7/8 19.8 (8.8) 0.8 (0.4)

1-1/8 33.8 (15.1) 1.4 (0.6)

1-3/8 51.5 (23.0) 2.1 (1.0)

Source:DPN003099 Rev. 1

Liquid Line,lb (kg) Suction Line, lb (kg)

Table 4.7 Liebert® PFD R-410A refrigerant charge

Model # Charge, lb (kg)

PFD037A-*L1 13.4 (6.1)

PFD037A-*H1 27 (12.2)

PFD054A-*L1 27 (12.2)

PFD067A-*L1 27 (12.2)

PFDZ67A-*L1 57 (25.8)

PFD067A-*H1 57 (25.8)

Evacuation and Leak-testing Air-cooled Systems

For proper leak-check and evacuation, you must open all system valves and account for all check valves,
see Figure 4.2 on the next page.

4 Piping and Refrigerant Requirements 15