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Liebert PEX User Manual - Large Frame

1. When re installing filter panels in downflow units ensure the filter pleat direction runs front to back 11 2 Blower System Belt Drive The blower system employs a self tensioning belt drive that automatically provides optimum belt ten sion Components that are part of the maintenance schedule include the blower wheel s drive shaft bearings pulleys belts motor base and motor See HVAC Maintenance Checklist on page 83 A WARNING Risk of crushing and pinching action from pivoting motor base Can cause serious injury to hands and fingers Improper drive belt removal may cause the motor base to slam down suddenly Read the directions in this manual before servicing the belts motors or pulleys Follow all directions when servicing the unit 11 2 1 Belt Removal 1 Disconnect power to unit Refer Figure 57 Fan Belt Removal Do not pry the belts off the pulleys For downflow units place a large screwdriver or suitable lever between the motor carrier plate and fan frame Carefully raise the motor to reduce belt tension sufficient to remove the belt Remove belt and lower the motor carrier plate For upflow units push up on the motor to overcome the belt tension Remove belt and lower the carrier plate until it rests against the stops on the fan frame 72 Maintenance Piv
2. 11 Cabinet and floor planning dimensional data 3 bay downflow large frame models 12 Cabinet and floor planning dimensional data 1 bay upflow large frame models 13 Cabinet and floor planning dimensional data 2 bay upflow large frame models 14 Cabinet and floor planning dimensional data 3 bay upflow large frame models 15 Cabinet and floor planning dimensional data 1 bay downflow large frame EC fan models 16 Cabinet and floor planning dimensional data 2 bay downflow large frame EC fan models 17 Cabinet and floor planning dimensional data 3 bay downflow large frame EC fan models 18 Cabinet and floor planning dimensional data 1 bay upflow large frame EC fan models 19 Cabinet and floor planning dimensional data 2 bay upflow large frame EC fan models 20 Cabinet and floor planning dimensional data 3 bay upflow large frame EC fan models 21 Equipment recommended for handling Liebert PEX 22 Removing packaging aaa 23 Floor Stand Arrangement Downflow units forward curve Tan 25 Floor Stand Arrangement Downflow chilled water units EC fan option 26 Minimum clearance requirements for EC Fan Installati0N oooooooooooooooo 26 Installation handle fixing locations eee a 27 Lowering EC fan motor into operating position sassa assesseer oaeee 27 Floorstand orientation amp base plate fixing details 0
3. 58 2 bay upflow chilled water forward curve fan 59 3 bay upflow chilled water forward curve fan 60 1 bay downflow chilled water EC fan 0 0 000005 61 2 bay downflow chilled water EC fad ooooooo o 62 3 bay downflow chilled water EC fan 63 1 bay upflow chilled water EC fan 0 0 0 0 cee eee 64 2 bay upflow chilled water EC an 0 0 00 00 00s 65 3 bay upflow chilled water EC fan 0 000 000 ae 66 deutet a st atadas 72 uL A che ei a f EET 73 EC Fan motor removal procedure handle fixing location 00 cece eens 74 EC fan motor removal procedure 75 Correct orientation of float switCh o o ooo ooooomocrrrr ees 76 PEDI UU Em 77 AE HE EHO 78 79 Electrode orientation for different water qualities 0 0 0 nananana nucen cece Table 1 Table 2 Table 3 Table 4 Table 5 Table 6 Table 7 Table 8 Table 9 Table 10 Table 11 Table 12 Table 13 Table 14 Table 15 Table 16 Table 17 Table 18 Table 19 Table 20 Table 21 LIST OF TABLES Weights for 1 bay downflow large frame modela oo 10 Weights for 2 bay downflow large frame models oe 11 Weights for 3 bay downflow large frame modela o 12 Weights for 1 bay upflow large frame models nor 13 Weights for 2 bay upflow large frame models oro 14 Weights for 3 bay upflow large frame models nor 15 Weights for 1 bay downflow large fr
4. Liebert PEX Components and Nomenclature Figure 2 Upflow model component locations air water glycol chilled water systems c o O D o _ D o c D s Y c o2 o o OD 2 um sE oO 3 EH CT N d do oc oogooc S oD Ti w 9 gt CN r 0 O gt amp G E 2 85 E SE c gt ovogorg2 OB O50 0 so2058 OE GEM D QO 6 Goo gt O UC UC C UU ui 1 2 3 4 5 6 Liebert PEX Components and Nomenclature Figure 3 Downflow model component locations chilled water EC fan systems 1 iCOM Control Display 6 Infrared Humidifier 2 Filters 7 EC Fan Motor guard not shown 3 Evaporator Coil 8 Condensate Pump optional 4 Electrical Panel 9 Chilled water supply return pipes 5 Input Isolator 10 Dual chilled water valves actuators Liebert PEX Components and Nomenclature Figure 4 Upflow model component locations chilled water EC fan systems 1 iCOM Control Display 2 EC Fan Motor 3 Electric Reheat 4 Evaporator Coil 5 Electrical Panel 6 Input Isolator 7 Filters 8 Chilled water supply return pipes 9 Return Air Grille 10 Dual chilled water valves actuators Liebert PEX Components and Nomenclature Figure 5 Liebert PEX model number nomenclature 1 2 3 4 5 6 7 8 10 11 12 13 14 15 9 P 2 0 4 0D A RM L 1 R 0 0 Product Range P PEX No Modules Bays Fans Nominal kW 20 30 40 to 150 Air Path Downflow Forwar
5. 68 Startup Checks Inspection With Panels Removed and Input Isolator Switch Off 69 Commissioning Procedure With Panels On 0 0 ccc cc eee ene 70 11 0 11 1 11 2 11 3 11 4 11 5 11 6 11 7 11 8 11 0 11 10 11 11 11 12 12 0 MAINTENANCE Ind 6 pox ae RAR a a ROO ORAS RES So CPDL OH AR A aR Rie 71 11 1 1 Filter Replacement Procedure sse 72 Blower System Belt Drive 0 A A A NSA SAS Y 72 11 21 Belt Removals techo ES aden Pal dete shen a ia dt 72 11 2 2 Belt Installationyas 5 cies rd ab e a 73 Blower System Direct Drive EC Fans oo 74 11 3 1 Removal Downflow Chilled Water Una 74 Infrared Hag Quiet os x ea A AAA NA A tag d 76 11 4 1 Cleaning Humidifier Pan and Float Switch 76 11 4 2 Changing Humidifier LaMpS ooooooo ehh ha 77 Immersed Electrode Humidifier lt 5002 3 46 RIA ES ho hed Re RAE x ED 78 11 5 1 Cleaning Humidifier Bottle Electrodes and Steam Din 0 0 0 79 Condensate Drain and Condensate Pump Systems 0 0 0 ccc cece eee ee ees 80 11 61 Condensate Dranm 5 25 A Oa eee edu ee ets 80 116 2 Condensate PUMP olus cute A Ec ere tds ew are ei erede el etd 80 Air Cooled Condenser and Drycoolers eee 80 Reheadt BElectrie Reheat ss vu svp vp Re pe ey A e ea gs 80 Compressor ioco Mo oua iuto E LECHE ERU d sui BA A Ltd 81 T 1 941 Compressor Ollas DR user tbe ue ees Dole atentos o fal BUDE dase 81 11 9 2 Scroll
6. 11 19 18 16 6 7 10 ss s ss les szojssojozejase s7 as 2a sof s1 55 s6 7o 7t poArrtA Refer to 6 1 Electrical Field Connection Descriptions for keys to numbered items Figure 31 Field connection terminals A CAUTION Field wiring to terminals 24VAC MAXIMUM VOLTAGE CONNECTION ONLY 34 Electrical Connections 6 1 Electrical Field Connection Descriptions Standard Electrical Connections 1 amar wn 10 11 High voltage entrance 35mm 1 3 8 diameter hole and 44mm 1 3 4 knockout located in bottom of box Low voltage entrance 51mm 2 diameter hole located in bottom of box Three phase electrical service Input isolator Three phase service not by Liebert Earth ground Terminal for field supplied earth grounding wire Neutral Terminal for field supplied neutral wire Remote unit shutdown Replace existing jumper between terminals 37 and 38 with field supplied normally closed switch having a minimum 75VA 24VAC rating Use field supplied Class 1 wiring Customer alarm inputs Terminals for field supplied normally open contacts having a minimum 75VA 24VAC rating between terminals 24 and 50 51 55 56 Use field supplied Class 1 wiring Terminal availability varies by unit options SiteScan Terminals 77 and 78 for a two wire twisted pair communication cable to optional SiteScan Common alarm On any alarm normally open dry contact is closed across terminals 75
7. 26 6 0 ELECTRICAL CONNECTIONS 6 1 Electrical Field Connection Descriptions 0 ccc cee cece eee eens 35 6 1 1 Water Under Floor Sensor LWD 000 ce eh 36 6 1 2 Remote Air Cooled Condenser Power Kit Option 0 0 cc ccc ee eens 36 6 1 8 iCOM Network Cabling RR K RT Rr R R a 0 a es 36 6 1 4 IntelliSlot 485 and WEB SNMP Cards 36 7 0 7 1 7 2 7 3 8 0 9 0 9 1 9 2 9 3 9 4 10 0 10 1 10 2 10 3 PIPING Fluid C Oonnecblotse 22 245 2nd d A AOE 246 Co rd sae te Meee ees 37 7 1 1 Condensate Piping Field Installed cece eens 37 7 1 2 Humidifier Supply Water 38 7 1 3 Requirements of Systems Using Water or Glycol 0 0 0 0 0c eens 38 Refrigeration Piping RH PER Vea EA RR NUES Re RIVER UR e 39 7 2 1 Piping Guidelines Air Cooled Units 39 7 2 0 Piping Guidelines Chilled Water units Al Dehydration Leak Test and Charging Procedures for R 407C and R 22 42 7 3 1 Air Cooled Condenser with Electronic Fan Speed Head Pressure Control System 42 PIPING SCHEMATICS CHECKLIST FOR COMPLETED INSTALLATION Moving and Placing Equipment 2 0 een eens 67 El ctrica elec cet uscd o e eer AA E onu n ul ada tenu quu didit hid aqnis doe cure a 67 lanum EET 67 Mets oris e atte et eut lt Rete da 67 INITIAL STARTUP CHECKS AND COMMISSIONING PROCEDURE FOR WARRANTY INSPECTION Information for Warranty Inspection Remove Power From Unit Input Isolator
8. Electrical Conn High Volt Fan Outlet Fan Outlet 745 29 1 4 869 34 1 4 60 2 3 8 315 12 3 8 997 39 1 4 681 26 3 4 632 25 760 29 7 8 735 28 7 8 358 14 1 8 358 14 1 8 1 2 BSP 25mm OD 1 1 2 34 9 1 3 8 44 4 1 3 4 K O 25 1 410 x 310 16 1 8 x 12 1 4 410 x 310 16 1 8 x 12 1 4 Field pitch condensate drain line a minimum of 10mm per metre 1 8 per ft Infrared humidifier units contain a factory installed condensate trap Do not trap external to unit Immersed electrode humidifier units require an external trap Drain line may contain boiling water Select appropriate drain materials The drain line must comply with local codes Water circuit includes regulating valve and bypass valve 48 Piping Schematics Figure 38 Primary connection locations 2 bay downflow air water glycol cooled dual scroll compressor models forward curve fan All dimensions from rear corner of unit including panels SECTION A A X 874 mm 34 4 FRONT OF UNIT 1704 mm 67 x X Y Connection Size Opening mm in polni ed mm in mm in 2040F 2050F 2060 2070F G1 Hot Gas Circuit 1 169 6 5 8 775 30 1 2 5 8 LD 7 8 LD G2 Hot Gas Circuit 2 1549 61 775 30 1 2 5 8 ID 7 8 LD i ID Liquid Line Circuit 2 1479 58 1 4 5 8 LD WS1 Water Glycol Supply Circ 1 239 9 3 8 1 3 8 ID Water
9. 760 29 7 8 34 9 1 3 8 44 4 1 3 4 K O Electrical Conn Low Volt 792 31 1 4 764 30 25 1 Field pitch condensate drain line a minimum of 10mm per metre 1 8 per ft Infrared humidifier units contain a factory installed condensate trap Do not trap external to unit Immersed electrode humidifier units require an external trap Drain line may contain boiling water Select appropriate drain materials The drain line must comply with local codes mil 61 Piping Schematics Figure 51 Primary connection locations 2 bay downflow chilled water EC fan Note Fan guard not shown SECTION A A All dimensions from rear corner of unit including panels FRONT OF UNIT Description Chilled Water Supply Chilled Water Return Condensate Drain Infrared w Optional Pump 1704 mm 67 1 X mm in 1618 63 3 4 1618 63 3 4 1602 63 884 34 3 4 Y mm in 687 27 523 20 1 2 632 25 506 09 14 Connection Size Opening mm in 3 8 comp HUM IR Humidifier water supply Infrared 1644 64 3 4 523 20 1 2 1 2 BSP CD IE Condensate Drain Elect 884 34 3 4 632 25 25mm OD 1 HUM IE Humidifier water supply Elect 775 30 1 2 681 26 3 4 1 2 BSP E Electrical Conn High Volt 60 2 1 4 760 29 7 8 34 9 1 3 8 44 4 1 3 4 K O LV Electrical Conn Low Volt 1642 64 3 4 764 30 25 1 Field pitch condensate drain line
10. nnana nannan ee eens 28 Upflow ducting configurations forward curve fan systems type D air path 29 Duct connection details forward curve fan systems type D air path nnnnnanan nuanua 30 Duct connection details backward curve EC fan systems type V air path 31 Plenum discharge details forward curve fans type U and V air path 32 Electrical panel general arrangement eee hr 34 Field connection terminals eer as 34 Water Under Floor Sensor LWD wiring s 36 Piping schematic air cooled scroll compressor models lille 44 Piping schematic water glycol scroll compressor modela llle 45 Piping schematic chilled water modela eese 46 Primary connection locations 1 bay downflow air water glycol cooled single scroll compressor OL Ward CUE d usamos eee sex AS aie poh Pd secte AUR A Ra ae e 47 Primary connection locations 2 bay downflow air water glycol cooled single scroll compressor forward Curve daqm a a a S wd wi cle A ad 48 Primary connection locations 2 bay downflow air water glycol cooled dual scroll compressor mod els forward curve tania A in e S 49 Primary connection locations 3 bay downflow air water glycol cooled dual scroll compressor for Watd Curve fati NN 50 Primary connection locations 1 bay upflow air water glycol cooled single scroll compressor mod els forward curve fAnu s vues dedere bles Rat age Dae gs ick ede a P VR UST er
11. 1 1 8 LD WS2 Water Glycol Supply Circ 2 1543 60 3 4 665 26 1 8 WR1 Water Glycol Return Circ 1 114 4 1 2 665 26 1 8 1 1 4 O D WR2 Water Glycol Return Circ 2 1473 58 665 26 1 8 1 1 4 O D CD IR Condensate Drain Infrared 867 34 1 8 w Optional Pump 867 34 1 8 473 18 5 8 3 8 comp HUM IR Humidifier water supply Infrared 712 28 CD IE Condensate Drain Elect 473 18 5 8 25mm OD 1 HUM E Humidifier water supply Elect E Electrical Conn High Volt LV ElecticalConn Low Voll S Fan Out F2 Fan Outlet 1065 41 7 8 311 12 1 4 404 x 258 15 7 8 x 10 1 8 Field pitch condensate drain line a minimum of 10mm per metre 1 8 per ft Infrared humidifier units contain a factory installed condensate trap Do not trap external to unit Immersed electrode humidifier units require an external trap Drain line may contain boiling water Select appropriate drain materials The drain line must comply with local codes 53 Piping Schematics Figure 43 Primary connection locations 3 bay upflow air water glycol cooled dual scroll compressor models forward curve fan All dimensions from rear corner of unit including panels FanOutlet FanQuilet L A_i LA F2 F1 874 mm 34 4 A Fan outlet shown for duct connection illustration purposes only L1 G1 ws1 OO wri FRONT OF UNIT 2553 mm 100 5 Note Upflow units must be connected to field supplied ductwork
12. Filters A CAUTION Risk of improper filter installation and filter collapse Can cause equipment damage To maximize the performance and reliability of Liebert PEX equipment use only Emerson filters Contact your local Emerson representative to order replacement filters Table 18 Filter quantities downflow units Filter Quantities Filter Size 100mm 4 Filter Unit Size Width x Length G4 Merv 8 1 Bay 1 785 x 785mm 2Bay 81xalin 2 3 Bay 3 Table 19 Filter quantities upflow units Filter Quantities Filter Size 100mm 4 Filter Unit Size Width x Length G4 Merv 8 1 Bay 1 785 x 650mm 2 Bay 31 x 25 5in 3 Bay 3 71 Maintenance 11 1 1 Filter Replacement Procedure 1 2 3 4 5 6 Disconnect power to unit Open the front doors and remove or slide out the used filters from the unit Replace with new filters install filters according to airflow direction arrow Test the operation of the filter clog switch The unit fan access panels must be in place and closed to accurately find this point Operate the blower and set the switch counterclockwise until the alarm is energized Turn the adjusting knob one turn clockwise or to the desired filter change point Figure 56 Proper filter pleat direction 785mm 31 in 785mm 31 in la gt
13. large frame models Dry Weight kg Ib Approximate 2045 2055 2040 2050 2060 2070 Model No FA W G FA W G FA W G FA W G FA W G FA W G Air Cooled 520 530 540 560 590 600 1145 1165 1190 1230 1300 1320 Water Glycol Cooled 540 550 570 590 620 630 1190 1210 1255 1300 1365 1385 Dry Weight kg Ib Approximate Model No 2050FC 2090FC Chilled Water 480 1055 480 1055 500 1100 11 Liebert PEX Dimensions and Weights Figure 8 Cabinet and floor planning dimensional data 3 bay downflow large frame models 2553 100 5 874 84 4 19 0 75 Shaded area indicates a recommended minimum clearance for unit servicing Pd and component access Table 3 Weights for 3 bay downflow large frame models Dry Weight kg Ib Approximate Model No 3080FA W G 3090FA W G 3100FA W G Air Cooled 840 1850 860 1890 880 1935 Water Glycol Cooled 880 1935 900 1980 920 2025 Dry Weight kg Ib Approximate Model No 3110FC 3140FC Chilled Water 710 1560 730 1605 12 Liebert PEX Dimensions and Weights Figure 9 Cabinet and floor planning dimensional data 1 bay upflow large frame models 38 Shaded area indicates a recommended minimum clearance for unit servicing and component access Note Upflow units must be connected to field supplied ductwork or factory discha
14. Compressors esses e eee eens 81 Compressor Replacement d ATEN A TT K eee cece hes 81 11 10 1 Compressor Motor Burnout 81 11 10 2 Compressor Replacement Procedure 81 Facility Fluid and Piping Maintenance osc tq ars ia A A A Ad ORE AAA AGA quU 82 Plate Heat Exchanger Water Cooled Condenser 0 0000 c cece ene teens 82 HVAC MAINTENANCE CHECKLIST iii Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 Figure 18 Figure 19 Figure 20 Figure 21 Figure 22 Figure 23 Figure 24 Figure 25 Figure 26 Figure 27 Figure 28 Figure 29 Figure 30 Figure 31 Figure 32 Figure 33 Figure 34 Figure 35 Figure 36 Figure 37 Figure 38 Figure 39 Figure 40 Figure 41 Figure 42 LIST OF FIGURES Downflow model component locations air water glycol cooled systems ananunua 3 Upflow model component locations air water glycol chilled water systems 4 Downflow model component locations chilled water EC fan systems 000 0c eee 5 Upflow model component locations chilled water EC fan systems 00000 c eee eae 6 Liebert PEX model number nomenclature 0 0 cect ees 7 Cabinet and floor planning dimensional data 1 bay downflow large frame models 10 Cabinet and floor planning dimensional data 2 Bay downflow large frame models
15. Equipment Inspection and Handling 5 2 1 5 2 2 5 2 3 Removing the Unit from the pallet With a Forklift 1 Align a forklift with either the front or rear side of the unit A WARNING Risk of improper moving Can cause equipment damage injury or death The center of gravity varies depending on the unit size and selected options 2 Insert the tines of the forklift completely under the base of the Liebert PEX A WARNING Risk of improper moving Can cause equipment damage injury or death Ensure that the tines are level not angled up or down The tines must be at a height that will allow proper clearance under the unit Ensure the tines extend beyond the opposite side of the unit 3 Remove the lag bolts from each bracket holding the Liebert PEX to the pallet 4 Lift the unit off the pallet no more than 150mm 6 and remove the pallet Moving the Unit to the Installation Location with Piano Jacks 1 With the Liebert PEX elevated place two piano jacks into position one at either end of the unit 2 Lower the Liebert PEX to a height suitable for the piano jacks and place protective material between the Liebert PEX and the piano jacks 3 Secure the unit to the piano jacks and remove the forklift 4 Use the piano jacks to move the Liebert PEX for installation Removing Piano Jacks 1 Lower the unit as much as the piano jacks will allow 2 Undo all strapping holding the piano jacks to the unit 3 Use a pry bar
16. Glycol Supply Circ 2 1549 61 1 1 8 LD 1 3 8 ID WR1 Water Glycol Return Circ 1 169 6 5 8 775 30 1 2 1 1 4 OD WR2 Water Glycol Return Circ 2 1479 58 1 4 775 30 1 2 1 1 4 O D CD IR Condensate Drain Infrared 869 34 1 4 632 24 7 8 3 4 BSPM w Optional Pump 869 34 1 4 632 24 7 8 3 8 comp Humidifier water supply Infrared 745 29 3 8 1 2 BSP 26mm 0D 17 Humidifier water supply Elect 745 29 3 8 1 2 BSP Electrical Com High Volt 60 2 3 8 34 9 1 3 8 44 4 1 3 4 K O LV Electrical Conn Low Volt 1652 65 735 28 7 8 25 1 F1 Fan Outlet 315 12 3 8 358 14 1 8 410 x310 16 1 8 x 12 1 4 F2 Fan Outlet 997 39 1 4 358 14 1 8 410 x310 16 1 8 x 12 1 4 Field pitch condensate drain line a minimum of 10mm per metre 1 8 per ft Infrared humidifier units contain a factory installed condensate trap Do not trap external to unit Immersed electrode humidifier units require an external trap Drain line may contain boiling water Select appropriate drain materials The drain line must comply with local codes 49 Piping Schematics Figure 39 Primary connection locations 3 bay downflow air water glycol cooled dual scroll compressor forward curve fan FRONT OF UNIT All dimensions from rear corner of unit including panels aw YO Description 2553 mm 100 5 X mm in Y mm in Connection Size Opening mm in 3080F 3090 3100F G1 Hot
17. No 2050GC 2070GC 2090GC Chilled Water EC 500 1100 500 1100 520 1145 17 Liebert PEX Dimensions and Weights Figure 14 Cabinet and floor planning dimensional data 3 bay downflow large frame EC fan models Note Fan guard not shown Table 9 Weights for 3 bay downflow large frame EC fan models Dry Weight kg Ib Approximate Model No 3110GC 3140GC Chilled Water EC 740 1630 760 1670 Liebert PEX Dimensions and Weights Figure 15 Cabinet and floor planning dimensional data 1 bay upflow large frame EC fan models P 33 6 850 Shaded area indicates a bw 33 5 recommended minimum clearance for unit servicing and component access Note Upflow units must be connected to field supplied ductwork or factory discharge air plenum Table 10 Weights for 1 bay upflow large frame EC fan models Model No Chilled Water EC Dry Weight kg Ib Approximate 1020VC 270 595 1030VC 270 595 19 Liebert PEX Dimensions and Weights Figure 16 Cabinet and floor planning dimensional data 2 bay upflow large frame EC fan models 1704 ee A A 3 IE ZEE 22 E wA D L z E 0 75 1970 77 5 Shaded area indicates a recommended 850 Pad minimum clearance for unit servicing and E 33 5 component access Note Upflow units must be connected to field supplied ductwork or factory
18. ZONE Oh eZ ISZ Ue Note Internal duct opening sizes shown Mounting flange 38mm 1 5 2 BAY 2 6 i SSS e F TITHI et IE Y 5 BAY a ZI TI RZ EA a A option 550 high plenum shown is Electrical Connections 6 0 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 for unit full load amps Refer to electrical schematic when making connections Refer to Figure 30 for electrical service entrances into unit A manual electrical isolation switch should be installed in accordance with local codes and distribu tion system Consult local codes for external isolation requirements A gt gt WARNING Risk of electric shock Can cause injury or death Disconnect local and remote power supplies before working within Use voltmeter to make sure power is turned off before making any electrical connections 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 Follow all local codes WARNING Risk of improper wiring piping moving lifting and handling Can cause equipment damage injury or death Installation and service of this equipment should be done only by qualified personnel w
19. a minimum of 10mm per metre 1 8 per ft Infrared humidifier units contain a factory installed condensate trap Do not trap external to unit Immersed electrode humidifier units require an external trap Drain line may contain boiling water Select appropriate drain materials The drain line must comply with local codes 62 Piping Schematics Figure 52 Primary connection locations 3 bay downflow chilled water EC fan All dimensions from rear corner of unit including panels Note Fan guard not shown SECTION A A X FRONT OF UNIT 2553 mm 100 5 IL X Y Connection Size Opening mm in P D oint escription mm in mm in 3110 3140GC CS Chilled Water Supply 2468 97 1 4 588 23 1 4 2 OD CR Chilled Water Return 2468 97 1 4 687 27 2 OD CD IR Condensate Drain Infrared 794 31 1 4 523 20 1 2 3 4 BSPM w Optional Pump 794 31 1 4 523 20 1 2 3 8 comp HUM IR Humidifier water supply Infrared 2494 98 1 4 523 20 1 2 1 2 BSP CD IE Condensate Drain Elect 1734 68 1 4 632 25 25mm OD 1 HUM IE Humidifier water supply Elect 1625 64 681 26 3 4 1 2 BSP Electrical Conn High Volt 60 2 1 4 760 29 7 8 34 9 1 3 8 44 4 1 3 4 K O Electrical Conn Low Volt 2492 98 764 30 25 1 Field pitch condensate drain line a minimum of 10mm per metre 1 8 per ft Infrared humidifier units contain a factory installed condensate trap Do not trap
20. and trap for clogs 2 Check clean pan for mineral deposits 3 Clean reflector 4 Check water make up valve for leaks 5 Check humidifier lamps replace if burnt out 6 Check wire connections inside humidifier box 7 Humidifier amp draw L1 L2 L3 Immersed Electrode Bottle Humidifier 1 Check drain lines trap for clogs Check water make up valve and all hoses connections for leaks Clean strainer Check operation of humidifier fill flush 2 3 4 Replace electrodes humidifier bottle if necessary Check orientation and re tighten 5 6 Humidifier amp draw L1 L2 L3 83 HVAC Maintenance Checklist Condensate Pump 1 Check for debris in sump __ 2 Check operation of float s free movement Refrigeration Piping __ 1 Check refrigerant lines clamps secure no rubbing leaks __ 2 Check for moisture sight glass Water Cooled Condensers 1 Check water regulating valve operation ___ 2 Cap tubes not rubbing 3 Check for water glycol leaks 4 Entering water temperature C __ 5 Leaving water temperature C Compressor Section 1 Check oil level __ 2 Check for oil leaks ___ 3 Check compressor mounts 4 Cap tubes not rubbing 5 Check wire connections inside compressor terminal box __ 6 Compressor operation vibration noise 7 Suction Pressure Circuit 1 Circuit 2 __ 8 Discharge Pressure Circuit 1 Circuit 2 9 Superheat Circuit 1 Circuit 2 _
21. crane with belts or cables slings and spreader bars f using a forklift or pallet jack make sure that the forks if adjustable are spread to the widest allowable distance that will fit under the pallet Ensure the fork length is suitable for the unit length When moving the packaged Liebert PEX with a forklift carefully lift the unit centrally and no higher than 150mm 6 off the ground If the unit must be lifted higher than 150mm 6 great care must be exercised Personnel who are not directly involved in moving the unit must be kept 5m 20 or farther from the lift point of the unit 5 2 Unpacking the Unit Remove outer packaging when ready to install the unit Identify the unit front by locating the styrene control cover Remove the unit straps packing tape and exterior stretch wrap packaging material from around the unit exposing the protective corner and vertical styrene packaging planks Remove the timber frame packing corner pieces and plastic cover from the unit top Remove the balance of the stretch wrap packaging styrene planks and kickplates from the unit Figure 19 Removing packaging Timber frames Corner pieces Top plastic PE gt SO cover E LLL R Pa if iE A 1 Control cover unit front Stretch wrap Unit straps Corner pieces c IN Pallet Vertical planks Kickplates 23
22. in Tables 14 15 and 16 Weigh in as much of the system charge as possible before starting the unit CAUTION Risk of improper refrigerant charging Can cause equipment damage Refrigerant R407C is a blend of three components 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 line access valve Care must be exercised to avoid damage to the compressor Emerson recommends connecting a sight glass between the charging hose and the compressor suction line accesse valve This will permit adjustment of the cylinder hand valve so that liquid can leave the cylinder while allowing vapor to enter the compressor Turn on unit isolation switch Operate the unit for 30 minutes using the charging function for Compressor 1 and Compressor 2 in the diagnostic section of the iCOM control see iCOM user manual 051536 The charging function operates the compressor at full capacity and energizes the evaporator fan motor and the liquid line solenoid valve The reheat and humidifier are disabled A minimum 140kPa 20psig must be established and maintained for the compressor to operate The charging function can be reset as many times as required to complete unit charging Charge the unit until the liquid line sight glass becomes clear As head pressure builds the fan speed controlled condenser fans begin rotating
23. maintenance work sheet To locate your local Emerson Representative for Liebert engineered parts check the Emerson Web site www emersonnetwork com au or call 1300 367 686 85 HVAC Maintenance Checklist NOTES 86 HVAC Maintenance Checklist 87 HVAC Maintenance Checklist 88 Ensuring The High Availability Of Mission Critical Data And Applications Emerson Network Power the global leader in enabling business critical continuity ensures network resiliency and adaptability through a family of technologies including Liebert power and cooling technologies that protect and support business critical systems Liebert solutions employ an adaptive architecture that responds to changes in criticality density and capacity Enterprises benefit from greater IT system availability operational flexibility and reduced capital equipment and operating costs While every precaution has been taken to ensure the accuracy and completeness of this literature Emerson assumes no responsibility and disclaims all liability for damages resulting from the use of this information or for any errors or omissions 2008 Emerson Electric Co All rights reserved throughout the world Specifications subject to change without notice Liebert and the Liebert logo are registered trademarks of Emerson Electric All names referred to are trademarks or registered trademarks of their respective owners 051535_Rev 0_0708 Emers
24. the compressor NOTE The Liebert PEX indoor cooling unit has a factory installed high pressure safety switch in the high side retrigerant circuit 7 2 1 Piping Guidelines Air Cooled Units Indoor unit ships with a nitrogen holding charge do not vent the evaporator until all refrigerant piping is in place ready for connection to the unit and condenser Ensure unit field connection isolation valves are wrapped when brazing Use copper piping with high temperature brazed joints Isolate piping from building using vibration isolating supports Refer to Table 13 for piping sizes Refer to condenser installation manual for charging information Install traps on hot gas discharge lines at the base of vertical risers and every 7 5m 25 feet of vertical rise Consult factory if condenser is installed more than 5m 16 feet below the evaporator Consult factory if piping run exceeds 60m 200 feet equivalent length Keep piping clean and dry Avoid piping runs through noise sensitive areas Do not run piping directly in front of airstream Refrigerant oil do not mix oil types see 11 9 1 Compressor Oil Refer to ASHRAE Refrigeration Handbook for general good practice refrigeration piping 39 Piping Table 13 Equiv Length 15m 50ft 30m 100ft 45m 150ft sw eoo Equiv Length 15m 50ft 30m 100ft 45m 150ft 5 60 Recommended refrigerant line sizes OD copper mm inches Model 3080 Equiv
25. 0UC DC Chilled Water Supply 1515 59 3 4 600 23 1 2 1 5 8 O D i 600 23 1 2 1 5 8 O D Chilled Water Return 1630 64 1 4 23 1 2 3 4 BSPM 3 8 comp Humidifier water supply Infrared 1 2 BSP Condensate Drain Elect Humidifier water supply Elect E Electrical Conn High Volt 60 2 1 4 760 29 7 8 34 9 1 3 8 44 4 1 3 4 K O Electrical Conn Low Volt 1642 64 3 4 765 30 1 8 25 1 Field pitch condensate drain line a minimum of 10mm per metre 1 8 per ft Infrared humidifier units contain a factory installed condensate trap Do not trap external to unit Immersed electrode humidifier units require an external trap Drain line may contain boiling water Select appropriate drain materials The drain line must comply with local codes 59 Piping Schematics Figure 49 Primary connection locations 3 bay upflow chilled water forward curve fan All dimensions from rear corner of unit including panels SECTION A A FRONT OF UNIT r Hy A Fan outlet shown l for duct connection illustration purposes only Note Upflow units must be connected to field supplied ductwork or factory discharge air plenum Connection Size Opening mm in 3 4 BSPM 537 21 1 4 Humidifier water supply Infrared 2494 98 1 4 492 19 1 4 1 2 BSP 1718 67 3 4 484 19 25mm OD 1 Electrical Conn High Volt 60 2 1 4 760 29 7 8 34 9 1 3 8 44 4 1
26. 3 4 K O Electrical Conn Low Volt 2492 98 765 30 1 8 25 1 195 7 3 4 456 18 476 x 385 18 3 4 x 15 1 4 1080 42 1 2 456 18 476 x 385 18 3 4 x 15 1 4 1895 74 1 2 456 18 476 x 385 18 3 4 x 15 1 4 Field pitch condensate drain line a minimum of 10mm per metre 1 8 per ft Infrared humidifier units contain a factory installed condensate trap Do not trap external to unit Immersed electrode humidifier units require an external trap Drain line may contain boiling water Select appropriate drain materials The drain line must comply with local codes Point Description CD IR HUM IR CD IE HUM IE 60 Piping Schematics Figure 50 Primary connection locations 1 bay downflow chilled water EC fan Point CS CR CD HUM E LV Description Chilled Water Supply Chilled Water Return Condensate Drain w Optional Pump Humidifier water supply Note Fan guard not shown SECTION A A FRONT OF UNIT 853 mm 33 6 All dimensions from rear corner of unit including panels 874 mm 34 4 X Y Connection Size Opening mm in mm in mm in 1020 1030 1040GC 768 30 1 4 588 23 1 4 1 1 4 O D 768 30 1 4 687 27 1 1 4 OD gt 752 29 1 2 523 20 1 2 752 29 1 2 523 20 1 2 3 8 comp mil IR 3 4 BSPM IE 1 794 31 1 4 523 20 1 2 1 2 BSP Electrical Conn High Volt 60 2 1 4
27. 42 64 5 8 765 30 1 8 25 1 F1 Fan Outlet 235 9 1 4 311 12 1 4 404 x 258 15 7 8 x 10 1 8 F2 Fan Outlet 1065 41 7 8 311 12 1 4 404 x 258 15 7 8 x 10 1 8 Field pitch condensate drain line a minimum of 10mm per metre 1 8 per ft Infrared humidifier units contain a factory installed condensate trap Do not trap external to unit Immersed electrode humidifier units require an external trap Drain line may contain boiling water Select appropriate drain materials The drain line must comply with local codes Water circuit includes regulating valve and bypass valve 52 Piping Schematics Figure 42 Primary connection locations 2 bay upflow air water glycol cooled dual scroll compressor models forward curve fan All dimensions from rear corner of unit including panels L Fan Outlet A Fan Outlet ES BE NN CD O Fan outlet shown FRONT OF UNIT for duct connection illustration purposes 1704 mm only 67 Note Upflow units must be connected to field supplied ductwork or factory discharge air plenum Point Description Y Connection Size Opening mm in mm in mm in 2040U 2050U 2060 2070U G1 Hot Gas Circuit 1 114 4 1 2 665 26 1 8 5 8 LD 7 8 LD G2 Hot Gas Circuit 2 1543 60 3 4 665 26 1 8 5 8 LD 7 8 LD L1 Liquid Line Circuit L2 Liquid Line Circuit 2 665 26 1 8 5 8 LD WS1 Water Glycol Supply Circ 1 665 26 1 8
28. 7 18 19 Remote unit shutdown Two additional contact pairs available for unit shutdown labeled as 37B and 38B 37C and 38C Replace jumpers with field supplied normally closed switch having a minimum 75VA 24VAC rating Use Class 1 field supplied wiring Common alarm On any alarm two additional normally open dry contacts are closed across terminals 94 and 95 and 96 and 97 for remote indication 3A 24VAC max load Use Class 1 field supplied wiring Main fan auxiliary switch On closure of main fan contactor normally open dry contact is closed across terminals 84 and 85 for remote indication 1A 24VAC max load Use Class 1 field supplied wiring Liqui tect shutdown and dry contact On Liqui tect activation all fans shutdown and a normally open dry contact is closed across terminals 58 and 59 for remote indication Liqui tect sensor ordered separately 1A 24VAC max load Use Class 1 field supplied wiring Cannot be used in conjunction with LWD factory supplied water under floor sensor NOTE Refer to specification sheet for total unit full load amps wire size amps and maximum overcurrent protective device size 35 Electrical Connections 6 1 1 Water Under Floor Sensor LWD Each Liebert PEX unit is shipped from the factory with a water under floor sensor 3 7m 12ft lead and termination resistor for field connection A maximum of 5 sensors may be connected in series Regardless of the quantity a single te
29. 7 1 4 794 31 1 4 794 31 1 4 588 23 1 4 687 27 523 20 1 2 523 20 1 2 2 OD 2 OD 3 4 BSPM 3 8 comp Humidifier water supply Elect 1625 64 681 26 3 4 HUM HR Humidifier water supply Infrared 2494 98 1 4 523 20 1 2 1 2 BSP CD IE Condensate Drain Elect 1734 68 1 4 632 25 25mm OD 1 1 2 BSP HUM IE L Electrical Conn High Volt Electrical Conn Low Volt Fan Outlet Fan Outlet Fan Outlet iv F E V 1 2 3 60 2 1 4 2492 98 206 8 1067 42 1857 73 760 29 7 8 764 30 401 15 3 4 401 15 3 4 401 15 3 4 34 9 1 3 8 44 4 1 3 4 K O 25 1 476 x 385 18 3 4 x 15 1 4 476 x 385 18 3 4 x 15 1 4 476 x 385 18 3 4 x 15 1 4 Field pitch condensate drain line a minimum of 10mm per metre 1 8 per ft Infrared humidifier units contain a factory installed condensate trap Do not trap external to unit Immersed electrode humidifier units require an external trap Drain line may contain boiling water Select appropriate drain materials The drain line must comply with local codes 57 Piping Schematics Figure 47 Primary connection locations 1 bay upflow chilled water forward curve fan All dimensions from rear corner of unit including panels SECTION A A 874 mm 34 4 A Fan outlet shown for duct connection illustration purposes only FRONT OF UNIT 853 mm 33 6 Note Upflow un
30. Bulbs 77 Maintenance 11 5 Immersed Electrode Humidifier During normal humidifier operation mineral deposits will collect in the humidifier bottle on the elec trodes and water level sensor Regular inspection and cleaning is necessary to ensure proper opera tion The frequency is dependant on humidifier usage and local water quality Refer Figure 63 for details on alternate electrode orientations The humidifier employs an automatic flush cycle that allows application in a wide range of water conditions see iCOM user manual 051536 for flush cycle setup The humidifier is fully serviceable ensuring quick and cost effective maintenance A WARNING Risk of electric shock Can cause injury or death Disconnect local and remote power supplies before working on humidifier Risk of contact with hot surfaces Can cause injury Allow sufficient time to cool Wear protective gloves when working on or near humidifier Figure 62 Immersed electrode humidifier Water inlet hose Steam outlet hose Solenoid valve Electrode connection Removeable lid Strainer Humidifier bottle Isolator Water level sensor Overflow Humidifier tray Drain hose clamps supplied loose 78 Maintenance 11 5 1 Cleaning Humidifier Bottle Electrodes and Steam Pipe Before turning off unit With unit operating remove call for humidification at iCOM control Manually flush the humidifier to cool down the bottle con
31. CHRADER ACCESS CONNECTION WITH VALVE CORE 100S with optional long line kit Single compressor models only NOTE SCHEMATIC REPRESENTATION SHOWN THIS SCHEMATIC DOES NOT IMPLY OR DEFINE ELEVATIONS AND REV 02 08 COMPONENT LOCATION UNLESS SPECIFICALLY NOTED REVO 44 Piping Schematics Figure 34 Piping schematic water glycol scroll compressor models Optional Dual Pump System shown WATER SYSTEM AND PUMP y SYSTEM BY OTHERS COOLING rouen I RETURN SUPPLY LIEBERT PEX UNIT and associated piping LIQUID Access Rotalock Connector Rotalock Connector COMPRESSOR Check Valve External Equaliser DISCHARGE Access Expansion Solenoid Sight Valve Valve Glass Filter Drier w rotalock connections XPAN Po GLYCOL SYSTEM T DRYCOOLER Glycol Pressure Port Systems only Aquastat Sensing Bulbs Na L Hose Bib Shut Off Valve BELT in sr ee Shut Off Valve T RETURN Balancing Valve Optional 3 WayRegulating 7 N ie Valve N Tg Evaporator Coil Hose Bib 2 Way Regulating Rotalock Connector Brazed Plate Condenser Sensor NOTE SINGLE REFRIGERATION CIRCUIT SHOWN FOR CLARITY DEHUM SOLENOID VALVE IN CIRCUIT 1 ONLY FACTORY PIPING FIELD PIPING OPTIONAL FACTORY PIPING V Y SERVICE SCHRADER ACCESS CONNECTION NO VALVE CORE SERVICE SCHRADER ACCES
32. CONNECTION WITH VALVE CORE T Y Components are not supplied by Chilled Chilled Emerson but are recommended Water Water for proper circuit operation and Supply Return maintenance NOTE SCHEMATIC REPRESENTATION SHOWN THIS SCHEMATIC DOES NOT IMPLY OR DEFINE ELEVATIONS AND COMPONENT LOCATION UNLESS SPECIFCALLY NOTED 46 Piping Schematics Figure 36 Primary connection locations 1 bay downflow air water glycol cooled single scroll compressor forward curve fan A H S All dimensions from rear corner of unit including panels A A SECTION A A 874 mm 34 4 FRONT OF UNIT 853 mm 33 6 X Y Connection Size Opening mm in mm in mm in 1020 1025F G1 Hot Gas Circuit 1 103 4 714 28 1 8 5 8 LD 7 8 LD L1 Liquid Line Circuit 1 173 6 3 4 764 30 1 8 5 8 LD 764 30 1 8 1 1 8 LD 1 3 8 LD WS1 Water Glycol Supply Circ 1 173 6 3 4 714 28 1 8 1 1 4 OD WR1 Water Glycol Return Circ 1 103 4 3 4 BSPM Point Description CD IR HUM IR E Condensate Drain Infrared 532 21 w Optional Pump Humidifier water supply Infrared Electrical Conn High Volt 737 29 737 29 637 25 CD IE Condensate Drain Elect 737 29 HUM IE Humidifier water supply Elect 637 25 485 19 1 8 60 2 3 8 532 21 1 2 comp 485 19 1 8 1 2 BSP 532 21 25mm OD 1 1 2 BSP 34 9 1 3 8 44 4 1 3 4 K O 760 29 7 8 LV F1 Electrical Conn L
33. Gas Circuit 1 G 1019 40 1 8 775 80 1 2 7 8 LD Hot Gas Circuit 2 2399 94 1 2 775 30 1 2 7 8 LD 7 L1 Liquid Line Circuit 1 1089 42 7 8 L2 Liquid Line Circuit 2 2329 91 3 4 75 775 30 1 2 30 1 2 D 5 8 LD 8 I D Water Glycol Supply Circ 1 1089 42 7 8 775 30 1 2 1 3 8 LD 1 1 4 LD WS2 Water Glycol Supply Circ 2 2399 94 1 2 775 30 1 2 1 3 8 LD 1 1 4 1D WR1 Water Glycol Return Circ 1 1019 40 1 8 775 30 1 2 1 1 4 O D O Water Glycol Return Circ2 2329 91 3 4 775 30 1 2 1 1 4 O D Condensate Drain Infrared CD IR w Optional Pump 1719 67 5 8 632 24 7 8 3 4 BSPM 1719 67 5 8 632 24 7 8 3 8 comp HUM IR Humidifier water supply Infrared 1595 62 3 4 681 26 3 4 1 2 BSP Condensate Drain Elect 1719 67 5 8 Electrical Conn High Volt Electrical Conn Low Volt CD IE HUM IE Humidifier water supply Elect 1595 62 3 4 910 35 7 8 2502 98 1 2 632 24 7 8 25mmOD 1 681 26 3 4 1 2 BSP 760 29 7 8 34 9 1 3 8 44 4 1 3 4 K O LV F1 735 28 7 8 25 1 358 14 1 8 410 x310 16 1 8 x 12 1 4 Fan Outlet 247 9 3 4 Fan Outlet 1165 45 7 8 358 14 1 8 F3 Fan Outlet 1847 72 3 4 358 14 1 8 410 x 310 16 1 8 x 12 1 4 410 x 310 16 1 8 x 12 1 4 Field pitch condensate drain line a minimum of 10mm per metre 1 8 per ft I
34. Length Gas 15m 50ft 28 45m 150ft 28 EE sm 2 827 EA CS 60m 200ft 35 a WetitinperiatEguvatonis fmm 19 16 19 22 25 5 fin ve ss sa e rera Table 14 Indoor unit approximate refrigerant charge for R 22 or R 407C System Type Model Refrigerant Charge per Circuit kg Ib 1020 1025 1030 2 3 5 1 1035 3 1 6 8 2045 2055 4 9 10 8 Air Cooled 2040 2050 2060 2 4 5 3 2070 3 2 7 0 3080 3090 3 7 8 1 3100 5 0 11 0 1020 2 5 5 5 1025 1030 1035 2 75 6 1 2045 2055 4 0 8 8 Water Cooled 2040 2 5 5 5 2050 2060 2 75 6 1 2070 4 8 8 3080 3090 3100 4 8 8 Table 15 Liquid Line charges refrigerant per 30m 100 ft of Type L copper tube O D Liquid Line kg Ib 1 2 3 3 7 3 5 8 5 3 11 7 3 4 7 8 17 2 7 8 11 1 24 4 1 1 8 18 9 41 6 40 Piping Table 16 Outdoor condenser approximate refrigerant charge kg Ib per circuit Charge Model kg Ib LS20 1 1 2 4 LS25 1 9 4 2 LS40 1 9 4 2 LS50 2 9 6 4 LS60 2 8 6 2 LS70 4 2 9 2 LS80 4 0 8 8 LS100 6 0 13 2 System Charge Refer to Tables 14 15 and 16 to estimate the total refrigerant charge required per circuit TOTAL CHARGE per circuit indoor unit liquid line outdoor condenser Additional Oil Requirements Air Cooled Units only Whenever the TOTAL CHA
35. RGE per circuit exceeds the Base Charge Limit as listed in Table 17 addi tional oil refer 11 9 1 Compressor Oil must be added to the system according to the following Oil add ml Total Charge Base Charge Limit kg x 25 Oil add oz Total Charge Base Charge Limit Ib x 0 35 The Base Charge Limit is defined as the total charge of refrigerant in the circuit that can be sup ported by the oil volume of the compressor before additional oil is required The amount of oil required within a circuit is more dependant on the refrigerant charge and compres sor s oil pumping rate than the physical length of piping to be wetted Table 17 Base Charge Limit for Air Cooled Units System Type Model Base Charge Limit per Circuit kg Ib 1020 1025 7 7 17 0 1030 1035 14 2 31 2 f 2045 2055 14 2 31 2 Air Cooled 2040 2050 7 7 17 0 2060 2070 14 2 31 2 3080 3090 3100 14 2 31 2 7 2 2 Piping Guidelines Chilled Water units Units ship with a nitrogen holding charge vent the circuits via the service schrader access bleed valves on the cooling coil header pipes Use copper piping with high temperature brazed joints Insulate supply and return pipes valves to prevent condensation Do not run piping directly in front of airstream Downflow EC Fan units do not route piping or other services in no go regions refer Figure 22 Minimum clearance requirements for EC Fan Insta
36. S CONNECTION WITH VALVE CORE Components are not supplied by Emerson but are recommended for proper circuit operation and maintenance Field installed at highest point in system on return line to pumps dk Locate at tops of all risers and any intermediate system high points NOTE SCHEMATIC REPRESENTATION SHOWN THIS SCHEMATIC DOES NOT IMPLY OR DEFINE ELEVATIONS AND COMPONENT LOCATION UNLESS SPECIFICALLY NOTED Air Vents typical Flow Switch Supplied with Dual Pump Systems Flow Regulating L Gate Valves Pressure Port Ep bcd SUPPLY SUPPLY Shut Off Valve Hose y Bib Strainer mandatory 1 mm or 20 mesh 2045 2055 3090 3100 models only single compressor models only REV 02 08 REVO 45 Piping Schematics Figure 35 Piping schematic chilled water models Cooling Coil Cooling Coil y SERVICE SCHRADER ACCESS CONNECTION WITH VALVE CORE Isolation Y x Isolation Valve L Vave 2 WAY VALVE STD I I FACTORY PIPING Balancing FIELD PIPING Valve I I I A Y Components are not supplied by Emerson but are recommended Chilled Chilled for proper circuit operation and Water Water maintenance Supply Return Air Bleed 1 pf L PE Isolation Isolation Valve X X Valve 3 WAY VALVE OPT I Balancing X FACTORY PIPING Valve i l FIELD PIPING l y SERVICE SCHRADER ACCESS
37. S Precision Cooling For Business Critical Continuity Liebert PEX User Manual Large Frame 4 a a 1 El E 3 4 4 EMERSON Network Power TABLE OF CONTENTS IMPORTANT SAFETY INSTRUCTIONS lt 0c eee ee eee ee eee ee eee ee eee nnns 1 1 0 LIEBERT PEX COMPONENTS AND NOMENCLATURE 2 0 COOLING CONFIGURATIONS 3 0 PRE INSTALLATION GUIDELINES 3 1 Room Prepara A A er SEs Be ORES QUY DR a 9 3 2 Ave Distrib tion Raa A At a E Re E ent are 9 321 Downflow Unit Lexum ue De R E N T UTERE SE SERERE Em EMEN Us 9 3 202 M pflow U nii Ss eer res Db e E AME REN SU OUR EE Eee SS E ed 9 3 3 Location Considerations x lt SL aea g e o 9 3 4 Connections DL baee eue eee aw Aba ee Ea rs Se RS 9 4 0 LIEBERT PEX DIMENSIONS AND WEIGHTS 5 0 EQUIPMENT INSPECTION AND HANDLING 5 1 Packaging Material votre twas lade el ue shies e Ru o pan oe as 22 5 2 Unpacking the Unit laa n i bo a ee AS RAG a PG teh OS Fa Se eR aed 23 5 2 1 Removing the Unit from the pallet With a Forklift o o o oooooooooooomoo o 24 5 2 2 Moving the Unit to the Installation Location with Piano Jacks ooooo 24 5 273 Removing Piano Jackson Ai ret ne sc e ode ro DATE s 24 5 2 4 Removing Liebert PEX from pallet Using Rigging ooo o 25 5 3 Placing the Unit on a Floor Stand sarsie oni RT RAR TR eee o 25 5 3 1 Downflow Chilled Water Units with EC Fan Option 0 0 0 0 o
38. The fan s will run at full speed when sufficient head pressure is developed fans start to rotate at 1400 kPa 200 psig and reach full speed at 1800 kPa 260 psig On decreasing pressure the fans will stop at 1350 kPa 195 psig 43 Piping Schematics 8 0 PIPING SCHEMATICS Figure 33 Piping schematic air cooled scroll compressor models t Inverted trap on discharge amp liquid lines to extend above base of coil by a minimum of 190mm 7 1 2 n a for optional long line kit systems Liquid Return Condenser Coil Condenser R N q g Hot Gas Condenser located Condenser located Discharge p BELOW evaporator ABOVE evaporator N Coil Traps every 7 5m I l LIEBERT PEX UNIT 25ft of rise and associated piping LIQUID z l Evaporator Coil Rotalock Connector Rotalock Connector External Solenoid COMPRESSOR Equaliser Isolation Valve Hot Gas dee Valve DISCHARGE Discharge _ UN Access Liquid Return J Expansion __ Sight Filter Drier Isolation Valve y Solenoid Glass w rotalock Valve basu connections v PT Optional Long N Line kit 7 NOTE SINGLE REFRIGERATION CIRCUIT SHOWN FOR CLARITY DEHUM SOLENOID VALVE IN CIRCUIT 1 ONLY FACTORY PIPING Components are not supplied FIELDPIPING by dd Rn are recommended for proper circui Qu OPTIONAL FACTORY PIPING operation and maintenance y SERVICE S
39. __ 10 Subcooling Circuit 1 Circuit 2 ___ 11 High pressure cut out Circuit 1 Circuit 2 12 Amp draw Circuit 1 L1 L2 L3 Circuit 2 L1 L2 L3 Electrical Panel __ 1 Check circuit breakers 2 Check contactors __ 3 Check wire connections Controls 1 Check Verify Control Operation Sequence Check humidifier high water alarm operation Check operation of the air safety switch 2 3 4 Check setting operation of the filter clog switch 5 Check test changeover device s 6 Check test water detection device s 84 HVAC Maintenance Checklist Air Cooled Condenser Drycooler 1 Coil clean Motor mounts tight Piping support clamps secure Check wire connections Stat settings Glycol level Glycol solution Bearings in good condition motor naar o nN Fan speed control operation n Motor amp draw Circuit 1 Fan 1 Fan 4 Circuit 2 Fan 1 Fan 4 Fan 2 Fan 5 Fan 2 Fan 5 Glycol Pump 1 Check pump rotation ___ 2 Check for glycol leaks __ 3 Pump pressures 1 Suction Fan 3 Fan 6 Fan 3 Fan 6 Discharge 2 Suction Discharge 43 Suction Discharge _ 4 Amp Draw 1 L1 L2 L3 2 Li L2 L3 3 Li L2 L3 Notes 5 Pump changeover if multiple pumps Signature Company Make photocopies for your records Compare readings information to previous
40. allation handle and fit between the fan deck and rear panel using the fasteners removed in Step 2 Figure 23 Installation handle fixing locations EC Fan in shipping position viewed from unit front Figure 24 Lowering EC fan motor into operating position Shipping plate Installation handle Filler plate 27 Equipment Inspection and Handling Figure 25 Floorstand orientation amp base plate fixing details UNIT REAR Note M8 tapped fixing holes at each end for securing unit base Note Small cutouts at front for pipe penetrations 28 Equipment Inspection and Handling Figure 26 Upflow ducting configurations forward curve fan systems type D air path AO Straight section of duct off unit to be min 600mm 2 Recommended damper location 3 Alternate damper location Follow standard practices on all duct work 29 Equipment Inspection and Handling Figure 27 Duct connection details forward curve fan systems type D air path Be Pd N Y 23 A 0 90 gt iE CB m Width y L mm 853 33 1 2 1704 67 2553 100 1 2 Air Water Glycol Chilled Water PxxxxDA W G PxxxxDC 404 15 7 8 476 18 3 4 258 10 1 8 385 15 1 8 437 17 1 4 420 16 1 2 830 32 5 8 815 32 1 8 900 35 3 8 885 34 7 8 Equipment Inspection and Handling Figure 28 Duct connection details backward curve EC fan systems type V air path TSN UL
41. ame EC fan modela ooo eens 16 Weights for 2 bay downflow large frame EC fan modela ooo 17 Weights for 3 bay downflow large frame EC fan models ooo 18 Weights for 1 bay upflow large frame EC fan modela ooo 19 Weights for 2 bay upflow large frame EC fan modela ooo 20 Weights for 3 bay upflow large frame EC fan modela oo 21 Recommended refrigerant line sizes OD copper mm inches o oooooooooooooo 40 Indoor unit approximate refrigerant charge for R 22 or R 407C 0 ee 40 Liquid Line charges refrigerant per 30m 100 ft of Type L copper tube 40 Base Charge Limit for Air Cooled Units 0 0 0 0 cece tenes Al Outdoor condenser approximate refrigerant charge kg Ib per circuit annuau 41 Filter quantities downflow units 0 eee een ra 71 Filter quantities upflow units 0 een een tenet eens 71 Compressor OIL types eri a Bhar ayia ea 81 Guide to resistance of copper and AISI 316 stainless steel o o oooooooooooooo 82 vi IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This manual contains important safety instructions that should be followed during the installation and maintenance of the Liebert PEX 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 and installation op
42. and 76 for remote indication 1A 24VAC max load Use Class 1 field supplied wiring Heat rejection interlock On a call for compressor operation normally open dry contacts are closed across terminals 70 and 71 compressor 1 and 70A and 71A compressor 2 to heat rejection equipment 1A 24VAC max load Use Class 1 field supplied wiring Water under floor sensor LWD Field connections for factory supplied sensor and lead Up to 5 sensors can be connected in series up to a maximum of 20m 65ft Optional Electrical Connections 12 13 14 15 Smoke sensor alarm Factory wired dry contacts from smoke sensor are 91 common 92 NO and 93 NC Supervised contacts 80 and 81 open on sensor trouble indication This smoke sensor is not intended to function as or replace any room smoke detection system that may be required by local or national codes 1A 24VAC max load Use Class 1 field supplied wiring Reheat and humidifier lockout Remote 24VAC required at terminals 82 and 83 for lockout of reheat and humidifier Condensate alarm with condensate pump option On pump high water indication normally open dry contact is closed across terminals 88 and 89 for remote indication 1A 24VAC max load Use Class 1 field supplied wiring Analog inputs Terminals for up to two factory optional analog inputs Device 1 wires to 41 and 42 Device 2 wires to 43 and 44 Optional Low Voltage Terminal Package Connections 16 1
43. available utility power Follow all local codes A WARNING Risk of improper wiring piping moving lifting and handling Can cause equipment damage injury or death Only qualified service personnel should work on this equipment Read all installation operating and safety instructions before proceeding Read and follow all warnings in this manual The Liebert PEX product is a single component in the facility heat removal system The system includes air distribution raised floors duct systems outdoor heat rejection condensers pumps dry coolers cooling towers piping heat rejection fluid ambient temperature etc and indoor cooling and humidity loads equipment load location outside air infiltration Proper application and mainte nance of the entire system is critical to the life and reliability of the Liebert PEX 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 COM user manual 051536 for instructions on how to utilize the unit controller to predict some service maintenance intervals Emerson recommends the use of trained and authorized service personnel extended service con tracts and factory specified replacement parts Contact your local Emerson representative
44. cing 33 5 and component access Note Upflow units must be connected to field supplied ductwork or factory discharge air plenum Table 6 Weights for 3 bay upflow large frame models Dry Weight kg Ib Approximate Model No 3080UA W G 3090UA W G 3100UA W G Air Cooled 870 1915 890 1960 910 2000 Water Glycol Cooled 910 2000 930 2045 950 2090 Dry Weight kg Ib Approximate Model No 3080UC 3110UC Chilled Water 730 1605 730 1605 15 Liebert PEX Dimensions and Weights Figure 12 Cabinet and floor planning dimensional data 1 bay downflow large frame EC fan models 853 i 33 6 1970 77 5 Shaded area indicates a recommended minimum clearance for unit servicing and component access Note Fan guard not shown TET Table 7 Weights for 1 bay downflow large frame EC fan models Dry Weight kg Ib Approximate Model No 1020GC 1030GC 1040GC Chilled Water EC 270 595 270 595 280 615 16 Liebert PEX Dimensions and Weights Figure 13 Cabinet and floor planning dimensional data 2 bay downflow large frame EC fan models 1704 a 67 1 4 Shaded area indicates a hia 850 recommended minimum clearance for unit bw 33 5 servicing and component Note Fan guard not shown Table 8 Weights for 2 bay downflow large frame EC fan models Dry Weight kg Ib Approximate Model
45. d Curve Downflow EC Backward Curve Upflow Forward Curve Upflow EC Backward Curve Upflow Ducted Forward Curve F G U V D Cooling Type A Air Cooled W Water Cooled G lt Glycol Cooled C lt Chilled Water Cooling Control R R 22 scroll 2 compressors S R 407C scroll 2 compressors P R 22 scroll 1 compressor Z R 407C scroll 1 compressor 2 2 way CWV CW zero compressors 3 3 way CWV CW zero compressors Voltage M 400 3 50 A 460 3 60 B 575 3 60 C 208 3 60 D 230 3 60 E 416 3 60 2 380 3 60 J 200 3 60 iCOM Display S Small Graphics Display L Large Graphics Display Reheat Type 0 None 1 1 Stage 2 2 Stage Humidification None Infrared Immersed Electrode o Lu Factory Configuration Number A Z Options A Z Options A Z Options Cooling Configurations 2 0 COOLING CONFIGURATIONS NOTE All field installed piping must comply with applicable local state and federal codes Air Cooled Water Cooled Air cooled unit piping includes isolation valves from the Water cooled units are factory charged Field installed factory and contain a nitrogen holding charge Each water piping is required from the unit to the cooling installation requires refrigerant piping to a condenser tower A Glycol Cooled Chilled Water Glycol cooled units are factory charged with refrigerant Chilled water units are supplied
46. d by adjusting the feet The use of waffle pad between the unit baseplate and floor stand is recommended Lower the unit onto the floor stand and align the unit baseplate with the floor stand frame The shipping bolt holes in the baseplate should align with matching holes in the floor stand frame Refit the M8 shipping bolts in the baseplate and secure to the floor stand frame Figure 20 Floor Stand Arrangement Downflow units forward curve fan PEX large frame downflow unit PEX floorstand Overhang iront gussets provided om Front 50 mm 2 on floors over Rear 18mm 3 4 400mm 15 7 high Raised floor Seal air gaps a A Floorstand pedestal v 50 mm 2 0 height adjustable dE minimum mum clearance waffle pad 25 Equipment Inspection and Handling Figure 21 Floor Stand Arrangement Downflow chilled water units EC fan option EC FAN IN OPERATING POSITION Note Protective guard omitted PEX large frame downflow unit l ES PEX floorstand front Unit overhang gussets provided Front 50 mm 2 on stands 400mm Rear 18mm 3 4 15 7 or higher Raised floor E FAL L Seal air gaps Mira gt E ANGELL NIE Floorstand pedestal L w J3 Es 50 mm 2 0 height adjustable minimum clearance waffle pad 5 3 1 Downflow Chilled Water Units with EC Fan Option The optional EC fans are shipped in the transport position and must not be operated unt
47. d bypass valve 54 Piping Schematics Figure 44 Primary connection locations 1 bay downflow chilled water forward curve fan wN eT Ss A A All dimensions from rear corner of unit SECTION A A d including panels 874 mm 34 4 FRONT OF UNIT 853 mm 33 6 X Y Connection Size Opening mm in mm in mm in 1020 1030 1040FC Chilled Water Supply 768 30 1 4 588 23 1 4 1 1 4 O D CR Chilled Water Retum 768 30 1 4 687 27 Description m 752 29 1 2 523 20 1 2 IR 3 4 BSPM IE 1 w Optional Pump 752 29 1 2 523 20 1 2 3 8 comp UM 794 31 1 4 523 20 1 2 1 2 BSP E 760 29 7 8 34 9 1 3 8 44 4 1 3 4 K O V 1 0 2 1 4 Electrical Conn Low Volt 792 31 1 4 764 30 25 1 206 8 401 15 3 4 476 x 385 18 3 4 x 15 1 4 Field pitch condensate drain line a minimum of 10mm per metre 1 8 per ft Infrared humidifier units contain a factory installed condensate trap Do not trap external to unit Immersed electrode humidifier units require an external trap Drain line may contain boiling water Select appropriate drain materials The drain line must comply with local codes H L F 55 Piping Schematics Figure 45 Primary connection locations 2 bay downflow chilled water forward curve fan All dimensions from rear corner of unit including panels SECTION A A FRONT OF UNIT 1704 mm 67 1 Point Descripti
48. discharge air plenum Table 11 Weights for 2 bay upflow large frame EC fan models Dry Weight kg Ib Approximate Model No 2050VC Chilled Water EC 520 1145 2070VC 520 1145 20 Liebert PEX Dimensions and Weights Figure 17 Cabinet and floor planning dimensional data 3 bay upflow large frame EC fan models 2553 T 1008 IANI IT TEST Z RII QRZ H ou NW lt 7 L 0 75 Shaded area indicates a recommended minimum clearance for unit servicing 850 and component access 33 5 Note Upflow units must be connected to field supplied ductwork or factory discharge air plenum Table 12 Weights for 3 bay upflow large frame EC fan models Dry Weight kg Ib Approximate Model No 3080VC 3110VC Chilled Water EC 760 1670 760 1670 21 Equipment Inspection and Handling 5 0 EQUIPMENT INSPECTION AND HANDLING Upon arrival of the unit and before unpacking it verify that the labeled equipment matches the bill of lading Carefully inspect all items for damage either visible or concealed For initial access use a flat bladed screwdriver for panel removal Damage should be immediately reported to the carrier and a damage claim filed with a copy sent to Emerson or to your sales representative 5 1 SAFETY INFORMATION Packaging Material DY All material used to package this unit is recyclable Please save for future use or a d
49. e tis 51 Primary connection locations 2 bay upflow air water glycol cooled single scroll compressor mod els forward curye fama v cetero ek erdt d eeu eee Runs V OD eh piace o d 52 Primary connection locations 2 bay upflow air water glycol cooled dual scroll compressor models forward curve fan s ise A ERU RR NE EU eR Edo ERUNT RA EUR dn 53 Figure 43 Figure 44 Figure 45 Figure 46 Figure 47 Figure 48 Figure 49 Figure 50 Figure 51 Figure 52 Figure 53 Figure 54 Figure 55 Figure 56 Figure 57 Figure 58 Figure 59 Figure 60 Figure 61 Figure 62 Figure 63 Primary connection locations forward curve fan Primary connection locations Primary connection locations Primary connection locations Primary connection locations Primary connection locations Primary connection locations Primary connection locations Primary connection locations Primary connection locations Primary connection locations Primary connection locations Primary connection locations Proper filter pleat direction Fan Belt Removal Infrared humidifier lamps Immersed electrode humidifier 3 bay upflow air water glycol cooled dual scroll compressor models O E 54 1 bay downflow chilled water forward curve fan 55 2 bay downflow chilled water forward curve fan 56 3 bay downflow chilled water forward curve fan 57 1 bay upflow chilled water forward curve fan
50. ear corner of unit including panels SECTION A A X o 874 mm 34 4 FRONT OF UNIT 1704 mm 67 1 Note Upflow units must be connected to field supplied ductwork or factory discharge air plenum X Y Connection Size Opening mm in Point Description mm in mm in 2050 2070VC CS Chilled Water Supply 1515 59 3 4 600 23 1 2 1 5 8 O D CR Chilled Water Return 1630 64 1 4 600 23 1 2 1 5 8 O D ppp io 1644 64 3 4 537 21 1 4 3 8 comp HUM IR 1 2 BSP CD E 25mm OD 1 HUM IE 1 2 BSP i 2 1 4 CD IR Condensate Drain Infrared 1644 64 3 4 537 21 1 4 3 4 BSPM E Electrical Conn High Volt 60 2 1 4 760 29 7 8 34 9 1 3 8 44 4 1 3 4 K O LV Electrical Conn Low Volt 1642 64 3 4 765 30 1 8 25 1 Field pitch condensate drain line a minimum of 10mm per metre 1 8 per ft Infrared humidifier units contain a factory installed condensate trap Do not trap external to unit Immersed electrode humidifier units require an external trap Drain line may contain boiling water Select appropriate drain materials The drain line must comply with local codes 65 Piping Schematics Figure 55 Primary connection locations 3 bay upflow chilled water EC fan All dimensions from rear corner of unit including panels SECTION A A X 874 mm 34 4 FRONT OF UNIT 2553 mm 100 5 Note Upflow units must be co
51. ect all local and remote electric power supplies before working in the unit CAUTION Risk of contact with hot surfaces Can cause injury The compressors refrigerant discharge lines humidifiers and reheats are extremely hot during unit operation Allow sufficient time for them to cool before working within the unit cabinet Use extreme caution and wear protective gloves and arm protection when working on or near hot compressors discharge lines humidifiers and reheats A CAUTION Risk of leaking water Can cause equipment and building damage This unit requires a water drain connection It also requires an external water supply to operate Improper installation application and service practice can result in water leakage from the unit Water leakage can result in severe property damage and loss of critical data center equipment Do not locate unit directly above any equipment that could sustain water damage Emerson recommends installing leak detection equipment for unit and supply lines Liebert PEX Components and Nomenclature 1 0 LIEBERT PEX COMPONENTS AND NOMENCLATURE Figure 1 Downflow model component locations air water glycol cooled systems 1 iCOM Control Display 7 Fan Motor 2 Filters 8 Fan Pulley 3 Evaporator Coil 9 Compressor 4 Electrical Panel 10 Condensate Pump optional 5 Input Isolator 11 Water Cooled Condenser 6 Infrared Humidifier 12 Water regulating Valve
52. ependant on humidifier usage and local water quality A spare pan is recommended to reduce maintenance time at unit The Liebert autoflush system can greatly increase the time between cleanings but does not eliminate the need for periodic checks and mainte nance see COM user manual 051536 for autoflush setup To help reduce excessive scaling in loca tions with difficult water quality the use of Vapure is recommended contact your local Emerson representative NOTE The fill solenoid valve is a pilot assisted design and relies on supply water pressure to operate When energised it may buzz indicating a loss of water supply This condition is normal and not a valve fault Check water supply and confirm all isolation valves are open 11 4 1 Cleaning Humidifier Pan and Float Switch Before turning off unit With unit operating remove call for humidification at iCOM control Let blower operate 5 minutes to allow humidifier and water to cool If unit has a condensate pump turn unit OFF at iCOM control Remove centre frame mullion using a 3mm hex key 2 amp 3 bay units only Pull out humidifier standpipe in pan Inspect O ring replace if necessary Let pan drain and condensate pump operate if applicable Disconnect power from unit 0 309 pt R Boop Disconnect drain coupling from bottom of pan n Remove thermostat from bottom of pan and retaining screws from sides of pan Slide pan out Loosen scale on
53. erating and safety instructions on the unit and in this manual Follow all operating and user instructions A gt E P E WARNING Risk of electric shock Can cause injury or death Disconnect local and remote power supplies before working within 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 COM 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 iCOM control The PEX unit isolation 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 isolation switch Refer to unit electrical schematic Follow all local codes WARNING Risk of explosive discharge from high pressure refrigerant Can cause injury or death This unit contains fluids and gases under high pressure Relieve pressure before working with piping WARNING Risk of refrigerant system rupture or explosion from overpressurization Can cause equipment damage injury or death NOTE The Liebert PEX indoor cooling unit has a factory installed high pressure safety switch in the high side retrigerant circuit WARNING Risk of high speed moving parts Can cause injury or death Disconn
54. external to unit Immersed electrode humidifier units require an external trap Drain line may contain boiling water Select appropriate drain materials The drain line must comply with local codes 63 Piping Schematics Figure 53 Primary connection locations 1 bay upflow chilled water EC fan All dimensions from A A rear corner of unit including panels SECTION A A 874 mm 34 4 FRONT OF UNIT 853 mm 33 6 Note Upflow units must be connected to field supplied ductwork or factory discharge air plenum I X Y Connection Size Opening mm in Description l mm in mm in 1020 1030VC Chilled Water Supply 690 27 1 4 600 23 1 2 1 1 4 ODD CR Chilled Water Return 780 30 3 4 600 23 1 2 1 1 4 O D CD Condensate Drain 794 31 1 4 537 21 1 lena 4 3 8 comp 492 19 1 4 1 2 BSP 34 9 1 3 8 44 4 1 3 4 K O 792 31 1 4 25 1 Field pitch condensate drain line a minimum of 10mm per metre 1 8 per ft Infrared humidifier units contain a factory installed condensate trap Do not trap external to unit Immersed electrode humidifier units require an external trap Drain line may contain boiling water Select appropriate drain materials The drain line must comply with local codes IR 3 4 BSPM IE 1 a la p 64 Piping Schematics Figure 54 Primary connection locations 2 bay upflow chilled water EC fan All dimensions from r
55. eze protec tion requirements Install manual shutoff valves at the supply and return line to each indoor unit and drycooler to permit routine service and emergency isolation of the unit A CAUTION Risk of frozen fluids Can cause equipment damage and building damage Freezing system fluids can rupture piping Complete system drain down cannot be ensured When the field piping or unit may be exposed to freezing temperatures charge the system with the proper percentage of glycol and water for the coldest design ambient Automotive antifreeze is unacceptable and must NOT be used in any glycol fluid system A CAUTION Risk of corrosion Can cause equipment damage Read and follow individual unit installation instructions for precautions regarding fluid system design material selection and use of field provided devices Liebert systems contain stainless steel and copper alloys that require appropriate corrosion protection Contact a local water consultant regarding water quality corrosion and freeze protection requirements Water chemistry varies greatly by location 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 water used must be considered because water from some sources may contain corrosive elements that reduce the effectiveness of the inhibited formulation Preferably surface waters that are classified as soft and are low
56. his manual A WARNING Risk of fire suppression and alarm system activation Can cause injury during building evacuation and mobilization of emergency fire and rescue services Startup operation of optional electric reheat elements may activate facility alarm and fire suppression system Prepare and take appropriate steps to manage this possibility Activating reheat during initial startup may burn off particulate from electric reheat elements Before beginning initial startup checks make certain that unit was installed according to the instructions in this manual All exterior panels must be in place Confirm that all items in 9 0 Checklist for Completed Installation have been done Contact your local Emerson sales representative or Emerson Air Product Support if you have any questions or problems during unit startup and commissioning Liebert PEX Warranty startup procedure includes the following steps These steps must be completed to validate warranty NOTE Unauthorised operation startup of the system may void the warranty Contact your local Emerson office to arrange commisioning Information for Warranty Inspection Remove Power From Unit Input Isolator Complete the following items on the warranty inspection form Installer and address Owner and address Site Contact name and phone Installation date Indoor unit model and serial number Outdoor unit condenser or drycooler model and serial number Condi
57. ho have been specially trained in the installation of air conditioning equipment CAUTION Risk of backward compressor rotation Can cause equipment damage Three phase power must be connected to the unit line voltage terminals in the proper sequence so that scroll compressors rotate in the proper direction CAUTION Risk of improper electrical supply connection Can cause equipment damage CAUTION Risk of overheated terminals Can cause wiring and component damage Use copper wiring only Make sure that all connections are tight 33 Electrical Connections Figure 30 Electrical panel general arrangement Main Input Isolation Switch Neutral amp Earth Terminal 3 4 5 Circuit Breakers Opt Ground Current Detector GCD optional Temp Hum Sensor Air Sail Switch AS ind TH HU rear of elec panel Smoke Detector Control SDC optional Smoke Detector SD optional Fuse Board iCOM Board High Temperature Stat HTS optional Filter Clog Switch FC IntelliSlot Transformer Terminals Power Supply Field Terminals Transformer T6 Transformer T1 Contactors Overloads Field and Communication Electrode Humidifier Cables Isolation Board HIB Power Supply IE humidifier units only S Service 9 ig 12 8 19 13 14 f 41 42 as aa sees eo eo _ 75 76 o4 os o o7 or 2 os 0 et 77 78
58. icularly in open tower systems Regular chemical treatment particularly in areas of high pol lution or corrosive atmospheres is required The following table provides a general guide to the corrosion resistance of stainless steel and copper used in these plate heat exchangers Table 21 Guide to resistance of copper and AISI 316 stainless steel RECOMMENDED WATER PROPERTIES CONCENTRATION Electrical conductivity 10 500 microS cm Alkalinity 70 300 mg l or ppm Chlorides lt 300 mg l or ppm Free Chlorine lt 1 mg l or pom 82 HVAC Maintenance Checklist 12 0 HVAC MAINTENANCE CHECKLIST Inspection Date Job Name Indoor Unit Model Indoor Unit Serial Number Condenser Drycooler Model Condenser Drycooler Serial Room Temperature Humidity C 9erH Ambient Temperature C Filters 1 Check replace filters Grille area unrestricted 2 3 Wipe section clean 4 Coil clean Fan Section Fan wheels guards free of debris Check belt condition if applicable replace if needed Check bearings Ensure wheels rotate freely 1 2 3 4 Check pulleys if applicable replace if worn 5 Check motor mounts 6 Record motor current draw L1 L2 L3 L1 L2 L3 L1 L2 L3 Compare to nameplate amps Reheat 1 Inspect elements 2 Check wire connections and safeties inside reheat box 3 Reheat amp draw Stagel L1 L2 L3 Stage2 L1 L2 L3 Infrared Humidifier 1 Check drain lines
59. il they are secured in the operating position within the raised floor space Each fan assembly frame is pivoted to allow easy installation and removal from the front of the unit using the supplied installation handle mounted inside the rear of the unit Each fan frame is fitted with a protective guard Figure 22 Minimum clearance requirements for EC Fan Installation PLAN VIEW SIDE VIEW 1 BAY TYP 600mm 100mm 23 6 4 UNIT FRONT DO NOT ROUTE ANY SERVICES THROUGH DO NOT ROUTE ANY THIS AREA SERVICES THROUGH THIS AREA 874mm 34 4 780mm 30 7 400mm UNIT FRONT 26 Equipment Inspection and Handling EC Fan Installation Procedure A WARNING Risk of crushing and pinching action from pivoting fan motor assembly Can cause serious injury to hands and fingers Do not remove installation handle from unit Return to storage position when not in use Fan motor assembly mass approximately 50kg 110Ib 1 Locate the installation handle and M8 fixing screws in the rear of the unit and attach the handle to the fan plate in location A refer Figure 23 using the same screws Refer to Position 1 in Figure 24 2 Place downward pressure on the installation handle and remove the shipping plate that secures the fan in the transport position Retain the 6 fasteners 3 Slowly raise the installation handle to lower the fan assembly into operating position 3 4 Locate the filler plate stowed with the inst
60. in chloride and sulfate ion content should be employed Proper inhibitor maintenance must be performed in order to prevent corrosion of the system Consult glycol manufacturer for testing and maintenance of inhibitors Commercial ethylene glycol Union Carbide Ucartherm Dow Chemical Dowtherm SR 1 and Texaco E G Heat Transfer Fluid 100 when pure is generally less corrosive to the common metals of construction than water itself It will however assume the corrosivity of the water from which it is prepared and may become increasingly corrosive with use if not properly inhibited A CAUTION Risk of oxide layer formation Can cause equipment damage 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 system pump operating 38 Piping Leak Checking of Unit and Field Piping Liebert PEX unit fluid systems are factory checked for leaks and may be shipped with a nitrogen holding charge Liebert unit fluid circuits should be checked for leaks at installation as described below NOTE During leak checking of field installed piping Liebert recommends that the unit be isolated using field installed shutoff valves When the Liebert units are included in a leak test use of fluid for pressure testing is recommended When pressurized gas is used for leak testing the Liebert unit the maximum recommended pressure is 2 bar 30 psig and tight
61. ing Procedures for R 407C and R 22 A CAUTION Risk of improper component reinstallation Can cause equipment damage 9 19 MAR wh 81 Maintenance 11 11 11 12 Facility Fluid and Piping Maintenance Facility water and glycol quality remain a requirement throughout the life of the piping system Fluid and piping system maintenance schedules must be established and performed A local fluid mainte nance program must be established that will evaluate fluid chemistry and apply necessary treatment A periodic leak inspection of facility and unit fluid piping is recommended Refer to 7 1 3 Require ments of Systems Using Water or Glycol Plate Heat Exchanger Water Cooled Condenser NOTE A strainer with 20 mesh 1mm is mandatory in the supply pipework to protect particles in the water circuit from blocking the exchanger Regular inspection and cleaning of the strainer Is required to prevent elevated refrigerant head pressures The water cooled condenser is made from multiple AISI 316 stainless steel plates vacuum brazed together to form a compact and highly efficient heat exchanger The plates are arranged so that the ridges of every other plate intersect one another on adjacent plates forming a lattice of contact points The resultant separate channels provide counter current flow of the water and refrigerant Proper maintenance and treatment of the cooling water system is important to reduce the risk of scal ing part
62. ions completed between indoor 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 Allinternal 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 scroll only for proper rotation 10 INFRARED HUMIDIFIER UNITS ONLY Remove lamp protection blocks and rubber band from float switch Reconnect float switch in line plug 11 Factory supplied water under floor sensor LWD installed 9 3 Piping __ 1 Piping completed to refrigerant or coolant loop if required __ 2 Refrigerant check valve installed at condenser correctly if required 3 Refrigerant charge calculated and additional oil added to system if required ___ 4 Piping had been leak checked evacuated and charged if required 5 Refrigeration piping is properly sized sloped trapped as shown in the piping schematics 6 Check piping inside and outside of equipment for proper support 7 Ensure that factory clamps have been reinstalled 8 Drain line connected trapped if required and pitched per local code ___ 9 Water supply line connected to humidifier Isolation
63. ispose of the material appropriately Ws R 9 KT A WARNING Risk of top heavy unit falling over Can cause equipment damage injury or death Read all of the following instructions before attempting to move the unit lift it remove packaging or prepare the unit for installation A CAUTION Risk of sharp edges splinters and exposed fasteners Can cause personal injury Only properly trained personnel wearing appropriate safety headgear gloves shoes and glasses should attempt to move the unit lift it remove packaging or prepare the unit for installation A CAUTION Risk of overhead interference Can cause unit and or structure damage The unit may be too tall to fit through a doorway while on the pallet Measure the unit and doorway heights and refer to the installation plans to verify clearances prior to moving the unit A Risk of damage from forklift Can cause exterior and or underside damage Keep tines of the forklift level and at a height suitable to fit below the pallet and or unit A CAUTION Risk of improper storage Can cause unit damage Keep the unit upright indoors and protected from dampness freezing temperatures and Figure 18 Equipment recommended for handling Liebert PEX contact damage Spreader Bars and Slings Pallet Jack Piano Jacks Forklift 22 Equipment Inspection and Handling If possible transport the Liebert PEX with a forklift or pallet jacks If that is not possible use a
64. ith other low voltage field and communication cables Keep away from power cables Refer to Figure 30 Electrical panel general arrangement Refer to the IntelliSlot 485 and WEB SNMP card technical documents for further information 36 Piping 7 0 PIPING 7 1 TAA All fluid and refrigeration connections to the unit with the exception of the humidifier supply and condensate drain 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 require ments 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 it is recommended 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 Fluid Connections A CAUTION Risk of leaking water Can cause equipment and building damage This unit requires a water drain connection and an external water supply to operate Improper installation applica
65. its must be connected to field supplied ductwork or factory discharge air plenum X Y Connection Size Opening mm in Description mm in mm in 1020 1030UC DC Chilled Water Supply 690 27 1 4 600 23 1 2 1 1 4 O D Chilled Water Return 780 30 3 4 600 23 1 2 1 1 4 O D S RW BSPM ETT HUM Electrical Conn High Volt 60 2 1 4 760 29 7 8 34 9 1 3 8 44 4 1 3 4 K O lectrical Conn Low Volt 792 31 1 4 764 30 25 1 195 7 3 4 456 18 476 x 385 18 3 4 x 15 1 4 Field pitch condensate drain line a minimum of 10mm per metre 1 8 per ft Infrared humidifier units contain a factory installed condensate trap Do not trap external to unit Immersed electrode humidifier units require an external trap Drain line may contain boiling water Select appropriate drain materials The drain line must comply with local codes w Optional Pump 794 31 1 4 537 21 1 4 3 8 comp Humidifier water supply 794 31 1 4 492 19 1 4 1 2 BSP 58 Piping Schematics Figure 48 Primary connection locations 2 bay upflow chilled water forward curve fan All dimensions from rear corner of unit including panels 874 mm 34 4 FRONT OF UNIT A Fan outlet shown for duct connection 1704 mm illustration purposes 67 1 only Note Upflow units must be connected to field supplied ductwork or factory discharge air plenum ese X Y Connection Size Opening mm in P mm in mm in 2050 207
66. its with optional condensate pump NB factory installed in Infrared humidifier units Loose supplied for external installation in Immersed Elec trode humidifier units Condensate pump 50Hz is rated for approx 1625 l h at 3 2m 430 gph at 10 feet total head Size piping based on available condensate head 37 Piping 7 1 2 7 1 3 Humidifier Supply Water Infrared Humidifier 1 2 BSPM supply connection maximum water pressure is 1034kPa 150 psi Size humidifier supply line for 3 8 l m 1 gpm with a minimum water pressure of 140kPa 20 psi Do not supply de ionized water to the humidifier Immersed Electrode Humidifier 1 2 BSPF supply connection maximum water pressure is 700kPa 100psi Size humidifier supply line for 3 8 l m 1 gpm with a minimum water pressure of 140kPa 20 psi Do not supply de ionized water to the humidifier Requirements of Systems Using Water or Glycol These guidelines apply to the field leak checking and fluid requirements for field piping systems includ ing Liebert chilled water condenser water or glycol and drycooler circuits General Guidelines Equipment damage and personal injury can result from improper piping installation leak check ing fluid chemistry and fluid maintenance Follow local piping codes and safety codes Qualified personnel must install and inspect system piping Contact a local water consultant regarding water quality corrosion protection and fre
67. ld pitch condensate drain line a minimum of 10mm per metre 1 8 per ft Infrared humidifier units contain a factory installed condensate trap Do not trap external to unit Immersed electrode humidifier units require an external trap Drain line may contain boiling water Select appropriate drain materials The drain line must comply with local codes 51 Piping Schematics Figure 41 Primary connection locations 2 bay upflow air water glycol cooled single scroll compressor models forward curve fan All dimensions from rear corner of unit including panels SECTION A A X FanOutlt FanOutlt l A _ 4 l A Al Hu F2 B F1 Gp O 34 4 O HUM Fan outlet shown FRONT OF UNIT for duct connection illustration purposes only 1704 mm 67 Note Upflow units must be connected to field supplied ductwork or factory discharge air plenum Description Connection Size Opening mm in G1 Hot Gas Circuit 1 7 8 LD Li Liquid Line Cirouit 1 WS1 Water Glycol Supply Circ 1 1543 60 3 4 665 26 1 8 1 1 4 LD Water Glycol Return Circ 1 1473 58 665 26 1 8 1 1 4 O D Gondensate Drain hfrared w Optional Pump 867 34 1 8 473 18 5 8 3 8 comp Humidifier water supply Infrared 712 28 512 20 1 8 1 2 BSP CD IE Condensate Drain Elect 867 34 1 8 473 18 5 8 25mm OD 1 712 28 512 20 1 8 34 9 1 3 8 44 4 1 3 4 KO LV Electrical Conn Low Volt 16
68. llation 41 Piping 7 3 7 3 1 Dehydration Leak Test and Charging Procedures for R 407C and R 22 Air Cooled Condenser with Electronic Fan Speed Head Pressure Control System The Fan Speed Control system uses a pressure activated electronic fan speed control system to ensure operation at ambient temperatures as low as 5 C 28 F Refer to the Air Cooled Condenser technical data manual for further information Fan Speed Control Piping A copper discharge line and liquid line must be field installed between the indoor unit and the out door condenser for each refrigeration circuit See Figure 33 for details Electrical Interconnection The remote air cooled condenser is factory wired and requires a single phase power supply 230 1 50 to operate The power supply for the condenser can be provided either from the indoor PEX unit via optional Remote Air Cooled Condenser Power Kit or from a separate source A 24VAC interlock con nection is available from terminals 70 71 70A 71A in the PEX unit electrical panel Refer Figure 31 Field connection terminals Fan Speed Control Leak Check and Evacuation Procedure Proper leak check and evacuation can be accomplished only with all system solenoid and isolation valves open and check valves accounted for 1 If unit power is available open the unit liquid line solenoid valves using the evacuation function for Compressor 1 and Compressor 2 in the diagnostic section of the iCOM contr
69. loor planning dimensional data 1 bay downflow large frame models F amp n 874 34 4 19 0 75 850 1970 E 77 5 Shaded area indicates i 33 5 recommended minimum clearance for unit servicing and component access Table 1 Weights for 1 bay downflow large frame models Dry Weight kg Ib Approximate Model No 1020FA W G 1025FA W G 1030FA W G 1035FA W G Air Cooled 300 660 310 680 320 700 330 725 Water Glycol Cooled 310 680 320 700 330 725 340 750 Model No Chilled Water Dry Weight kg Ib Approximate 1020FC 260 570 1030FC 260 570 1040FC 270 595 10 Liebert PEX Dimensions and Weights Figure 7 Cabinet and floor planning dimensional data 2 Bay downflow large frame models oeo 77 1704 67 1 874 84 4 19 0 75 1970 Shaded area indicates 850 77 5 a recommended 33 5 minimum clearance for unit servicing and component access Table 2 Weights for 2 bay downflow
70. nd then remove power from the main unit input isolation switch and check with a meter Close all load circuit breakers you opened in Step 2 Restore power to unit turn ON the main unit input isolation switch press the ON OFF button Check and record the current draw on all line voltage components and match with rating plate NOTE Electric Reheat See Warning on page 68 Activate for a minimum of five 5 minutes 11 12 13 14 Check for unusual noises and vibration Check all refrigerant and water lines for leaks Record all of the following a All component voltages and current draws All air water temperatures indoor and outdoor All refrigerant and water glycol pressures All levels of refrigerant and oil in sight glasses Record refrigerant pressure switch settings and operating pressures Record superheat and sub cooling Note unit superheat can be adjusted at the TX valve and should be in the range of 5 8K 10 to 15F Test all control sequences and functions of your unit for proper operation Use iCOM User Manual 051536 for guide to system control operations mo a9 c 70 Maintenance 11 0 MAINTENANCE 11 1 A WARNING Risk of electric shock Can cause injury or death Disconnect local and remote power supplies before working within Before proceeding with installation read all instructions verify that all the parts are included and check the nameplate to be sure the voltage matches
71. nels Retain all fasteners Remove the infrared humidifier assembly Models P1040GC P2090GC P3140GC only Remove the base plate fill panel at the rear of the fan assembly Remove the front centre mullion using a 3mm hex key Models P2090GC and P3140GC only Locate the installation handle and M8 fixing screws in the rear of the unit and attach the handle to the fan assembly in location A using the same screws Refer to Position 1 in Figure 58 Slowly pull on the handle until the fan assembly is in Position 3 Refer Figure 59 Place a supporting piece of timber underneath the fan Remove the handle and using the opposite end refit the handle in location B on the fan plate as shown in Position 4 Pull on the handle until the fan is in Position 5 Remove the motor cover plate and disconnect the wiring Remove the top plate to access the fan motor assembly Reverse the procedure to install the new fan motor Figure 58 EC Fan motor removal procedure handle fixing location EC Fan in operating position viewed from above TUTTA Unit Front 74 Maintenance Figure 59 EC fan motor removal procedure 75 Maintenance 11 4 Infrared Humidifier During normal humidifier operation deposits of mineral solids will collect in humidifier pan and on the float switch These must be cleaned periodically to ensure proper operation Frequency of cleaning must be locally established since it is d
72. ness of the unit should be verified by pressure decay over time 2 psig hour 0 3 bars hour or sensing a tracer gas with suitable instrumentation Dry seals in fluid valves and pumps may not hold a high gas pressure 7 2 Refrigeration Piping A WARNING Risk of explosive discharge from high pressure refrigerant Can cause injury or death This unit contains fluids and or gases under high pressure Relieve pressure before working with piping Recover refrigerant as per local codes Both high pressure HP and low pressure LP switches do NOT have a schrader valve core fitted Lower system pressures to atmosphere BEFORE removing either switch A CAUTION Risk of oil contamination with water Can cause equipment damage All Liebert PEX Systems require the use of POE polyolester oil See 11 9 1 Compressor Oil for requirements 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
73. nfrared humidifier units contain a factory installed condensate trap Do not trap external to unit Immersed electrode humidifier units require an external trap Drain line may contain boiling water Select appropriate drain materials The drain line must comply with local codes Water circuit includes regulating valve and bypass valve 50 Piping Schematics Figure 40 Primary connection locations 1 bay upflow air water glycol cooled single scroll compressor models forward curve fan A A SECTION A A All dimensions from rear corner of unit including panels Xo 0 ub s 874 mm 34 4 A Fan outlet shown FRONT OF UNIT for duct connection illustration purposes 853 mm only 33 6 Note Upflow units must be connected to field supplied ductwork or factory discharge air plenum paint Descrinti n Connection ERA mm in P mm E gt mm ne 1030 1035U Gi 78 1 X SE Lb ws SD WRI TROD ppp 480 1878 314 BSPM 480 18 718 3 8 comp HUM IR Humidifier water supply Infrared 637 25 381 13 1 2 BSP CD IE Condensate Drain Elect 735 28 7 8 480 18 7 8 25mm OD 1 HUM IE Humidifier water supply Elect 637 25 1 8 331 13 1 2 BSP E Electrical Conn High Volt 60 2 3 8 760 29 7 8 34 9 1 3 8 44 4 1 3 4 K O LV Electrical Conn Low Volt 792 31 1 8 765 30 1 8 25 1 F1 Fan Outlet 185 7 1 4 311 12 1 4 404 x 258 15 7 8 x 10 1 8 Fie
74. nnected to field supplied ductwork or factory discharge air plenum Point Y Connection Size Opening mm in mm in mm in 3080 3110VC cs 600 23 1 2 2 O D CR 600 23 1 2 2 O D m 597 21 14 34 BSPM 537 21 1 4 3 8 comp HUM IR Humidifier water supply Infrared 2494 98 1 4 492 19 1 4 1 2 BSP CD IE ci Ae ee 484 19 25mm OD 1 HUM IE 477 18 3 4 1 2 BSP E 760 29 7 8 34 9 1 3 8 44 4 1 3 4 K O LV Electrical Conn Low Volt 2492 98 765 30 1 8 25 1 Field pitch condensate drain line a minimum of 10mm per metre 1 8 per ft Infrared humidifier units contain a factory installed condensate trap Do not trap external to unit Immersed electrode humidifier units require an external trap Drain line may contain boiling water Select appropriate drain materials The drain line must comply with local codes 66 Checklist for Completed Installation 9 0 CHECKLIST FOR COMPLETED INSTALLATION 9 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 Ifthe equipment has been disassembled for installation unit must be reassembled per instructions 5 Downflow EC Fan Units fans lowered into operating position and secured 9 2 Electrical ___ 1 Supply voltage and phase matches equipment nameplate __ 2 Wiring connect
75. ol refer to the 1COM user manual 051536 If unit power is not available a field supplied 24VAC 75VA power source must be directly connected to each of the unit solenoid valves 2 Connect refrigerant gauges to the suction and discharge line Schrader access valves on both compressors 3 For each circuit open the isolation valves and place a 150 PSIG 1034 kPa dry nitrogen charge Check system for leaks using an acceptable leak test method NOTE The use of fluorocarbon substances as a trace gas for leak testing is not permitted in many countries Check local refrigerant handling codes of practice before use 4 After completion of leak testing release the test pressure per local code and pull an initial deep vacuum on the system with a suitable pump 5 After four hours check the pressure readings and if they have not changed break vacuum with dry nitrogen Pull a second R 407C and R 22 and third R407C only vacuum to 250 microns or less Recheck the pressure after two hours After completing this step proceed to Fan Speed Charging 42 Piping Fan Speed Charging 1 2 3 4 5 Check unit nameplate for refrigerant type to be used Unit control configurations differ depending on refrigerant type Refrigerant charging requires unit operation Refer to 9 0 Checklist for Completed Installation Calculate the amount of charge for the system Refer to the unit condenser and refrigerant line charge data
76. ommissioning Procedure for Warranty Inspection 10 3 Commissioning Procedure With Panels On NOTE Unauthorised operation startup of the system may void the warranty Contact your local 8 9 10 Emerson office to arrange commisioning Disconnect all power to the environmental control unit and check Open all line voltage circuit breakers except the main fan circuit breaker and the control voltage circuit breaker in the electric panel Use COM to activate loads Turn on power to the unit and check line voltage on main unit input isolation switch Line voltage must be within 10 of nameplate voltage Turn ON the main unit input isolation switch and check secondary voltage at transformer T1 Voltage at T1 must be 24VAC 2 5VAC check at TB1 1 and TB1 5 T1 voltage must not exceed 28VAC Change primary tap if necessary Push the COM ON OFF button The fan s will start and ON lamp will light Check fan rotation if not correct make necessary changes to the line side of the unit disconnect with power OFF The unit is phased from the factory Your unit will operate at the factory set configuration for all component operations The operator may set the values for Temperature and Humidity setpoints the Proportional Band and the Deadband The USER Menu may used to set the alarms and other control functions Refer to COM User manual 051536 for large or small display operation and settings Turn OFF the unit by the ON OFF button a
77. on Connection Size Opening mm in P mm m J mm T s 2050 2070 2090FC CS Chilled Water Supply 1618 63 3 4 CR Chilled Water Return 1618 63 3 4 27 1 5 8 O D CD IR pondonsalts Drain Infrared e T 523 T 2 3 4 BSPM HUM IR Humidifier water supply Infrared um 64 a CD IE Condensate Drain Elect 884 34 3 4 m 25mm OD 1 HUM IE Humidifier water supply Elect 775 30 1 2 681 26 3 4 1 2 BSP E LV Electrical Conn Low Volt 1642 64 3 4 764 30 25 1 F1 Fan Outlet 217 8 1 2 401 15 3 4 476 x 385 18 3 4 x 15 1 4 F2 1007 39 3 4 401 15 3 4 476 x 385 18 3 4 x 15 1 4 Field pitch condensate drain line a minimum of 10mm per metre 1 8 per ft Infrared humidifier units contain a factory installed condensate trap Do not trap external to unit Immersed electrode humidifier units require an external trap Drain line may contain boiling water Select appropriate drain materials The drain line must comply with local codes 56 Piping Schematics Figure 46 Primary connection locations 3 bay downflow chilled water forward curve fan HUM IR cs CR LV 2553 mm 100 5 All dimensions from rear corner of unit including panels Point Description X mm in Y mm in Connection Size Opening mm in 3110 3140FC Chilled Water Supply Chilled Water Return Condensate Drain Infrared w Optional Pump CS CD IR 2468 97 1 4 2468 9
78. on Network Power The global leader enabling in Business Critical Continuity emersonnetworkpower com E ACPower Systems Z Embedded Computing E Outside Plant Services E Connectivity E Embedded Power E Power Switching and Controls Z Site Monitoring E DCPower Systems Z Integrated Cabinet Solutions Precision Cooling E Surge amp Signal Protection Emerson Network Power and the Emerson Network Power logo are trademarks and service marks of Emerson Electric Co 2007
79. or factory discharge air plenum X Y Connection Size Opening mm in Point Description mm in mm in 3080U 3090 3100U G1 Hot Gas Circuit 1 964 38 665 26 1 8 7 8 LD G2 Hot Gas Circuit 2 2393 94 1 4 665 26 1 8 7 8 LD L1 Liquid Line Circuit 1 1034 40 3 4 665 26 1 8 5 8 LD E Liquid Line Circuit WS1 Water Giycol Supply Circ 1 WS2 Water Glycol Supply Circ 2 wet Water Glyeol Return Ciro WR2 Water Glycol Return Ciro 2 opu Condensate Drain hrared w Optional Pump HUM IR Humidifier water supply Infrared CD IE Condensate Drain Elect 1717 67 5 8 473 18 5 8 25mm OD 1 HUM E Humidifier water supply Elec E Electrical Conn High Volt 60 2 3 8 760 29 7 8 34 9 1 3 8 44 4 1 3 4 K O LV Electrical Conn Low Volt 2492 98 1 8 765 30 1 8 25 1 F1 Fan Outlet 185 7 1 4 311 12 1 4 404 x 258 15 7 8 x 10 1 8 F2 Fan Outlet 1085 42 3 4 311 12 1 4 404 x 258 15 7 8 x 10 1 8 F3 Fan Outlet 1915 75 3 8 311 12 1 4 404 x 258 15 7 8 x 10 1 8 Field pitch condensate drain line a minimum of 10mm per metre 1 8 per ft Infrared humidifier units contain a factory installed condensate trap Do not trap external to unit Immersed electrode humidifier units require an external trap Drain line may contain boiling water Select appropriate drain materials The drain line must comply with local codes Water circuit includes regulating valve an
80. or similar device to lift one end of the unit just enough to allow removal of the piano jack from that end 4 Repeat Step 3 to remove the piano jack on the opposite end 5 Remove all material that might have been used to protect the unit from the piano jacks and strapping 24 Equipment Inspection and Handling 5 2 4 Removing Liebert PEX from pallet Using Rigging 5 3 A WARNING Risk of improper moving Can cause equipment damage injury or death The center of gravity varies depending on the unit size and selected options Remove unit packaging and access the unit internals Remove all M8 shipping bolts securing the Liebert PEX to the pallet Do NOT discard Space the slings equidistant on the unit Place the slings between the bottom rails of the Liebert PEX and the top of the pallet Use spreader bars or a similar device and padding to ensure the Liebert PEX will not be damaged when the unit is lifted Lifting will force the slings toward the Liebert PEX and the slings may damage the unit unless it is properly protected Que co a NOTE Depending on final installation location the pallet may need to remain under the unit Therefore the shipping bolts would not yet be removed 6 Lift the Liebert PEX off the pallet 7 Move the pallet from under the unit Placing the Unit on a Floor Stand Emerson Floor Stand Ensure that the floor stand is orientated correctly prior to placing the unit Level the floor stan
81. ot point Insert lever and pull downwards to remove belt Push upwards to remove belt Downflow Fan Upflow Fan Assembly Assembly Figure 57 Fan Belt Removal 11 2 2 Belt Installation 1 Select the appropriate replacement B section belt and position on the fan pulley To maximize performance and reliability of Liebert PEX equipment replace with the same belt specification Contact your local Emerson representative for replacement belts 2 Prepare to fit the belt by following the steps in Section 11 2 1 3 Fit the belt onto the motor pulley and carefully lower the motor to tension the belt 4 The drive is auto tensioning so no adjustments are necessary Fan Bearing Maintenance Field lubrication is NOT required for the life of the bearing Bearings are permanently sealed and self lubricating and cannot be greased Fan Bearing Inspection Disconnect power to unit Remove drive belts see 11 2 1 Belt Removal Inspect bearing for tightness of set screws and rubber collar condition Rotate fan wheel by hand Listen for unusual noise and look for signs of unusual play QU mai EA Fan Bearing Replacement 1 To maximize performance and reliability of Liebert PEX equipment use only factory approved bearings Contact Emerson Spare Parts to order replacement bearings 2 Properly mount and align bearings on shaft Tighten set screws in proper sequence and to proper torque using a torque wrench in accordance with the man
82. ow Volt Fan Outlet 807 31 3 4 247 9 3 4 780 358 30 3 4 14 1 8 25 1 410 x 310 16 1 8 x 12 1 4 Field pitch condensate drain line a minimum of 10mm per metre 1 8 per ft Infrared humidifier units contain a factory installed condensate trap Do not trap external to unit Immersed electrode humidifier units require an external trap Drain line may contain boiling water Select appropriate drain materials The drain line must comply with local codes 47 Piping Schematics Figure 37 Primary connection locations 2 bay downflow air water glycol cooled single scroll compressor forward curve fan SECTION A A FRONT OF UNIT Description 1704 mm 67 X mm in Y mm in All dimensions from rear corner of unit including panels 874 mm 34 4 Connection Size Opening mm in 2045 2055F Hot Gas Circuit 1 Liquid Line Circuit 1 Water Glycol Supply Circ 1 169 6 5 8 239 9 3 8 1549 61 775 30 1 2 775 30 1 2 7 8 LD 5 8 LD 1 1 4 1D Water Glycol Return Circ 1 Condensate Drain Infrared w Optional Pump 1479 58 1 4 869 34 1 4 869 34 1 4 775 30 1 2 775 80 1 2 632 25 632 25 1 1 4 OD 3 4 BSPM 3 8 comp CD IE E LV Electrical Conn Low Volt 1652 65 F1 F2 Humidifier water supply Infrared Condensate Drain Elect HUM IE Humidifier water supply Elect 745 29 1 4 681 26 3 4
83. ower even during the unit off mode of iCOM control Disconnect local and remote power supplies before working within Check and clear obstructions in gravity lines leading to condensate pump Remove sump and clean with a stiff nylon brush and flush with water Inspect and clear clogs in discharge check valve and float mechanism Reassemble and check for leaks 11 7 Air Cooled Condenser and Drycoolers Clear coil surface of all debris that will inhibit airflow Check for bent or damaged coil fins and correct Do not permit snow or loose materials to accumulate around or under outdoor unit Periodically consider commercial cleaning of coil surface Inspect fans motors and controls for proper operation and condition Check all piping and capillaries for proper support Inspect for leaks 11 8 Reheat Electric Reheat Inspect and clean reheat elements Inspect and tighten support hardware 80 Maintenance 11 9 Compressor 11 9 1 Compressor Oil A CAUTION 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 See oil types specified in Table 20 Do NOT mix polyolester POE and mineral based oils Do NOT mix oils of different viscosities Consult Emerson or the compressor manufacturer if you have ques
84. rge air plenum Table 4 Weights for 1 bay upflow large frame models Dry Weight kg Ib Approximate Model No 1020UA W G 1025UA W G 1030UA W G Air Cooled 310 680 320 700 330 725 Water Glycol Cooled 320 700 330 725 340 750 Model No Chilled Water Dry Weight kg Ib Approximate 1020UC 270 595 1030UC 270 595 13 Liebert PEX Dimensions and Weights Figure 10 Cabinet and floor planning dimensional data 2 bay upflow large frame models K B 0 75 Shaded area indicates a recommended minimum clearance for unit servicing and component access Note Upflow units must be connected to field supplied ductwork or factory discharge air plenum Table 5 Weights for 2 bay upflow large frame models Dry Weight kg Ib Approximate 2045 2055 2040 2050 2060 2070 Model No UA W G UA W G UA W G UA W G UA W G UA W G Air Cooled 540 550 560 580 610 620 1190 1210 1230 1275 1340 1365 Water Glycol Cooled 560 570 590 610 640 650 1230 1255 1300 1340 1410 1430 Dry Weight kg Ib Approximate Model No 2050UC 2070UC Chilled Water 500 1100 500 1100 14 Liebert PEX Dimensions and Weights Figure 11 Cabinet and floor planning dimensional data 3 bay upflow large frame models Shaded area indicates a E 850 recommended minimum clearance for unit servi
85. rmination resistor value 24K ohm must be fitted at the fur thest end of the line Figure 32 Water Under Floor Sensor LWD wiring Field connection terminals in electrical panel 6 1 2 3 Termination Sensori Sensor2 Sensor3 Sensor 4 sonoro e resistor 24K ohm Max 20 metres Remote Air Cooled Condenser Power Kit Option Air cooled Liebert PEX units can be supplied with an optional factory fitted power kit for remote elec trical service to the outdoor air cooled condenser A 16amp rated single pole circuit breaker and con tactor is provided for each refrigeration circuit A CAUTION Do not exceed the electrical rating for this circuit Consult the factory should this service be insufficient for condenser power requirements Unit FLA includes 16amp allowance when ordered as a factory option iCOM Network Cabling Up to 2 off CAT5e cables may be required to connect each PEX COM unit to an external network switch These should be routed up the left hand side of the unit along with other low voltage field and communication cables Keep away from any power cables Refer to Figure 30 Electrical panel gen eral arrangement Refer to 051536 COM User manual for PEX Applications for details on networking cable require ments IntelliSlot 485 and WEB SNMP Cards These optional cards require twisted pair shielded communication and CAT5e cables which should be routed up the left hand side of the unit along w
86. side and bottom of pan with a stiff nylon brush or plastic scraper Flush with water Carefully clean scale on float switch make sure to reinstall correctly seeFigure 60 Reinstall pan thermostat standpipe drain coupling and screws into humidifier Refit centre frame mullion if applicable Operate humidifier and check for leaks Be eee Pe Noor Co h2 2 Figure 60 Correct orientation of float switch Correct Switch Orientation Incorrect Switch Orientation 76 Maintenance 11 4 2 Changing Humidifier Lamps NOTE Touching quartz lamps with bare hands will severely shorten bulb lite Skin oils create hot O po SIS OC ds ES b spots on lamp surface Wear clean cotton gloves when handling lamps Remove humidifier pan see 11 4 1 Cleaning Humidifier Pan and Float Switch Steps 1 through 11 Disconnect power from unit At humidifier remove screws and cover from high voltage compartment Disconnect one end of purple jumper wires Using a continuity meter locate burned out lamp Remove lamp brackets under lamps Loosen two screws securing lamp lead wires to junction block Pull bulb straight down and discard Wrap lead wires once around new lamp s metal ends This will support lamp and allow for thermal expansion Insert lead wires into junction block and torque screws to 3 4 N m 80 in 1b 10 Reassemble by reversing Steps 1 through 9 Figure 61 Infrared humidifier lamps Infrared
87. tents Let fans operate 5 minutes to allow steam pipe s to cool If unit has a condensate pump turn unit OFF at iCOM control Turn off humidifier circuit breaker Remove water level sensor and cover from overflow Remove any scale buildup Carefully remove lid and inspect o ring Inspect and clean electrodes Replace if necessary Check orientation and re tighten Loosen velcro strap and carefully drain bottle into the tray Dispose of scale deposits separately Inspect bottle clean and or replace if necessary Reassemble lid to bottle Resecure strap Check all hose connections Inspect and clean steam distribution pipe s ADAN Rp 5 Na O Turn on humidifier circuit breaker Restart unit Operate humidifier and check for leaks m Ka o al Figure 63 Electrode orientation for different water qualities 2 Electrode Bottle 3 Electrode Bottle 2 Y D High Conductivity Standard Conductivity Low Conductivity gt 600ppm 100 600ppm lt 100 ppm 79 Maintenance 11 6 Condensate Drain and Condensate Pump Systems 11 6 1 Condensate Drain Check and clear obstructions in tubing during routine maintenance 11 6 2 Condensate Pump Disconnect power to unit using main input isolation switch A WARNING Risk of electric shock Can cause injury or death The COM microprocessor does not isolate power from the unit even in the Unit Off mode Some internal components require and receive p
88. tion and service practice can result in water leakage from the unit Water leakage can result in severe property damage and loss of critical data center equipment Do not locate unit directly above any equipment that could sustain water damage Emerson recommends installing leak detection equipment for unit and supply lines Condensate Piping Field Installed Do not reduce drain lines Do not expose drain line to freezing temperatures Drain line may contain boiling water Use copper or other suitable material Drain line must comply with local building codes Emerson recommends installing under floor leak detection equipment Gravity Drain Infrared Humidifier units 3 4 BSPM drain connection is provided on units without optional factory installed condensate pump Pitch drain line toward drain a minimum of 10mm per metre 1 8 per 1 foot of length Drain is trapped internally DO NOT trap external to equipment Drain line must be sized for 7 6 l m 2 gpm flow and suitable for boiling water Gravity Drain Immersed Electrode Humidifier units 25mm 1 O D drain connection is provided The install pack includes a length of hose to extend through the unit base Pitch drain line toward drain a minimum of 10mm per metre 1 8 per 1 foot of length Drain MUST BE trapped externally Drain line must be sized for 7 6 l m 2 gpm flow and suitable for boiling water Condensate Pump 1 2 copper sweat connection is provided on un
89. tion of unit when received Is there a freight damage claim in process Have manuals been kept with unit s the air product connected to site monitoring or switchover controls Provide model and serial number of connected controls for switchover controls 68 Initial Startup Checks and Commissioning Procedure for Warranty Inspection 10 2 Startup Checks Inspection With Panels Removed and Input Isolator Switch Off 1 2 Check all internal piping clamps and tighten or secure if needed Check field piping for proper support Check unit electrical connections and tighten or secure if needed Check control plugs and Mate N Loc connections to the control boards and components Check all major components such as compressors reheats humidifiers and motors that may have loosened during shipping Remove all debris tools and documents from unit area Store user manual unit documentation in document pocket located inside LHS door Record fan motor power and voltage from nameplate Record belt size motor and fan pulley if applicable Record filter size and quantity Record piping size for discharge and liquid lines Check piping for proper traps including inverted traps or check valves on condensers Record total equivalent length for discharge and liquid piping Record compressor s model and serial number Record unit configuration and verify with the startup document 69 Initial Startup Checks and C
90. tions Table 20 Compressor oil types Refrigerant Type Compressor Type R 22 R 407c Copeland Scroll POE Oil ISO 22 Viscosity 1 Use Copeland POE Oil ULTRA 22CC Mobil EAL Arctic 22CC or other Copeland approved oils 11 9 2 Scroll Compressors Hermetic scroll compressors do not have an oil sight glass 11 10 Compressor Replacement Replacement compressors are available through your local Emerson office If unit is under warranty complete and include a warranty claim form available from Spare Parts with compressor that is being returned The original compressor should be returned with sealed connections 11 10 1Compressor Motor Burnout If a burn out has occurred a full system clean out is required or continued compressor and system problems will be experienced For clean out warnings and procedures see Copeland Application Engineering Bulletin 24 1105 Prin ciples of Cleaning Refrigeration Systems 11 10 2Compressor Replacement Procedure 1 Disconnect power and follow all warnings at front of this manual Attach suction and discharge gauges to access fittings Recover refrigerant as per local codes Disconnect all electrical connections Detach rotalock valves from compressor Remove failed compressor If required follow compressor manufacturer s suggested clean out procedures Install replacement compressor and make all connections Evacuate charge and operate per 7 3 Dehydration Leak Test and Charg
91. ufacturer s instructions Fan Motor Inspect motor at regular intervals Fan Motor Lubrication Motors comes pre lubricated from the factory Bearings are permanently sealed and self lubricating and cannot be greased Fan Wheel Check to see if wheel s are tightly mounted on fan shaft Rotate wheel s and make sure they do not rub against fan housing The wheel s should be periodically cleaned of dirt and debris 73 Maintenance 11 3 Blower System Direct Drive EC Fans The blower system comprises a integrated backward curve centrifugal fan coupled to an EC motor and requires little no maintenance The motor is fed with 400V 3 phase power and uses a 0 10VDC signal from the iCOM controller for speed control Blower drive system components that are part of the maintenance schedule include the blower See HVAC Maintenance Checklist on page 83 A WARNING Risk of crushing and pinching action from pivoting fan motor assembly Can cause serious injury to hands and fingers Read the directions in this manual before servicing the blower system Follow all directions when servicing the unit Do not remove installation handle from unit Return to storage position when not in use Fan motor assembly mass approximately 50kg 110lb 11 3 1 Removal Downflow Chilled Water Units 9 Qt e AS n 8 9 10 11 12 13 Shut down unit and isolate power Remove the fan access panels and horizontal support chan
92. valve opened ___ 10 Unit baseplate pipe connection openings are sealed 9 4 Other 1 Ducting complete if required 2 Discharge air plenum fitted if required 3 Filters installed and airflow direction correct 4 Check fasteners that secure compressors reheats humidifier and motors some may have become loose during shipment 5 Verify additional water detection is properly installed around all units recommended Blower drive system rotates freely 7 Installation materials and tools have been removed from equipment literature shipping materials construction materials tools etc 67 Initial Startup Checks and Commissioning Procedure for Warranty Inspection 10 0 INITIAL STARTUP CHECKS AND COMMISSIONING PROCEDURE FOR WARRANTY INSPECTION 10 1 A WARNING Risk of electric shock Can cause injury or death Disconnect local and remote power supplies before working within 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 Follow all local codes A WARNING Risk of improper wiring piping moving lifting and or handling Can cause equipment damage injury or death Only qualified service personnel should move install or service this equipment Read all installation operating and safety instructions before proceeding Read and follow all warnings on page 1 and elsewhere in t
93. water units with EC fan option Seal floor openings to maximise raised floor airflow efficiency Upflow Units Upflow units are available for factory plenum or field ducted operation and are manufactured to support a nominal external static pressure ESP specific to the selected air path refer Figure 5 Liebert PEX model number nomenclature Due to variations in applications a speed change may be required to obtain the desired air flow Consult Emerson Technical Support for more informa tion Upflow units must be connected to field ductwork or factory discharge plenum with grille Ensure ductwork complies with good design practice refer Figure 26 for recommendations Location Considerations Provide minimum 850mm 83 5 front clearance for unit servicing and component access Position downflow units at the end of hot aisles for maximum efficiency Connections Plan the routing of wiring piping and ductwork to the unit See Figures 30 and 36 through 55 for unit connection locations The unit requires a drain which must comply with all applicable codes This drain line may con tain boiling water See 7 1 1 Condensate Piping Field Installed for details Three phase electrical service is required for all models Electrical service must conform to national and local electrical codes See equipment nameplate for details Liebert PEX Dimensions and Weights 4 0 LIEBERT PEX DIMENSIONS AND WEIGHTS Figure 6 Cabinet and f
94. with modulating control Field installed piping is required from the unit to the valves and supply return pipe connections drycooler and pump package Field installed piping is required from the unit to an external source of chilled water Pre Installation Guidelines 3 0 PRE INSTALLATION GUIDELINES 3 1 3 2 3 2 1 3 2 2 3 3 3 4 Room Preparation Verify the floor is level solid and sufficient to support the unit See tables for unit weights Confirm that the room is properly insulated and has a sealed vapour barrier For proper humidity control keep outside or fresh air to an absolute minimum Avoid locating units in an alcove or at the end of a long narrow room Locate the units as close as possible to the largest heat load Allow minimum recommended clearances for routine maintenance and service See Figures 6 through 17 for dimensions An under floor water detection system is recommended Contact your local Emerson office for additional information NOTE Liebert PEX units are supplied with a water under floor spot detector and cable Air Distribution Downflow Units Verify the raised floor has been properly sized for unit airflow and is free of any unintended restrictions Perforated floor tiles or aluminium air grilles in the raised floor should ensure minimal pressure loss Avoid floor elevations less than 300mm 12 Note a minimum floor height of 400mm 15 7 is required for downflow chilled

Liebert PEX User Manual - Large Frame

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