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Liebert® HPC-S Free-Cooling Chiller with Scroll Compressors

1. 9 0 OPTIONS AND ACCESSORIES 9 1 9 2 Pump Set The centrifugal pump units are direct driven with close coupled motors and a single shaft the induction motor has 2 poles with IP 55 protection and class F insulation The pumps are of the top pull out design i e the power head motor pump head and impeller can be removed for maintenance or service while the pump housing remains in the pipe work The electronic pump adjustment algorithm enables to modulate the pump speed to keep the delivery steady through the evaporator even if the hydraulic load changes in this way a significant energy saving is achieved and varies depending on the applications In particular in the free cooling units this benefit is obtained above all in summer when the free cooling coil is short circuited The adjustment set of the inverter driven pump is made in the factory It can be further adjusted during startup by an Emerson technician Pump casings and impellers are in cast iron shafts are in stainless steel the shaft seal is a brass neck ring permits ideal conditions for the use of water mixtures containing ethylene glycol The BQQE mechanical shaft seal is a rubber bellow seal with silicon carbide silicon carbide seal faces and secondary seals of EPDM The pump housing the motor stool and the motor stator housing are electrocoated The pump units have been chosen and sized to operate within specific limits namely e Water ethylene glycol
2. Rear View Condenser Coil WN Front View Fiske ea Air Inlet Refrigerant Circuit Electrical Left side SS IA DPNO02758 Connection End Piping Connection ping Pg 1 Rev 0 Figure 8 Isometric views FG0080 FB0110 with buffer tank Left Side i i o Right Side Piping Connection EP and Control kG DES A gt Rear View Condenser Coil Front View Refrigerant Circuit S Air Inlet Xy ir Inle Right Side es EP and Control Left Side DPN0O02760 Unit Panel T UN Pg 1 Rev 0 Piping Connection Liebert HPC S 20 Installation Figure 9 Liebert HPC S fluid circuit schematic Option only with Water Tank Version Assembly with Unit q Only with Twin Pump Version Water Tank Outlet Grooved rigid coupling DN80 3 88 9mm J y ALWAYS OPEN WAY Water Tank Inlet Grooved rigid coupling DN80 3 88 9mm Chilled Water Inlet Grooved rigid coupling DN80 3 88 9mm Chilled Water Outlet Grooved rigid coupling Unit Frame With Tank Assembled EA p Unit Frame Without Tank Tank Frame 8 Only With Single Pump Version me Gaee y 68 o ne EE 4 l L al o L a I 3 88 9mm 3 88 9mm i Only With Water Tank Version Assembly With e AR Unit Ref Description Ref Description 1 Evaporator 12 Water Outlet Evaporator Probe 3 Water Filter
3. configurable free contact external input for remote ON OFF Table 6 Internal fluid volume Unit Volume Model US Gal FG0052 33 3 FG0080 38 8 FB0110 39 9 Contactors for compressors and pumps Protection MCB s for compressors fans and pumps Main switch for auxiliary circuit and fast start feature optional NOTE Add the tank s volume for the units with optional buffer tank Table 7 Refrigerant and oil charge Relay for checking phase sequence minimum voltage loss one or more phase Manual operation through Liebert iCOM Volt free contacts for remote indication of Model Refrigerant charge each circuit Ib Oil charge each circuit US gal FG0052 44 1 0 90 0 90 FG0080 57 3 0 90 1 80 FB0110 57 3 1 80 1 66 NOTE Refrigerant type R410A Oil type ICI Emkarate RL 32 83MAF 33 Liebert HPC S Electrical Panel and Chiller Control Table 8 Operating range Models FG0052 FG0080 FB0110 Maximum outdoor temperature F 124 9 119 84 109 4 Safety devices settings High pressure switch psig 609 16 High pressure safety valve psig 653 12 High pressure safety valves each circuit 1 High pressure safety valve connection in G 1 ISO 228 Low pressure switch psig 72 52 1 With nominal air flow mixture outlet temperature 50 F full load R 410A refrigerant
4. 2 dB Liebert HPC S 34 Electrical Panel and Chiller Control Table 12 Electrical data Size FG0052 FG0080 FB0110 Power Supply V Hz Phase 460 60 3 3 Wire Y System Acceptable Voltage Range Volts 110 110 110 Number of Fans 4 5 5 Fan Motor Power each fan kW 2 8 2 8 2 8 Fan Motor Nominal Current A 4 3 4 3 4 3 Fan Motor FLA A 4 4 4 4 4 4 Single compressor 1 and 3 RLA current A 25 0 46 7 60 7 Single compressor 2 and 4 RLA current A 25 0 29 3 46 7 Single compressor 1 and 3 LRA current A 140 272 0 310 0 Single compressor 2 and 4 LRA current A 140 179 0 272 0 Total Unit Full Load Amps FLA No Pumps 117 6 174 0 236 8 Unit Wire Size Amps WSA No Pumps A 123 9 185 7 252 0 Unit Overcurrent Protection Device OPD Size No 125 225 300 Pumps Amps Total Unit Full Load Amps FLA Standard Head 126 9 186 0 248 8 Pumps Unit Wire Size Amps WSA Standard Head Pumps 133 2 197 7 264 0 Amps o a 225 300 Total Unit Full Load Amps FLA High Head Pumps 129 6 191 2 254 0 Unit Wire Size Amps WSA High Head Pumps Amps 135 9 202 9 269 2 Unit Overcurrent Protection Be Ae EA 160 225 300 35 Liebert HPC S Electrical Panel and Chiller Control Table 13 Weights and shipping dimensions Configuration FG0052 Shipping Weights Condenser Fans Shipped Separately Shipping Dimensions in mm Weight Ib kg Base Unit Shipping We
5. 9 Check all the cable connections including the main power connections on the power fuses contactors and MCB Check that all thermal protections are calibrated according the electrical data tables reported on wlring diagram Check all water connections Open the shutoff valve on the liquid line Ensure that the low pressure is higher than 101 5 psi for R410A If it is not higher extend pre heating of the compressor see Figure 21 and check that the refrigerant TXV is properly sealed Open all isolating valves and or water ball valve In areas where temperatures go below 32 F 0 C make sure that the chilled water circuit is filled with the correct concentration of water glycol Bleed all air out of the chilled fluid circuit Verify the water flow rate and its direction 10 Ensure that the thermal load is sufficient for startup 11 Record the functional data on the Start Up certificate NOTE The outer air temperature probe must be positioned in the shade and protected against the weather NOTE After the safety checks above have been performed set the handle of the door lock general knife switch to the Position 1 It is now safe to energize the chiller by closing the disconnection device upstream on the power supply line Liebert HPC S 22 Startup and Operation 5 2 5 3 5 4 First Startup or After an Extended Shutdown NOTICE Risk of improper startup Can cause equipment damage Read and fo
6. Maintenance 8 0 MAINTENANCE 8 1 The Maintenance Program below must be carried out by a qualified technician preferably working under a maintenance contract A WARNING Risk of electric shock Can cause injury or death Disconnect all local and remote electrical power supplies before working within electric connection enclosures When connecting the motor to input power dangerous voltages occur Do not open the motor electric connection enclosures within the first 5 minutes after disconnection of all phases Before performing any maintenance verify that the unit power supply line is disconnected at the start Make sure the disconnection device is locked and the suitable warning plate for no operation is applied on the start handle Before operating on the electrical connections make sure there is no voltage with a voltmeter or a phase detector Some components electronic pumps EC fans compressor s capacitors soft start inverter may remain energized for a short period after power supply removal Wait at least 5 minutes to remove their electrical box covers and access electrical connections and internal components Before any intervention on the unit or accessing the inner components always ensure the machine is turned off A CAUTION Risk of contact with hot surfaces Can cause injury The compressors pump motors and refrigerant discharge lines are extremely hot during unit operation Allow sufficient time f
7. Open the fan motor s electric box with the Torx tool by removing the four bolts Set the cover and bolts aside for reinstallation 10 Insert the cables through the holes and connect them to the terminal blocks as shown in the electric schematic and as shown below Figure 5 Fan cable terminal block connections vane Xor 11 Hold one of the cables to keep it from AE AUT screw the plastic stress reliever to the electric box Use the 24mm wrench or an adjustable wrench to tighten it to a torque of 31 inch lb 3 5Nm 12 Screw the cable caps to secure the cables 13 Repeat Steps 11 and 12 for the other cable 14 Reinstall the electric box cover using the four Torx bolts removed in Step 9 Tighten the screws to a torque of 31 inch lb 3 5Nm Perform Steps 1 through 14 above for each fan Liebert HPC S 12 Installation 4 2 1 Securing the Cables to the Grilles The input power cables must be secured to the fans grilles Each fan has two cables to be secured as shown in Figure 6 Two ties are needed on the fan farthest from the Liebert HPC S electric box Cables crossing subsequent fans should have five cable ties Wrap the cable ties around the cables and a wire in the fan guard and cut off the excess cable tie Figure 6 Securing power cables to fan grilles ON SNA e sim Two cable ties on AS last fan on the Liebert HPC S Cable ties secure cables from this fan and previous fan on Liebert HPC S A
8. Optional 14 Flow Switch 4 Manual Air Valve 15 Service Valve With Cap 5 Isolation Valve 16 Free Cooling Coil 6 Single Pump Optional 17 Air Temperature Sensor 7 Twin Pump Optional 18 Three Way Valve 8 Expansion Tank Safety Valve Optional 19 Control Free Cooling Thermostat Sensor 9 Manometer 20 Fans 10 Discharge Valve 21 Diff Transducer Only With Inverter Pump 11 Water Inlet Evaporator Probe 22 Calibrate Baffle 21 Liebert HPC S Startup and Operation 5 0 STARTUP AND OPERATION 5 1 Initial Check NOTICE Risk of improper start up and control Can cause equipment damage Initial startup and operation must be performed by a properly trained and qualified factory trained technician with experience on Liebert HPC chillers and the Liebert iCOM and its software Verify that the unit power supply line is disconnected before performing the actions below Verify that the disconnect device is locked and a suitable warning tag to prevent any changes is applied to the start handle Before working on the electrical connections use a voltmeter or a phase detector to verify that is no voltage is present Some components electronic pumps EC fans compressor s capacitors soft start inverter may remain at high voltage levels for a short period after power supply removal Wait at least 5 minutes to remove their electrical box panels and access electrical components 1 2 A 8
9. WD 659 Ib 299kg 4 465 Footprint dana y 1180 wc 9 20 wb air 2 125 p 750 125 Table 18 Dimensions Dimensions ft m Models A B FG0052 15 58 4 7 4 92 1 5 FG0080 18 86 5 7 6 56 1 9 FB0110 18 86 5 7 6 56 1 9 Table 19 Operating weight distribution Unit without tank Weight distribution Ib kg Total Models wi wW2 W3 W4 W5 W6 W7 ws Ib kg FG005 608 608 794 794 606 606 791 791 5598 275 8 275 8 360 2 0 274 8 274 8 358 8 358 8 2539 2 FG0080 714 714 1021 1021 714 714 1023 1023 6943 323 8 323 8 463 1 463 1 323 8 323 8 464 0 464 0 3149 3 FB0110 732 732 1025 1025 739 739 1032 1032 7053 332 0 332 0 464 9 464 9 335 2 335 2 468 1 468 1 3199 1 Table 20 Operating weight distribution Unit with tank Weight distribution Ib kg Total Size w1 Wi W2 w3 W4 WT2 w5 W6 W7 ws Ib kg FG0052 1093 1093 805 805 805 992 992 730 730 730 8775 495 7 495 7 365 1 365 1 365 1 449 9 449 9 331 1 331 1 331 1 3980 3 FG0080 1113 1113 1012 1012 1012 1027 1027 933 933 933 10 116 504 8 504 8 459 0 459 0 459 0 465 8 465 8 423 2 423 2 423 2 4588 5 FB0110 1124 1124 1021 1021 1021 1041 1041 946 946 946 10 231 509 8 509 8 508 4 508 4 508 4 472 2 472 2 429 1 429 1 429 1 4640 7 Liebert HPC S 42 Electrical Panel and Chiller Cont
10. 0040 104 61 94 0 0075 122 61 69 0 0116 Electrical Connections A WARNING Arc flash and electric shock hazard Can cause injury or death Disconnect local and remote power supplies and wear appropriate personal protective equipment per NFPA 70E before working within Customer must provide earth ground to unit per NEC CEC and local codes as applicable Before proceeding with installation read all instructions verify that all the parts are included and check the nameplate to be sure the voltage matches available utility power The Liebert 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 Liebert iCOM control The factory supplied optional disconnect switch is inside the unit The line side of this switch contains live high voltage The only way to ensure that there is NO voltage inside the unit is to install and open a remote disconnect switch Refer to unit electrical schematic Follow all local codes A CAUTION Risk of contact with hot surfaces Can cause injury The compressors refrigerant discharge lines fan and pump motors 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
11. A pressure washer may be used periodically to remove dust pollution and similar substances from between the coils fins Before operating Disconnect the unit from the electrical power supply by opening all local and remote electric disconnect switches Remove the air filters Verify that all fan blades have stopped rotating Ensure that the fans impellers cannot move for any reason e g wind Block them mechanically to avoid accidental contacts with the rotating blades The high pressure water flow should be sprayed in the direction opposite of the airflow and parallel to the coil fins To do this insert the water nozzle inside the unit following these possible methods 1 Remove the side panels in case of single coil units and insert the nozzle into the internal space 2 Remove one or more fans 3 Insert the water nozzle though the fan opening Figure 10 Washing coils 8 3 Steps 2 and 3 Step 1 4 A A neutral degreaser may be used to clean away greasy obstructions After cleaning the chiller reassemble the parts previously removed and unblock the blocked fans before reconnecting the electrical power supply Spare Parts The use of original spare parts is recommended When placing an order refer to Component List enclosed with the machine and quote the unit model number and serial number 29 Liebert HPC S Maintenance 8 4 8 4 1 Dismantling the Unit The machi
12. C are required then special modification must be carried out in the factory at the time of testing or by qualified and authorized personnel at the time of installation 23 Liebert HPC S Startup and Operation 5 5 Free Cooling The free cooling feature Liebert Economizer is a system of pre cooling and or cooling the water glycol mixture using ambient air when the ambient air temperature is below the return water glycol mixture temperature If the outside temperature is sufficiently low to dissipate the entire heat load the refrigeration compressors automatically switch Off and the mixture s temperature is controlled by the fan speed adjustment If the mixture temperature is too high for free cooling the compressors will operate as long as necessary to ensure the correct water glycol mixture temperature 5 5 1 Three Way Valve NOTICE Risk of excessive water hardness and high water pressure Can cause valve damage The maximum allowed water hardness to prevent valve damage is 7 5 mmol gal US The maximum working pressure is 87psi 5 9bar The valve position is shown by reference on the valve end of the valve shaft when the servo is disassembled and by pin indicator mounted on the motor body Valve shaft marking is visible only when the actuator has been removed from the shaft Actuator running time 90 angle rotation is 90 seconds Unlock To unlock the actuator open the top cover and push the activation butto
13. Grooved rigid coupling connection system a Small Pipe Kit 81 ala 8 Table 14 Grooved rigid coupling connection system dimensions Dimensions OD Y inch 3 4 5 6 8 A inch 0 625 0 625 0 625 0 625 0 750 Tolerance inch 0 030 0 030 0 030 0 030 0 030 B inch 0 313 0 375 0 375 0 375 0 438 Tolerance inch 0 030 0 030 0 030 0 030 0 030 C inch 0 078 0 083 0 084 0 085 0 092 D inch 3 344 4 334 5 335 6 455 8 441 Tolerance inch 0 020 0 020 0 022 0 022 0 025 in 0 000 0 000 0 000 0 000 0 000 For welded hydraulic connection use the line sections supplied otherwise directly connect grooved lines with the unit s grooved rigid couplings taking care to suitably grease the joint gaskets A WARNING Risk of very heavy unit falling Improper handling can cause equipment and building damage injury or death Use extreme caution and lift and move the Liebert HPC S chiller only as described in these instructions Installers must wear OSHA approved safety headgear eye protection gloves and shoes when moving lifting and installing the unit Equipment used in moving lifting and installing the chiller must meet OSHA requirements and be rated for the weight of the chiller unit See Tables 19 and 20 for chiller unit weights Read and follow the lifting equipment and or ladder manufacturer s operating instructions and safety require
14. an option for heaters for low ambient installations Electrical panel uses cleanable filters for ventilation air openings This unit has a high Short Circuit Current Rating SCCR of 65kA at the unit s rated voltage The SCCR value is the maximum amperage that the unit can withstand for a very short duration when a short circuit occurs The SCCR should not be confused with a kAIC value that includes a device that can interrupt when a short occurs All Liebert HPC S s for the U S and Canadian markets are designed for 460V 3 phase 60Hz single point power only Liebert iCOM The Liebert HPC S uses the Liebert iCOM microprocessor based unit controller to control all functions of the chiller including but not limited to compressor staging condenser fan staging and speed control economizer system control including three way valve position and compressor run time management to ensure equal run time of compressors The Liebert iCOM controller has a display interface measuring at least 320 x 240 pixels and push buttons for data entry Monitoring Cards The Liebert HPC S can come equipped with Liebert IntelliSlot Cards directly from the factory Up to two cards can be installed in each chiller The different card options are Liebert IntelliSlot Web Card IS WEBL shall be provided to deliver 10 100 baseT Ethernet and RS 485 Modbus network connectivity The supported management interfaces shall include SNMP for Network Management Systems ex
15. and reheats 17 Liebert HPC S Installation 1 Before wiring check that e the electrical components are in good condition all terminal screws are well tightened the supply voltage and frequency comply with those indicated on the unit and within the tolerances indicated in the paragraph 3 3 Operating Range the maximum unbalance between the phases does not exceed the value indicated in the paragraph 3 3 Operating Range 2 Provide NEC CLASS 1 wiring to low voltage connections 3 Connection of the supply cable The units are equipped with an electrical panel containing one main switch for the power section and one switch option for the control section based on the minimum wire size ampacity displayed on the unit s serial tag Choose a supply wire three conductor with ground for the power section and a supply wire two conductor with ground for the control section if remote control of chiller is required that is consistent with all applicable electrical codes expected current of the unit unit voltage wire length Precut knockouts should be used if possible for power and control wiring entry into the unit Install power and control wiring so that it does not contact any parts of the chiller that may become hot Connect the power wiring to the inlet terminal board disconnecting switch terminals for phases and ground bar for PE conductor After connecting the power wiring reinstall the protections agai
16. cause equipment damage injury or death Do no exceed nameplate pressure ratings and relieve system pressure through an access port before working on the refrigeration system A WARNING Risk of contact with high speed moving parts Can cause injury or death Disconnect all local and remote electric power supplies and confirm that all fan blades have stopped rotating before working in the unit Do not operate unit with any or all cabinet panels removed 1 Liebert HPC S Important Safety Instructions A A A WARNING Risk of electric shock Can cause injury or death Disconnect all local and remote electric power supplies before working within the unit When connecting the EC fan motor to input power dangerous voltages occur Do not open the motor within the first 5 minutes after disconnection of all phases WARNING Risk of electric shock Can cause injury or death Disconnect all local and remote electric power supplies before working within Dangerous external voltages can be present at main fan Terminal KL2 even after the EC fan motor has been turned Off CAUTION Risk of handling heavy and lengthy parts Can cause equipment damage and injury Unit panels can exceed 5ft 1 5m in length and weigh more than 351b 15 9kg Follow OSHA lifting recommendations and consider using a two person lift for safe and comfortable removal and installation of cabinet panels Only properly trained and qualified personnel
17. control max operating pressure 87 psi Built in carbon steel and coated with anti condensate insulation with PVC film proper for outdoor installation It is installed inside a cabinet which can be supplied either already connected to the unit mechanically and hydraulically jointed to it or loose completely separate from the unit Table 5 Technical data Internal volume 264 US gal Net weight 882 lb Working weight 3086 Ib Liebert HPC S 32 Electrical Panel and Chiller Control 10 0 ELECTRICAL PANEL AND CHILLER CONTROL The electrical panel is designed constructed and tested in compliance with CSA standards It is installed on the compressor compartment side and can be accessed through the unit right side panel It is possible to access the Liebert iCOM control display without switching the unit off so as to aid maintenance operations The electrical panel is cooled through forced ventilation controlled by a microprocessor board For ambient temperatures below 5 C it is possible to have an electric heater fitted inside optional and controlled as well by the microprocessor board Main features Power supply 460V 10 3Ph 60Hz Auxiliary power supply circuit 230V 1Ph 60Hz and 24V 1Ph 60Hz Main switch compressors in operation pump s in operation general alarm warning alarm tandem compressor alarm 1 2 water flow alarm condenser fan failure
18. installation of the fans is the responsibility of the installing contractor Compressors Each unit contains four compressors arranged in two independent circuits to provide overall unloading capability of the entire unit down to 25 single compressor operating Compressors are Copeland scroll compressors with self lubricated Teflon bearings and use R 410A refrigerant Compressors are solid mounted as close as possible on rigid rails to minimize stress of interconnected tubing and reduce gas oil equalization line length These compressors rails are mounted on rubber mounts to prevent vibration transmission to the structure The compressors include crankcase heater oil indicating sight glass and oil charge discharge connections Evaporator The evaporator is a direct expansion weld brazed plate type evaporators fabricated from seamless carbon stainless steel AISI 316 with welds of pure copper The design includes intertwined circuits so the primary fluid is always cooled by at least one circuit Evaporators are externally insulated with closed cell elastomer and connected with lines equipped for drainage and vent connections The corrugation of the plates is optimized specifically for R 410A refrigerant Liebert HPC S 4 Introduction 2 3 5 2 3 6 2 3 7 2 3 8 2 3 9 2 3 10 Combination Condenser and Economizer Coil Condenser coils are constructed of copper tubes and aluminum fins mounted in vertical configuration The c
19. weight and unit center of gravity position Unit without tadk Shipping weight and unit center of gravity position Unit with tadk Dimensions er ee wi A MaRS beer at weet a a A ads Wed Operating weight distribution Unit without tank 0 0 0 0 ccc eens Operating weight distribution Unit with tank 0 0 0 0 saasaa aaraa eens Rubber supports 264 17 gal US tank 0 cence nnn ees 38 iii Important Safety Instructions IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This manual contains important safety instructions that should be followed during the installation and maintenance of the Liebert HPC S chiller Read this manual thoroughly before attempting to install or operate this unit Only qualified personnel should move install or service this equipment Follow to all warnings cautions and installation operating and safety instructions on the unit and in this manual Follow all operating and user instructions This manual has been prepared to enable the end user to carry out operations that can done with the panels closed Any operations that require the opening of doors or equipment panels must be carried out only by properly trained and qualified personnel Each machine is equipped with an electric isolating device that allows the operator to work in safe conditions This device must always be used to eliminate risks during maintenance The panel key sup
20. 1 Hydraulic Circuit Acc ssonmes ia D AA Bed Saas 31 Water Chiller with Inertial Tank A A eS os GA Ne APE AOE GE BROS 32 ELECTRICAL PANEL AND CHILLER CONTROL 00000 ee eeeeee eee eee eens 33 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 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 FIGURES Calculating phase to phase variability example 0 ccc ccc eee Fan orientation on Liebert HPC Fan bolts and washer arrangement and tightening sequence 000 cece eee ee eee Fan motor cable connection location bolts 0 0 0 eee eee eens Fan cable terminal block connections 0000 ccc eee eee eee eens Securing power cables to fan grilles o ooooooooor eee e een nee Isometric views FG0052 with buffer tank 0 2 cee eens Isometric views FG0080 FBO110 with buffer tank 2 0 0 0 eee Liebert HPC S fluid circuit sehematic nennu eee eens WaS NICOS rencana A dd A td tate Phar tigers aed Dimensions and clearances for Liebert HPC S model FG0052 no buffer tank Dimensions and clearances for Liebert HPC S model FG0052 with buffer tank Di
21. 2 gal for all units It is recommended that the total required expansion vessel capacity is always checked depending on the unit s internal fluid volume with the volume of the buffer tank if installed the user circuit volume the glycol percentage in the mixture and the expected maximum temperature variation of the mixture The water flow switch is a required device protecting the unit It is standard on units with the optional on board pump set and is available as a option for units without pumps on board in the latter case the flow switch if not installed on the machine must be installed on the hydraulic circuit by the installer and wired to the electric panel terminal board as indicated on the wiring diagram 31 Liebert HPC S Options and Accessories 9 3 Water Chiller with Inertial Tank The machine can be supplied complete with a buffer tank The buffer tank provides thermal mass to stabilize the refrigeration circuit and deliver better compressor operation by offering these benefits It reduces the frequency of the compressor startups and consequent high current peaks It naturally eliminates the operation troubles caused by sudden load variations shown by variations of the chilled water temperature The buffer tank is supplied complete with manometer and temperature sensor well air purge valve discharge valve and sinking connection for electric heaters to be installed as option managed by the Liebert iCOM
22. 3 6 Foundation The chiller must be placed on a level surface that will support the unit s weight while it is in operation A sufficiently thick concrete pad is the recommended surface Chiller must be installed level to within 1 8 per foot 8 2mm per 305mm If necessary position the unit on suitable anti vibration supports supplied by others Position the anti vibration supports on a level surface lower the chiller onto them and attach the antivibration supports to the chiller Then adjust the unit s position on the supports NOTE For weight distribution see Figure 18 The weights and their distribution refer to standard units with without tank but without options Add the weights of any installed accessories to those of the standard units see Table 12 3 7 Service Area e Minimum area must be left free of obstructions around the unit to allow free air flow and maintenance see Figure 11 The hot air expelled by the fans must be allowed to rise unimpeded by obstacles for a minimum height of 8 2 ft 2 5m Limit recirculation of condenser fan exhaust air to prevent reduced performance 9 Liebert HPC S Installation 4 0 INSTALLATION 4 1 Fan Assembly This section details how to assemble and install the condenser fans of Liebert HPC S chiller units The assembly must be completed before the unit is connected to the water and electric lines The Liebert HPC S is factory tested as a unit the condense
23. A I E Cable routes near fan motor housing secured to tab with a cable tie Cable ties secure cable from the previous fan on the Liebert HPC S y INN MA 13 Liebert HPC S Installation 43 Piping Connections 4 3 1 Piping Circuit Construction The piping must be connected to the chiller Construct a chilled water circuit as described below 1 2 e 10 11 12 Place shutoff valves within the circuit to allow servicing Install a pump system suitable for the flow rate required at a pressure head equal to the sum of all the pressure drops Liebert HPC S chillers can be equipped with pumps having performance as indicated in Table 9 Install manometers at the chiller inlet outlet Install thermometers at the chiller inlet outlet Use flexible joints with connecting chilled fluid supply and return lines to avoid transmitting vibrations and to allow for thermal expansion This applies to all chillers regardless of options Emerson recommends including a water pressure switch to give an early warning of low water pressure Place a mesh filter at the inlets of the pump and water chiller If the fluid contains particles larger than 0 04 in 1 mm Emerson recommends installing a 14 20 mesh strainer before the exchanger Particles of this size could block the channels in the brazed plate evaporator causing poor performance increased pressure drop and risk of freezing Install piping components that allow th
24. Condenser Fans Shipping Crate 2 3 Condenser Fans 42x42x45 1067x1067x1143 400 181 Base Unit Operating Weight without Buffer Tank 6 943 3 149 accounts for mass of water in unit ee een 9 055 4 107 Options Additional Weight No Pumps With Piping Specialties Digit 12 1 22 10 Single Standard Head Pump with Piping Specialties Digit 12 2 247 110 Single High Head Pump with Piping Specialties Digit 12 3 375 170 Dual Standard Head Pump with Piping Specialties Digit 12 4 450 204 Dual High Head Pump with Piping Specialties Digit 12 5 721 327 Single Inverter Driven Pump with Piping Specialties Digit 12 6 450 204 Condenser Coil Filter Guard Digit 17 1 110 50 FB0110 Shipping Weights Condenser Fans Shipped Separately Base Unit Shipping Weight without Buffer Tank 195x60x92 4953x1524x2337 6 174 2 800 Base Unit Shipping Weight with Buffer Tank 240x60x92 6096x1524x2337 7 144 3 240 accounts for mass of water in unit Condenser Fans Shipping Crate 1 2 Condenser Fans 42x42x45 1067x1067x1143 300 136 Condenser Fans Shipping Crate 2 3 Condenser Fans 42x42x45 1067x1067x1143 400 181 Base Unit Operating Weight without Buffer Tank 7 053 3 199 Base Unit Operating Weight with Buffer Tank accounts for mass of water in unit 9 165 3 497 Options Additional Weight No Pumps With Piping Special
25. FG0052 90 gallons per minute 5 7 liters per second FG0080 134 gallons per minute 8 5 liters per second e FBO110 184 gallons per minute 11 6 liters per second Maximum leaving fluid temperature 68 F 20 C and maximum entering fluid temperature of temperature of 78 8 F 26 C Higher temperatures are allowed only at the system startup for limited periods of time and not during normal operation Temperature range limits must be met at all times Maximum glycol concentration 50 for units without factory installed pumps 30 with the optional pump assembly installed Minimum allowed glycol concentration determined by design authority to provide either burst or freeze level protection at the site location see Table 1 Maximum pressure of the hydraulic circuit 87 psi limit is independent of presence absence of pumps installed from factory in unit It is the responsibility of the design authority to confirm that the combined total of maximum pump static head indicated on pump nameplate and pressurized the water circuit are not more than the pressure limit of the unit 3 3 3 Power Supply Make all wiring and electrical connections in accordance with local and national codes Refer to electrical schematic when making connections e Voltage in standard operating conditions from 0 9 to 1 1 times the rated voltage Frequency from 0 99 to 1 01 times the rated frequency continuously Voltage unbalance m
26. Liebert HPCS Free Cooling Chiller with Scroll Compressors User Manual EMERSON Network Power TABLE OF CONTENTS IMPORTANT SAFETY INSTRUCTIONS 00 0c eee ee eee eee eee eee eee eee eee eee eee 1 1 0 LIEBERT HPC S COMPONENTS AND NOMENCLATURE 00005 3 2 0 INTRODUCTION oir Oe oe Sear Se eae ee a ae ates eee 4 21 Smart Design a A A a a A E makati aoe ios 4 2 2 Responsibility 4 2262 E DANS A ats BA OLE Shh A 4 2 3 Product Description c of e Pee ede we heh ah ee Aone IA ACN Oe Meo Je 4 2 3 1 Frame and Unit Cabinet 000 ccc ccc cee cee a eee een bese reeeebeees 4 2 3 2 Electrically Commutated EC Condenser Fans 4 2 3 3 Compressors so sat A cost ede cca seca sa at ete ee tah Rete acto O ae ae aha E ae ng 4 23 4 Byaporator Axo A NN 4 2 3 5 Combination Condenser and Economizer Coll eee 5 2 3 6 Refrigeration Circuit Components 5 22307 RA CINCU nae eenen Gt RR e Sts Sl a a OR Bo wie he 5 2 3 8 High Voltage Electrical eee eee e etsi 5 2 3 9 Liebert iCOM ihe Gils cs eda Scola shu AA A ae Atha Be AAA ak E sa Neate he BI She A Reach ly A BRN ay He 5 2 910 Monitoring Cards tt dt sd one Mahou ld a dde de 5 2 911 Butter Tank ueno td a rs De dy da IA BO ade be ita 3 6 2 3 12 Pumps and Piping Options oe neea biae ehe e eee eee e teen ene 6 2 3 13 Electrical Panel Options 6 2 3 14 Condenser Coil Filter Guard 6 3 0 PRELIMINARY OPERATIONS 00 ce cece eee ee eee ee
27. Table 9 Standard head pump characteristics Models FG0052 FG0080 FB0110 Water Flow gpm US 139 52 212 52 272 4 Available Pressure Head psig 29 23 4 Pump s number Nr 1 2 1 2 1 2 Pump Rotor Model 65 340 2 65 390 2 65 390 2 Nominal Motor Power kW 5 5 7 5 7 5 Noise Level dB A 68 65 65 According to ISO 3744 Table 10 High head pump characteristics Models FG0052 FG0080 FB0110 Water Flow gpm US 139 52 212 52 274 4 Available Pressure Head psig 39 36 17 Pump s number Nr 65 390 2 65 480 2 65 480 2 Pump Rotor Model 1 2 1 2 1 2 Nominal Motor Power kW 7 5 11 11 Noise Level dB A 65 64 5 64 5 According to ISO 3744 Table 11 indicates the overall sound pressure level at full load conditions measured 3 ft 1m from the unit according to ISO 3774 with an outdoor temperature of 95 F 35 C and referred to free field conditions Table 11 Sound pressure power level Octave Band Frequency Hz Total Models 63 125 250 500 1000 2000 4000 8000 dB A SPL Sound Pressure Levels dB FG0052 87 83 79 76 75 71 63 55 79 FG0080 88 83 79 76 75 71 63 56 79 5 FBO110 88 83 79 76 75 71 63 56 79 5 PWL Sound power levels dB FG0052 107 102 98 95 94 90 82 75 98 5 FG0080 108 103 99 96 95 91 83 76 99 5 FBO110 108 103 99 96 95 91 83 76 99 5 Sound power levels tolerance for each octave band 0
28. United States 614 888 0246 Locations United States 1050 Dearborn Drive P O Box 29186 Columbus OH 43229 Europe Via Leonardo Da Vinci 8 Zona Industriale Tognana 35028 Piove Di Sacco PD Italy 39 049 9719111 Fax 39 049 5841 257 Asia 29 F The Orient Square Building F Ortigas r Road Ortigas Center Pasig City 1605 Philippines 63 2687 6615 Fax 63 2 730 9572 www EmersonNetworkPower com
29. al 460 461 Pump 2 On closes when active Note this terminal is present only in units that have a factory installed dual pump option Terminal 462 463 Free Cooling On closes when active General Alarm Set through Liebert iCOM Terminal 400 common Terminal 401 Normally closed opens on alarm Terminal 402 Normally open closes on alarm Liebert HPC S 18 Installation Warning Alarm Set through Liebert COM Terminal 300 common Terminal 301 Normally closed opens on alarm Terminal 302 Normally open closes on alarm Remote Shutdown Terminal 470 471 Field supplied 24VAC 1 2VA min power supply to operate remote shutdown A WARNING Arc flash and electric shock hazard Can cause equipment damage injury and death Disconnect local and remote power supplies and wear appropriate personal protective equipment per NFPA 70E before working within Failure to comply can cause serious injury or death All work may be performed only by properly trained and qualified personnel wearing appropriate safety gear and using properly insulated equipment The Liebert COMP 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 Liebert iCOM control The factory supplied optional disconnect switch is inside the unit The line side of this switch contains live high voltage The only way to ensure that t
30. al view o o o o iinta o o_o o Front view amp Prepunched for supply cables inlet N 56 N 2 x 63 N 1 x 36 N 1 x 28 1185 115 60 6750 Supply cable inlet Left lateral view T 6597 153 See frontal view 101 5 1097 101 Prepunched for supply cables inlet o N 2x 63 N 1x036 N 1x 28 B g Prepunched for supply cables inlet o E10 N 2 x 63 N 1 x 036 3 o T e q Top view Part G 6810 Victaulic Unit connection system a A pa 1 F 2 if Rear view from H NLR Victaulic Air flow R view coupling m Removable panel 2 a er Unit fixed by screws O o connection pipe Removable panel P fixed by 1 4 turn locks ats a 60 Overall frame unit 6750 o o o o o o o o o o Liebert HPC S 017 032 5 Fans with Tank A ft B ft Chilled water connections X Inlet Y Outlet 0 95 8 3 Grooved Rigid Coupling 3 Liebert HPC S 44 Electrical Panel and Chiller Control Figure 21 Refrigerant circuit gB B OU Evaporator Water Outlet B 4 Evaporator Water Inlet O 22 C C z Insulated Pipe Uninsulated Pipe N Description N Description 1 Compressor 13 Condenser 2 High pressure Switch 14 Condenser Fans 3 Low pressure Switch 15 Service Connection 4 Crankcase Heater 16 Sight Glass 5 High pressure Mano
31. ample HP OpenView Web pages and RS 485 Modbus for Building Management Systems Liebert IntelliSlot Web Card IS IPBML shall be provided to deliver communications via the following protocols HTTP HTTPS Telnet Modbus IP BACnet IP and Emerson Protocol Liebert IntelliSlot 485 Card S485 L shall be provided to deliver RS 485 Modbus network connectivity to Building Management Systems for unit monitoring and management Liebert IntelliSlot SiteScan Web Protocol IS 485EX shall be provided to deliver ground fault isolated EIA 485 Emerson Protocol connection to a Liebert SiteLink E allowing Liebert SiteScan Web 4 0 monitoring and communications 5 Liebert HPC S Introduction 2 3 11 2 3 12 2 3 13 Buffer Tank The Liebert HPC S can come with buffer tank pre installed from the factory This buffer tank can also be ordered as a shipped loose item The tank is 264 gallons 1 000 liters whether pre installed at the factory or shipped loose The purpose of the tank is to provide increased thermal inertia and system volume in applications with short piping runs This will reduce the frequency of compressor starts and diminishes the operation issues associated with sudden load variations It is not meant to provide ride through in the event of a unit failure The buffer tank is built of carbon steel and coated with an anti condensate insulation with woven PVC outer layer for outdoor installation The tank comes with a manometer a
32. ate in the correct direction During the unit startup an inlet fluid temperature higher than 64 F 18 C is allowed Under standard operating conditions check that the limits indicated in 3 3 Operating Range are not exceeded Check the correct operation of the control and safety devices Check the outlet temperature of the chilled fluid determine whether the setpoint on the controller is reached Check the oil level when both compressors are running With the compressors at full load check the sight glass to determine whether any bubbles are visible If there are any bubbles contact Liebert Product Support Starting and Stopping Always ensure that the compressor oil has been preheated Maintain electric power to the compressor the crankcase heater during brief unit shutdowns Start the unit by turning the microprocessor switch On Stop the unit by turning the microprocessor switch Off Turn the machine off by turning the microprocessor switch Off during extended times without operation Confirm that the crankcase heater remains powered For seasonal shutdown of the unit de energize the chiller at the main switch located on the main electrical power supply This will disconnect power from the compressor crankcase heaters Chillers Serving Special Plants The units are capable of cooling a water glycol mixture to temperatures close to 32 F 0 C without the need for significant modifications If temperatures below 32 F 0
33. ctrical panel can be provided with a fast start ramp and or electric heater from the factory Fast Start Ramp Speeds up restarting the unit and reduces the time required to return to full power To do this the Liebert iCOM overrides internal compressor start and restart time restrictions This requires UPS power to the Liebert iCOM main board UPS power feed by others e Electric Panel Heater This is option is used in applications in areas with extended periods with low ambient temperatures It is recommended whenever the minimum ASHRAE design temperature is below 23 F 5 C 2 3 14 Condenser Coil Filter Guard The condenser coil filter guard is composed of expanded metal cloth sandwiched between two layers of rigid metal netting in a sheet metal frame These filter guards are removable without tools The condenser coil filter guards protect against hail and other debris and help filter out airborne objects such as milkweed cottonwood and leaves Liebert HPC S 6 Preliminary Operations 3 0 PRELIMINARY OPERATIONS 3 1 Packing Removal Remove the polythene package taking care not to damage the unit Dispose of the packaging properly or recycle it if applicable 3 2 Inspection All the units are assembled and wired at the factory Before shipment they are charged with the correct quantities of refrigerant and oil and then tested under the operating conditions required by the customer The machine s hydraulic circuit is e
34. e bleeding of air and filling of glycol at the highest points in the circuit Place a drain valve at the lowest point in the circuit and immediately at the outlet of the water chiller Install a water filling set including filling water meter manometer non return valve air separator removable supply tube which must be disconnected after each charge top up For maximum protection ensure that all piping exposed to low outdoor temperatures is fitted with anti freeze heaters and insulated with closed cell synthetic rubber elastomer The circuit must include an expansion vessel with safety valve of suitable capacity NOTE Confirm that the combined expansion volume of the system meets minimum requirements This is the responsibility of the engineer of record The expansion vessel option may provide enough volume to meet requirements If additional volume is required then another expansion vessel must be provided See 4 3 6 Sizing the Expansion Tank for details on this calculation NOTE The piping circuit must contain a water volume suitable for the capacity of the installed chiller Confirm that the total fluid volume of the system is sufficient including piping water volume inside the chiller and the buffer tank if one is installed Install a secondary tank in the circuit if necessary to provide the requisite volume See 4 3 6 Sizing the Expansion Tank for details on this calculation NOTE The chilled fl
35. e eee eee eee eee eee eee 7 3 1 Packing Removal iio ici tae ees detec este dt eet id a ERS he Beings Re heed teh 7 3 2 Inspection A p m ea A T 3 3 Operating Range cui A a Se a AS kd aad 7 3 3 1 Outer Air Temperature eee a ce eee een ene e eee eenenes 7 3 30 27 Mud CIU a edhe Ie Be gh RS Ned a TIE Bile da hbk eed Stade oh ah 8 8 85389 POWER Supply ai at oY rai thie aa 8 3 4 Sound Pressure evel ss sacs A AAA Ree PE a PEN ea OER PR ila 9 3 5 Transport esita Ad ede dan Sepa ante is Bye gel Fo tied SME wes Pl OAR Aen Ps 9 3 6 FOUndAatION 6 62 22 EA A RO EO AROS TAS SARA BORE I RS 9 3 7 DELVICO ALCA A eines A a a RAM oe BN as ANN A A IY Ok Se oS 9 4 0 INSTALLATION idee Sc Scere A A ee A 10 4 1 BancAssembly 2229 E S ts cle oa le SO eet le ae A AD oe Ad a aN oe 10 ADA Components 14 05 02 3 0 A od A ido tds 10 4 1 2 Required Tools ie atrii maaar dto dl bi dd ta dd di tintos 11 4 2 Mount and Connect the Fans r ia ayie a a TE eee eee eens 11 4 2 1 Securing the Cables to the Grilles o 13 4 3 5 0 5 1 5 2 5 3 5 4 5 5 6 0 6 1 6 2 7 0 8 0 8 1 8 2 8 3 8 4 9 0 9 1 9 2 9 3 10 0 Piping Connections sr bar ti h dee a abba toe de de ala a id 14 4 31 Piping Circuit Construction a 14 4 3 2 Additional Water and Ethylene Glycol ooo oooooocoonoororoorrr ene 15 4 353 Water Glycol Mixture vices a ti bw Sod epee wil a Hale ley Sewn an eer 15 4 3 4 Protection and Cleaning of the Evaporator a
36. e fan collar as shown below Figure 2 Fan orientation on Liebert HPC S Identification Code on fan One of eight bolt holes for mounting a fan Identification Code on Liebert HPC S 4 Assemble the bolts and washers as shown below 5 Insert the eight M6 bolts into the holes and partly tighten them leaving them slightly loose Refer to Figure 3 begin with the bolts in hole 1 and hole 5 then insert the bolts in hole 3 and hole 7 then insert the bolts in hole 4 and hole 8 and finally insert the bolts in hole 6 and hole 2 Figure 3 Fan bolts and washer arrangement and tightening sequence Bolt 4 Lock Washer 8 bolt holes around fan opening for Fan ee numbers do not es re ES appear on Liebert HPC S Opening Flat Washe 11 Liebert HPC S Installation 6 Tighten all eight bolts to a torque of 53 inch lb 6Nm the washers and bolt heads must be touching and secure against the fan collar 7 Remove the cover over the cable connection holes on the fan motor electric box if present see Figure 4 Figure 4 Fan motor cable connection location bolts Torx head bolts securing fan motor lt electric box there are four bolts one on each corner gt Torx head bolts securing fan motor electric box there are four bolts one on each corner Cable connection holes cover 8 Find the cables with the same eT as the fan and aks them out of their plastic bag 9
37. er glycol mixtures must be used as the fluid in very cold climates or with temperatures below 32 F 0 C See Table 1 to determine the ethylene glycol that must be added to the water Table 1 Ethylene glycol to be added to water in weight of total mixture Ethylene glycol in weight 0 10 20 30 40 50 Freezing temperature F 32 24 14 2 13 35 Mixture density at 68 F a Ib galUS 8 487 8 621 8 746 8 880 9 013 Values are for Clariant Antifrogen N For different brands check manufacturer s data For the chiller internal water volume refer to Table 6 If the optional buffer tank is installed on the machine add the tank hydraulic volume NOTICE Risk of a leaking coil or heat exchanger due to freezing and or corrosion Can cause equipment and building damage Always charge the fluid circuit with the required glycol mixture necessary for the minimum ambient temperature at the installation site Failing to comply with this instruction will invalidate the unit warranty Refer to Table 1 15 Liebert HPC S Installation 4 3 4 Protection and Cleaning of the Evaporator and Components of Hydraulic Circuit The user must establish the quality of the water and ensure that it is compatible with the materials used in the piping components and heat exchangers The quality of water may significantly affect the operation and the life of the exchangers Emerson recommends developing a regu
38. g side is 10 ft 3m Do Side not obstruct the air exitingg the fans AA for a minimum distance of 8 2 ft 2 5m 37 Liebert HPC S Electrical Panel and Chiller Control Figure 13 Dimensions and clearances for Liebert HPC S models FG0080 and FB0110 no buffer tank 42 6 Le ja 220 4 5597mm E 1067mm 153mm Uy do Wi L 42 ___ 1524mm Side 1067mm 3 5 90mm 15 5 e 393mm pr 75mm a K Piping mm i Connection Electrical oh E 2 2 Ws Connection 687mm 55mm E LLL A Minimum distance between two units 60 from condensng side is 10 ft 3m Do 1524mm not obstruct the air exitingg the fans 7 ZA for a minimum distance of 8 2 ft 2 5m Figure 14 Dimensions and clearances for Liebert HPC S models FG0080 and FB0110 with integral free cooling and buffer tank 51 2 1300mm 60 1524mm j 42 is 259 4 je 1067mm 6597mm 153mm Se 60 Condensef Li ADM 9 1524 Side 1067mm _ 152 mm oy 3 5 90mm 15 5 393mm ls 75mm Piping 1 Vo j rf onnection T l ag Electrical aan Connection LK Minimum distance between two units from condensing side is 10 ft 3m Do not obstruct the air exiting the fans for a minimum distance of 8 2 ft 2 5m Liebert HPC S 38 Electrical Panel and Chiller Control Figure 15
39. here is no voltage inside the unit is to install and open a remote disconnect switch Refer to unit electrical schematic Before working on the electrical connections use a voltmeter or a phase detector to verify that is no voltage is present NOTICE Risk of no water flow to the chiller Can cause equipment damage Water flow to the chiller must be present prior to starting and during operation Incorrect operation will cause the unit to lock out due to the internal flow switch not sensing flow NOTICE Risk of improper electric power phase sequence Can cause equipment damage The compressors are equipped with an electronic protection device blocking their start if the phase sequence of the power supply is not correct or stopping their operation if a thermal relay is tripped This device is essential for the integrity of the mechanical and electrical components of the compressors Reset the standard functions by isolating this device and removing the causes of the lock out NOTICE Risk of temperature control Can cause equipment damage The chillers are equipped with their own microprocessor control adjustment Using the remote On Off input located in the electric panel terminal board as a system temperature control element is prohibited and will void the warranty 19 Liebert HPC S Installation Figure 7 Isometric views FG0052 with buffer tank Left Side l Right Side iping Connection Electrical Connection End
40. ight without Buffer Tank 195x60x92 4953x1524x2337 4 880 2 214 Base Unit Shipping Weight with Buffer Tank 240x60x92 6096x1524x2337 5 848 2 654 Condenser Fans Shipping Crate 1 Qty of 2 fans 42x42x45 1067x1067x1143 300 136 Condenser Fans Shipping Crate 2 Qty of 2 fans 42x42x45 1067x1067x1143 300 136 Base Unit Operating Weight without Buffer Tank accounts for mass of water in unit 5 598 2 539 Base Unit Operating Weight with Buffer Tank accounts for mass of water in unit 7 710 3 497 Options Additional Weight No Pumps With Piping Specialties Digit 12 1 22 10 Single Standard Head Pump with Piping Specialties Digit 12 2 243 110 Single High Head Pump with Piping Specialties Digit 12 3 247 112 Dual Standard Head Pump with Piping Specialties Digit 12 4 441 200 Dual High Head Pump with Piping Specialties Digit 12 5 449 204 Single Inverter Driven Pump with Piping Specialties Digit 12 6 276 125 Condenser Coil Filter Guard Digit 17 1 66 30 FG0080 Shipping Weights Condenser Fans Shipped Separately Base Unit Shipping Weight without Buffer Tank 240x60x92 6096x1524x2337 6 070 2 754 Base Unit Shipping Weight with Buffer Tank 275x60x92 6985x1524x2337 7 038 3 193 Condenser Fans Shipping Crate 1 2 Condenser Fans 42x42x45 1067x1067x1143 300 136
41. ipped with the other sections of the Liebert HPC S Each fan is are identified by the identification code used in the electric schematic typically M followed by a number e g M8 M9 and M10 and shipped in a cardboard box Each box is identified in the same way A WARNING Risk of handling heavy objects Can cause property damage injury and death The fan assembly weighs 112 5 lb 51 kg Two or more properly trained and qualified personnel are required for assembling the fans and attaching them to the Liebert HPC S The fans cabling lays on the top of the unit Each set of terminations is dedicated to a single fan The cables are protected by a plastic bag and identified by the same code of its fan Each box contains a fan collar and grille Two of the three original cables of each fan motor are part of the cabling terminations The respective holes in the electric box of the fan are covered by adhesive tape Liebert HPC S 10 Installation 4 1 2 Required Tools 10mm wrench or adjustable wrench SAE tools could damage the bolts T20 Torx screwdriver 24mm wrench or adjustable wrench small screwdriver 4 2 Mount and Connect the Fans Each fan may be assembled as follows 1 Unpack the fan 2 Place the fan on the roof of the Liebert HPC S on the hole marked with the same code as the fan Take precautions not to damage the cables on the Liebert HPC S roof 3 Orient the identification tags on the roof and on th
42. lar water treatment plan based on a chemical analysis performed by a properly trained and qualified water treatment service provider Heat exchangers must be cleaned only with a commercially available chemical product that removes scale and prevents corrosion Maximum allowed water hardness is 7 5 mmol gallons In the chiller with pumps and in all free cooling units water quality must be in accordance with VDI 2035 The main factors causing corrosion are acids with sulfur and carbon components such as sulfuric acid see the Langelier and Ryznar indices The oxygen dissolved in water increases the rate of corrosion Fouling from to dust and organic matter also provides a support for bacteria fungi and algae which also can damage the machine and reduce cooling Corrosion is more prevalent in materials on the liquid side of the heat exchanger The water circuit side components are made of several metals Table 2 shows suggested limits of chemicals in the water to avoid corrosion on copper the material in the Liebert HPC with highest corrosion risk Table 2 Water component for corrosion limit on copper pH 7 5 9 0 SO ppm lt 100 HCO3 S04 gt 10 Total hardness dH 4 5 85 CJ ppm lt 50 PO ppm lt 2 0 NH3 ppm lt 0 5 Free Chlorine ppm lt 0 5 Ear ppm lt 0 5 Mn ppm lt 0 05 CO ppm lt 50 H2S ppb lt 50 Temperature F lt 149 Oxygen Content ppm lt 0 1 4 3 5 Minimum Sys
43. librations and fill it with at least twice the amount of oil required Isolate the compressor by closing the cock on the liquid line Connect to the fittings on the compressor body Schraeder valves and empty it of refrigerant until atmospheric pressure 14 5 psi is reached Using a pipe connect the oil container to the oil service fitting on the lower part of the compressor Open the oil service cock lifting the container so that the oil flows by gravity Charge the required quantity of oil make sure the tube always remains below the oil level in the container Stop the oil flow by closing the oil service fitting open the shutoff cock on the refrigerating circuit and restore the drained refrigerant charge Liebert HPC S 26 Safety Device Settings SAFETY DEVICE SETTINGS The water chiller has been tested and calibrated by the manufacturer Emerson suggests using the following field settings Table 4 Factory refrigerant switch settings Component Setting Notes Operation with R410A standard factory setting Low Pressure START 6 5 bar 94 3 psi Switch LP DIFF 1 5 bar 21 8 psi STOP 5 0 bar 72 8 psi Operation with R410A standard factory setting High Pressure STOP 42 0 bar 609 psi Switch HP START 38 0 bar 551 psi DIFF 4 bar fixed 58 psi The settings for the safety valves installed on the machine are 65 psi 27 Liebert HPC S
44. llow all of the instructions below before starting the unit up for operation Before beginning the following operations make sure all protections on the units have been reset set the handle of the door lock general knife switch to the Position 1 verify that the display LED is switched On and check again with a voltmeter or tester if the voltage and phase difference falls within the indicated limits To begin the initial startup or for a startup after a long shutdown 1 10 11 Power the crankcase heaters at least 8 hours before the start up by setting the main isolator switch On Make sure the auxiliary circuit has been powered and check the operation a fault due to an incorrect procedure will void the compressor guarantee Open the valves of the refrigeration circuit that had been closed before the initial check Check the machinery supplying the thermal load connected with the unit and start the system pump s Make sure the compressor oil has been heated for at least 8 hours Serious compressor damage may occur if it is started before the compressor oil is properly heated NOTICE Risk of improper operation Can cause equipment damage The compressor oil temperature is critical to proper operation The oil will not reach operating temperature unless it is reheated for at least 8 hours Make sure the fans rotate in the correct direction counterclockwise check the electrical connections if necessary Make sure the pumps rot
45. ls on the base Table 16 Shipping weight and unit center of gravity position Unit without tank Unit without X Base Xg pumps Shipping Models ft m ft m Yg ft m Weight Ib kg FG0052 15 58 4 7 8 48 2 6 2 10 0 6 5320 2413 FG0080 18 86 5 7 10 48 3 2 2 10 0 6 6619 3002 FB0110 18 86 5 7 10 48 3 2 2 10 0 6 6724 3050 Table 17 Shipping weight and unit center of gravity position Unit without X Base Xg pumps Shipping Models ft m ft m Yg ft m Weight Ib kg FG0052 18 83 5 7 10 19 3 1 2 10 0 6 6292 2854 FG0080 22 15 6 8 12 22 3 7 2 10 0 6 7591 3443 FB0110 22 15 6 8 12 19 3 7 2 10 0 6 7697 3491 Unit with tank 41 Liebert HPC S Electrical Panel and Chiller Control Figure 18 Support positions and loads Tank Mounted Option F 1000 ml A 60 e a a Sas 120 _ AeA AS LAAELLEE LLL LTT FLL OEA LLLLLLL LRA 7 t IWT1 Wi w2 w3 pa 1180 a FOOT PRINT d 20 1300 WT2 W5 W6 W7 1201 _ PALL EZ LLAMA LLLLLL HIIT ZLA Z LLLLLLL LER a L 125 125 a 875 se B 1500 ja B X Tank 1000 60 supply not mounted on unit y 120 ig ZJ tT WA N WB WA WB 895 Ib 406kg f WC
46. mensions and clearances for Liebert HPC S models FG0080 and FB0110 no buffer tank Dimensions and clearances for Liebert HPC S models FG0080 and FB0110 with integral free cooling and buffer tank Grooved rigid coupling connection system 6 6 eee eee eens Lifting instructions with t bes persee terry aaki EAn een ene e nett nee Lifting center of gravity axis Support positions and loads eee EE n teen nnn Rubber anti vibration support 264 17 gal US tank 0 tee Overall dimensions cos Foti ee ee ae PR ae OP Bt a ee Bene RT PAS ew Ba REESE FAME circuiti it rR eset bls A a Mie Wut a belt ie hc TABLES Ethylene glycol to be added to water in weight of total mixture oooooooooo Water component for corrosion limit on Copper Water expansion coeficiente Factory refrigerant switch settings Mechnicaleda tas ii A ag MOE Sh ats BOR GSR ahs tae ee eT Tnternal fluid voluime renine eA her ese ap RBM Bo ee CR aan Ba nicely BE ADA ee 8 Cas ele a Refrigerant and oil charge sereen te an e eea E a eee teen eee teen eens Standard head pump characteristics High head pump characteristics Sound pressure power level Operating ranger A A ds Ba hn Fa a IOS Be PO a ee a ee Electrical data A ee ES SEG ENE GE wh BOG a eS Weights and shipping dimensions 0 0 eee eee eee ees Grooved rigid coupling connection system dimensions 0 00 eect eens Tait ep sgt A ee A ae en wae ea aN ae Shipping
47. ments 39 Liebert HPC S Electrical Panel and Chiller Control Figure 16 Lifting instructions with tubes Protection Plank Rigid Struts Possibily Steel fo oy Area to Insert Detail A Belt or Strap Straight Shackle Size 25 1 Uni 1947 A Type Not Supplied with Lifting Tubes Option Base Unit A Part A EE Base Unit A Lifting Tube Fixing Nut Protection Lifting Frame Gasket I Bracket Lifting Tubes Hardware Arrangement 1 Place the lifting tubes in the holes in the base indicated by the word LIFT HERE 2 Lock the ends of the tubes in position with the locking pins and split pins as shown above The capacity of the lifting gear must be adequate to lift the load in question 3 Check the weight of the units the capacity of the lifting gear and ropes and the condition and suitability of the aforementioned equipment 4 Lift the unit with a speed suitable for the load to be moved so as not to damage the Liebert HPC S 052 110 structure Table 15 Lifting Liebert HPC S 40 Electrical Panel and Chiller Control Figure 17 Lifting center of gravity axis Lifting With Cords Lifting With Belt Protection Planks Cord Rigid Struts The lifting point must be on the vertical center of gravity axis which is marked with symbo
48. meter 17 Shutoff Valve 6 Low pressure Manometer 18 Filter Dryer 7 Shutoff Solenoid Valve 22 Thermostatic Expansion Valve 11 Transducer Press Sensor hp Control 23 Evaporator 12 Safety Valve 26 External Air Sensor B s do ne lo TE pi A pP Ea 0 ed gB Install tandem compressor piping according to the supplier s instructions 45 Liebert HPC S While every precaution has been taken to ensure the accuracy and completeness of this literature Liebert Corporation assumes no responsibility and disclaims all liability for damages resulting from use of this information or for any errors or omissions 2013 Liebert Corporation All rights reserved throughout the world Specifications subject to change without notice Liebert is a registered trademark of Liebert Corporation All names referred to are trademarks or registered trademarks of their respective owners SL 17610_REVO_12 13 Emerson Network Power Division Liebert Web www emerson com Technical Support Service Web Site www liebert com Monitoring liebert monitoring emerson com 800 222 5877 Outside North America 00800 1155 4499 Single Phase UPS amp Server Cabinets liebert upstech emerson com 800 222 5877 Outside North America 00800 1155 4499 Three Phase UPS amp Power Systems 800 543 2378 Outside North America 614 841 6598 Environmental Systems 800 543 2778 Outside the
49. mixtures up to 65 35 by weight Temperatures of the standard pumped fluid not lower than 40 F The motor stool forms connection between the pump housing and the motor and is equipped with a manual air vent screw for venting of the pump housing and the shaft seal chamber It is very important to carry out this operation as the circulation of liquid through the duct of the air vent screw ensures lubrication and cooling of the shaft seal Between the outlets of the two chambers and the discharge flange twin head pumps have a non return flap valve in EPDM rubber The flap is opened by the flow of the pumped liquid and cuts off the port of the idle pump chamber In the electrical panel there are automatic circuit breakers for each pump the microprocessor control manages the operating rotation between the two pumps and start up of the standby pump if the primary pump fails In case of electronic inverter pump replacement it s necessary to set specific service level control parameters user panel is not feasible for this operation this operation must be performed by an experienced Emerson technician For the technical features of the pumps and the piping schematic see Table 9 and Figure 9 Hydraulic Circuit Accessories Made up of an expansion vessel pre charged at 22 psi maximum operating pressure 145 psi and a safety valve set at 87 psi Their position in the piping circuit is illustrated in Figure 9 Expansion vessel volume 3
50. n Liebert HPC S 24 Refrigerant and Oil Charge 6 0 REFRIGERANT AND OIL CHARGE NOTICE Risk of refrigerant system rupture and or explosive discharge of high pressure refrigerant from overpressurization that can cause equipment damage injury or death Do no exceed nameplate pressure ratings Relieve system pressure in the manner approved by local building codes through an access port before working on the refrigeration system All work on pipes or components of the refrigerating circuit under pressure must be carried out by properly trained and qualified personnel 6 1 Refrigerant Charge NOTICE Risk of improper refrigerant evacuation Can cause compressor damage and environmental pollution While repairing the refrigerating circuit recover all the refrigerant in a container do not allow it to escape Using the compressor for the system vacuum will invalidate the warranty The unit is delivered charged according to the Table 7 6 1 1 Warnings for the Refrigerant Charge Checklist 1 Ensure there are no refrigerant leaks 2 Check the refrigerant type in the refrigeration circuit a unit originally charged by the manufacturer with R410A cannot be charged with other gas and vice versa 3 Charge with the compressor in operation connecting the cylinder with the charge connector after the thermostatic expansion valve Drain the connection pipe between the cylinder and the charging point tighten the seal joint and then
51. nd Components of Hydraulic Circuit 16 4 3 5 Minimum System Volume Requirements 0 000 c eee eee ene 16 4 3 6 Sizing the Expansion Tank 17 4 3 7 Electrical Connections 0 0 ccc cece ene ene n eens 17 STARTUP AND OPERATION s ni 244 4 ad tees eek Sete Ae 22 Initial Ch ck i enean avd nd dee ew ee as 22 First Startup or After an Extended Shutdown 0 0 0 0 0 23 Starting and Stopping ss z a blake eal Ii avon Ws ES BO a OA and BG ene 23 Chillers Serving Special Plants 23 Pre Cooling os A etd ah ae eh Se Bae Ee A eo gs a 24 Dbl Whr e Way Valve A A aad te ee eee Be ee 24 REFRIGERANT AND OIL CHARGE 020 c cece cence eee eee eens 25 Refrigerant Ohart iii es ho A ik Gs ee A se AEE A RA A a 25 6 1 1 Warnings for the Refrigerant Charge Checklist 0 0 0 0 0 ccc cee 25 Oil Charges ia A Musca rd MiNi ok Wee aed Mle ech Mars a MN Sonal CON atch sts Aa de 26 6 2 1 Procedure for Topping Up Ol 26 SAFETY DEVICE SETTINGS 1 2 cece eee eee ees 27 MAINTENANCE 25 S 04 eect es oe Set AS 28 Lubrication Pump n osii Sh RG BNE BR OBA A Che a RS Bs BAS OSE 28 Coil Cleaning Procedure occ A oA a at 29 Spare Parts a dmc ect bdo lh oy Ae api e e a ts BIE Eee OAR ies Bacto ae 29 Dismantling the Wnts lt 2 i554 pac a Hd BEG he i howe Oo 30 8 4 1 Monthly Maintenance 0 0 0 eee eee eee ee eee nes 30 OPTIONS AND ACCESSORIES 200 e cece ence tenet eee eee ee eens 31 PUMP Debut TA e Bete 3
52. nd temperature sensor well air purge valve discharge valve and sinking connection for electric heaters The buffer tank is installed on the return side of the piping system internal to the chiller Refer to Figures 7 8 and 9 the piping system diagram for further information This tank is not ASME certified Pumps and Piping Options The Liebert HPC S can come with a variety of different pump options factory installed These pumps are controlled by the Liebert iCOM These pumps may be utilized to provide flow through the entire chilled water system as long as the system head is not in excess of what the pump can provide In multi chiller systems these unit based pumps will typically just provide the pumping power through their respective chiller and pumping for the rest of the system is provided by a variable speed system pump separate from the chiller It is important to note that the Liebert HPC chillers require constant flow through the evaporator to operate properly Pumping options for the Liebert HPC S are No pumps or piping options provided No pumps provided with piping options Single standard head centrifugal pump with piping options Single high head centrifugal pump with piping options Dual standard head centrifugal pump with piping options Dual high head centrifugal pump with piping options Single inverter driven standard head centrifugal pump with piping options Electrical Panel Options The Liebert HPC S ele
53. ne has been designed and built to ensure continuous operation The working life of some of the main components such as the fans and the compressors depends on the maintenance that they receive The unit contains substances and components hazardous for the environment electronic components lead battery SUPERCAP refrigerating gases and oils At the end of the useful life when the unit is dismantled the operation must be carried out by specialized technicians The unit must be delivered to suitable centers specialized for the collection and disposal of equipment containing hazardous substances Lead battery refrigerating fluid and the lubricating oil inside the circuit must be recovered according to national and local laws and regulation Monthly Maintenance Fans Check that the fan motor rotates freely without any abnormal noise Ensure that the fan motor bearings are not running hot Also check the amperage levels Condenser and Air Filter Check the conditions of the filters if they are supplied if necessary clean them including the electrical panel ventilation filter Check the condenser coils and clean if necessary see 8 2 Coil Cleaning Procedure Control Check that the control equipment LEDs and display are operating correctly Check the supply voltage Check the operation of the compressor s oil heaters Check the conditions of the remote control switch contacts Check the operation of the evaporator
54. nst direct contact with the high voltage components 4 The power and control wiring protection outside the Liebert HPC S is the responsibility of the customer If the the circuit containing the Liebert HPC employs a Ground Fault Circuit Interrupter GFCI Emerson recommends using a Type B device because of the use of EC fans in the Liebert HPC 5 Ethernet cable connection The Liebert HPC chiller s iCOM can be used with a remote display through an Ethernet network cable Specific instructions are shown in the Liebert HPC iCOM User Manual 273826 Rev 4 0 Fasten the control wiring to the clamp holding plates and make it pass through the first free hole on the panel bottom arrange a cable clamp Knockouts should be used if possible for power and control wiring entry into the unit The cable must be protected by a sheath 6 The terminal points listed below are all on terminal block TBI in the low voltage control panel and are provided to indicate unit status to a remote automation system Remote Indicators Normally open contact when the component is inactive Terminal 450 451 Compressor 1 On closes when active Terminal 452 453 Compressor 2 On closes when active Terminal 454 455 Compressor 3 On closes when active Terminal 456 457 Compressor 4 On closes when active Terminal 458 459 Pump 1 On closes when active Note this terminal is present only in units that have a factory installed pump option Termin
55. ombination condenser coil pack has headers at opposite end of the coil for the two different heat exchange media refrigerant and water glycol solution Condenser coil tubes are leak tested to 650 psi 45 bar The condenser coil shall be equipped with additional sub cooling circuit that increases the efficiency of the refrigeration system Fluid economizer coil headers shall have vent and drainage valves Refrigeration Circuit Components Each refrigeration circuit includes a high pressure safety switch low pressure safety switch TXV filter dryer with disposable cartridge moisture indicating sight glass high pressure safety valves manual shut off valves high pressure gauges and low pressure gauges Fluid Circuit Fluid circuit piping is constructed of carbon steel pipes connected with grooved rigid couplings with gaskets Piping and fluid containing components are insulated with closed cell synthetic elastomer A factory installed flow switch is provided to confirm fluid flow to the evaporator The fluid circuit requires a minimum of 10 glycol solution and must not exceed a 50 glycol solution Units with factory provided pumps must not exceed a 30 glycol solution High Voltage Electrical The electrical panel is designed constructed and tested in compliance with CSA standards The panel contains the main unit switch electrical contactors and overcurrent protection devices The electrical panel is kept cool through ventilation and has
56. omizer Nominal Size 052 Nominal 175 kW 50 ton 080 Nominal 264 kW 75 ton 110 Nominal 338 kW 96 ton Digit 9 Monitoring 0 No monitoring card provided 2 IS WEBL Liebert IntelliSlot Web Card 3 1S 485L Liebert IntelliSlot Modbus Card 4 1S 485EXI Liebert SiteScan Protocol Card 5 IS WEBL Liebert IntelliSlot Web Card IS 485L Liebert IntelliSlot 485 Modbus Card 6 IS WEBL Liebert IntelliSlot Web Card IS 485EXI Liebert SiteScan Protocol Card 7 IS 485L Liebert IntelliSlot 485 Modbus Card IS 485EXI Liebert SiteScan Protocol Card 8 IS IPBML Liebert IntelliSlot Web Modbus IP BACnet IP Card Digit 10 Buffer Tank 0 No buffer tank provided 1 With buffer tank factory installed 11 12 13 14 15 16 17 18 3 1 0 B 0 0 1 Digit 12 Pumps and Piping Options 0 No pumps or piping options 1 No pumps provided with piping options 2 Single standard head centrifugal pump with piping options 3 Single high head centrifugal pump with piping options 4 Dual standard head centrifugal pumps with piping options 5 Dual high head centrifugal pumps with piping options 6 Single inverter driven standard head centrifugal pump with piping options Digit 14 Electrical Panel Options 0 No electric panel options 1 With electric heaters A Fast start ramp B Fast start ramp and electric heaters Digit 17 Condenser Coil Filter Guard 0 No condenser coil guard filte
57. or them to cool before working within the unit Use extreme caution and wear protective gloves and arm protection when working on or near hot compressors pump motors and discharge lines The front part of the compressor and the discharge pipe are very hot be careful when working near either component Be very careful when working near the finned coils because the fins are very sharp Do not remove the fan protection grille before shutting down the whole machine Do not insert foreign objects through the fan protection grille After the maintenance always close the unit by reinstalling any panels that were removed If the front upper panels are removed coil compartment wait for the fan s to stop before accessing the compartment if the front lower panels are removed pay special attention when working near the compressor upper part and the discharge line they are very hot wait for them to cool Lubrication Pump The bearings of motors up to 11kW are greased for life and require no lubrication The bearings of motors of 11kW and up must be greased in accordance with the indications on the motor nameplate The motor should be lubricated with a lithium based grease meeting the following specifications NLGI grade 2 or 3 e Viscosity of basic oil 70 to 150 cSt at 40 C 104 F Temperature range 22 F to 284 F 30 C to 140 C during continuous operation Liebert HPC S 28 Maintenance 8 2 Coil Cleaning Procedure
58. plied with the unit must be kept by the person responsible for maintenance Read the identification labels affixed to the outside and inside of the unit for identification of the unit model and serial no The model and serial number are necessary to receive the most effective support from the factory A WARNING Arc flash and electric shock hazard Can cause equipment damage injury and death Disconnect local and remote power supplies and wear appropriate personal protective equipment per NFPA 70E before working within Failure to comply can cause serious injury or death Customer must provide earth ground to unit per NEC CEC and local codes as applicable Before proceeding with installation read all instructions verify that all the parts are included and check the nameplate to be sure the voltage matches available utility power The Liebert iCOM microprocessor does not isolate power from the unit even in the Unit Off mode Some internal components require and receive power even during the Unit Off mode of Liebert iCOM control The factory supplied optional disconnect switch is inside the unit The line side of this switch contains live high voltage The only way to ensure that there is no voltage inside the unit is to install and open a remote disconnect switch Refer to unit electrical schematic A WARNING Risk of refrigerant system rupture and or explosive discharge of high pressure refrigerant from overpressurization Can
59. quipped with drain plugs and open vent valves The free cooling coils are supplied dry to avoid the possibility of water freezing while the unit is being transport and while it is stored Inspect the machine carefully on delivery to check for damage during transportation or missing components Claims must be made immediately to the carrier and the factory or its representative 3 3 Operating Range Review all the parameters in this section for the operating limits for each model contact your local Emerson representative if your installation requires operation outside these limits 3 3 1 Outer Air Temperature The units are designed to operate at e Minimum temperatures 13 F 25 C for free cooling e Maximum temperatures Depending on the model as indicated in the Table 8 All working limits refer to steady state operation mode NOTE Avoid installation in areas where strong winds may be expected Excessive wind may impair the operation and affect the indicated limits The units are designed to be stored at Temperatures 14 113 F 10 and 45 C e Humidity 80 R H non condensing 7 Liebert HPC S Preliminary Operations 3 3 2 Fluid Circuit Chiller is designed for constant flow only Maximum water flow allowed FG0052 177 gallons per minute 11 2 liters per second FGOO080 265 gallons per minute 16 7 liters per second e FBO110 313 gallons per minute 19 7 liters per second Minimum allowed water flow
60. r 1 With condenser coil guard filter 1 Capacity Rating Point at 95 F ambient 10 EG 50 F Leaving Fluid Temperature and 62 F Entering Fluid Temperature Liebert HPC S Introduction 2 0 INTRODUCTION 2 1 2 2 2 3 2 3 1 2 3 2 2 3 3 2 3 4 The manual is intended to enable both the installer and the operator to install operate and maintain the Liebert HPC S without damaging it or harming personnel Smart Design The Liebert HPC S is a SmartDesign technology appropriate for use with the SmartDesign approach Responsibility Emerson Network Power accepts no present or future responsibility for damage to persons things or to the machine itself due to operators negligence failing to comply with the installation operation and maintenance instructions of this handbook failed application of the safety norms in force for the system and the qualified staff charged with the operation and maintenance Product Description The Liebert HPC S is an air cooled liquid chiller utilizing scroll compressors electrically commutated EC condenser fans thermal expansion device integral economizing coil brazed plate heat exchanger and Liebert iCOM microprocessor controls The entire unit is run tested at the factory prior to shipment to the customer site The unit is only used with constant flow through the chiller All units are 460 3 60 only Frame and Unit Cabinet The unit frame and unit cabine
61. r fan assemblies are removed from the unit and shipped separately Each individual condenser fan assembly consists of the condenser fan and motor grille and collar section A WARNING Arc flash and electric shock hazard Do not connect local and or remote power supplies to the unit before working within Failure to comply can cause serious injury or death 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 national state and local codes A WARNING Risk of working with heavy objects in hazardous location Can cause property damage injury and death The fan assembly weighs 112 5 lb 51 kg Two or more properly trained and qualified personnel are required for assembling the fans and attaching them to the Liebert HPC S Some of the work must be performed on top of the chiller Emerson recommends that the work area be assessed for hazards such as high winds and that the conditions be minimized to protect personnel Components Condenser fan assembly consisting of condenser fan and motor grille and collar the number depends on the Liebert HPC S model Mounting Hardware number of items per fan Bolts 8 Lock washers 8 Flat washers 8 Cable ties 5 Spare mounting Hardware packaged separately Bolts M6x20 hex head Lock washers Flat washers Cable ties The fans are sh
62. resistance if present Check the operation of the electrical panel fan and heaters if present Electrical Circuit Check the electrical supply on all phases Ensure that all electrical connections are tight Refrigeration Circuit Check the condensing and the evaporating pressures to be done by a refrigeration technician Check the compressor s current absorption the delivery temperature and possible unusual noises Check the refrigerant charge by means of the sight glass Check that the safety devices operate correctly Check the correct operation of the TXV superheating between 9 F 14 2 C Check that the oil level is approximately 3 4 indicated by the sight glass fitted on oil and gas equalization tube of each tandem compressor after a short operating time of both compressors Chilled Water Circuit e Ensure that there are no water leaks Bleed any air out of the hydraulic circuit using the bleed valves Verify that the water flow rate is correct Check the inlet outlet liquid temperature and pressure Check the correct operation of the three way valve free cooling systems only Check if the system is charged with the specified glycol percentage and that no ice has formed in the hydraulic circuit Check the evaporator cleanliness Check the motor pump current Check the motor pump noise e Ensure the motor pump is lubricated periodically Liebert HPC S 30 Options and Accessories
63. rol Figure 19 Rubber anti vibration support 264 17 gal US tank ee Rubber Support Dimensions 108mm Single Rubber Support 270326 Unit 3 26 83mm Base y nj Fixing Screw 19 5mm 6 29 160mm Screw Anchor Sin FAR we Not Supplied EH ES DS a N ay ay S ape nee Concrete Base 190mm Access Hole For Support Fixing Table 21 Rubber supports 264 17 gal US tank Support Kit Single Support Kit Support Unit Configuration Code Code Pieces FG0052 FG0080 Without tank 485625 270326 8 FB0110 FG0052 FG0080 With tank 485626 270326 10 FB0110 264 17 gal US tank Loose supplied 485649 270326 4 Each kit is complete with stainless steel fixing screws and plain washers for unit assembly 43 Liebert HPC S Electrical Panel and Chiller Control Figure 20 Overall dimensions E P and control unit 1065 2 lt gt Rear removable panel E P Accessory o Rear removable panel E only with opt TRIAC or a Soft Starter Part G a See See See F Right E later
64. shortage of charge generates an increase in superheating and possible compressor safety trips and failures Whenever work is performed on the unit ensure afterwards that the working conditions are correct checking subcooling and superheating 25 Liebert HPC S Refrigerant and Oil Charge Check the oil level 3 4 of maximum in sight glass fitted on oil and gas equalization tube of each tandem compressor after a short operating time of both compressors installed in the same refrigerant circuit NOTE Check the oil level moving in sight glass fitted on oil and gas equalization tube of each tandem compressor from the stopped compressor to the running one NOTE If only one compressor is running it s possible that the oil level in sight glass fitted on oil and gas equalization tube of each tandem compressor reach the min level or lower it s a normal operating mode and it doesnt affect the reliability of the unit 6 2 Oil Charge Contact the Technical Support Department for the specifications of the oil to be used for topping up the oil changes according to the type of used refrigerant Top ups of up to 20 30 of the total amount of oil contained in the compressor crankcase are permitted For larger percentages contact Emerson s technical support department 6 2 1 Procedure for Topping Up Oil If any oil has been lost it must be topped up as follows 1 Take a clean dry transparent container with volume ca
65. start charging the unit It is imperative that the cylinder is weighed both before and after the operation 4 Charge the unit until the bubbles in the sight glass have disappeared and the working conditions of the entire refrigeration circuit have returned to normal subcooling and superheating within the limits indicated below 5 Measure the superheating as follows a Measure the temperature on the suction line close to the temperature sensor of the electronic expansion valve using a contact thermometer b Connect a pressure gauge by maximum a 12 305mm length pipe with the Schraeder connection and read the corresponding saturated evaporating temperature ___c The superheating is the difference between the two readings 6 Verify that the superheating is 9 F to 14 4 F 17 7 C to 9 8 C 7 Measure the subcooling as follows a Detect the temperature on the liquid line using a contact thermometer a Connect a pressure gauge by maximum a 12 805mm length pipe with the Schraeder connection on the liquid line and read the corresponding saturated condensing temperature ___b The subcooling is the difference between the two readings 8 Verify that at the condenser outlet subcooling is 5 4 F to 9 F 14 8 C to 12 8 C NOTICE Risk of improper refrigerant charging Can cause reduced cooling capacity An excess of refrigerant causes an increase in subcooling and consequent operating difficulties in the hot season a
66. t are constructed of 2mm steel with a highly robust polyester powder RAL7082 paint The base is constructed of 3 mm galvanized steel channels with use of strategic rivets to increase resistance to mechanical deformation All sections containing the refrigerant and hydronic circuits low voltage and high voltage sections use removable panels with captive quarter turn keyed fasteners to provide access and weather protection Unit panels for sections used for access to condenser fans are secured with captive screws All non structural panels are removable for maintenance The cabinet contains all factory wiring refrigeration components hydronic piping high voltage electrical components low voltage electrical components economizing coil and any special features required Electrically Commutated EC Condenser Fans Condenser fans are direct driven with electronically commutated EC motors and fan blades to deliver industry leading efficiency and noise levels Fans are statically and dynamically balanced prior to use in the unit Integral fan guards protect fans from contacting foreign objects and provide for safety of operating personnel Condenser air is discharged vertically upward and intake is on single side only Fan speed is varied to maximize refrigeration and economizer system control at low ambient conditions Fans are removed from unit for shipment after run testing in factory and shipped in an export packaging container with the unit The
67. tem Volume Requirements Use the following formula to determine the minimum system volume for the chilled fluid system 71 87 xR Xa where V minimum required total water volume in gal US R refrigerating capacity in tons Xq design fluid temperature rise across the evaporator in F The minimum required system fluid volume V must be at least equal to the sum of the fluid volume of the Liebert HPC S chiller Am plus the volume of the piping circuit connected to it Vpc It is necessary to install an buffer tank if the total system volume is not greater than or equal to the minimum volume V given by the volume equation Liebert HPC S 16 Installation 4 3 6 Sizing the Expansion Tank 4 3 7 The total volume of the expansion tank is calculated with the following ratio Cxe Pi Pf Ve where e C quantity of water inside the system in liters e water expansion coefficient with water at 10 C as a reference Pi absolute pressure of initial charging equivalent to the tank pre charge pressure typical value 2 5 bara Pf absolute final tolerated pressure lower than the operating pressure or than the safety valve calibration pressure typical value 4 02 bara Use the values of the water expansion coefficient in the table below Table 3 Water expansion coefficient 3 Expansion T H20 F Density Ib ft Coefficient e s eao T 68 62 30 0 0017 86 62 15 0
68. ties Digit 12 1 22 10 Single Standard Head Pump with Piping Specialties Digit 12 2 247 110 Single High Head Pump with Piping Specialties Digit 12 3 375 170 Dual Standard Head Pump with Piping Specialties Digit 12 4 450 204 Dual High Head Pump with Piping Specialties Digit 12 5 721 327 Single Inverter Driven Pump with Piping Specialties Digit 12 6 450 204 Condenser Coil Filter Guard Digit 17 1 110 50 Liebert HPC S 36 Electrical Panel and Chiller Control Figure 11 Dimensions and clearances for Liebert HPC S model FG0052 no buffer tank a 42 j6 181 4597mm 1067mm 153mm YY LY aoe p3 51 2 Y Piping 1300mm Comnection A A ole 1524mm Electrical 4 Connection 4 ELE WZ ot Ww tp WE 4 Minimum distance between two units from condensing side is 10ft 3m Do not obstruct the air exiting the fans for a minimum distance of 8 2ft 2 5m Figure 12 Dimensions and clearances for Liebert HPC S model FG0052 with buffer tank E 49 oe 220 4 6 1067mm 5597mm 153mm PE 60 49 eed 1067mm 1524mm ide 1 15 5 A 893mm 51 2 Piping 1300mm c tion j oneal Electrical 27 d onnection4 687mm 60 Minimum distance between two units 1524mm Service from condensn
69. uid piping system must ensure a constant fluid supply to the evaporator in all operating conditions to prevent damage to the chiller NOTE Emerson recommends installing a water check valve if multiple chillers are installed in parallel in the piping system The check valve should be installed on the fluid return side of each chiller before the connection to the main header NOTE Maximum allowed water hardness is 7 5 mmol gal US Liebert HPC S 14 Installation 4 3 2 4 3 3 Additional Water and Ethylene Glycol Add water and ethylene glycol to the fluid circuit to level required to prevent freezing The amount will be based on the weather data for the specific site location of the chiller and is to be determined by the system designer Do not exceed the nominal operating pressure of the circuit s components NOTES To avoid stratification run the circulation pump for at least 30 minutes after adding any glycol If the pumps are supplied within the chiller then all must be run all together Water glycol fluid mixture has to be circulated inside the chiller hydraulic parts including free cooling coils and bypass pipes in order to do it move the three way valve on both positions for the time necessary Disconnect water supply lines after filling the piping system with the required amounts of fluid Check the glycol concentration after any topping up of the water add glycol as needed Water Glycol Mixture Wat
70. ust be lower than 2 Figure 1 shows a calculation example of the voltage imbalance Figure 1 Calculating phase to phase variability example 1 The 460V supply has the following variability RS 458V ST 469V RT 465V 2 The average voltage is 458 465 469 464 3 3 The maximum deviation from the average is 4 The phase to phase variability is 464 458 6V 6 462 X 100 1 29 Liebert HPC S 8 Preliminary Operations 3 4 Sound Pressure Levels The Table 11 shows the noise data for the units in standard configuration without pumps operating continuously and measured according to the ISO 3744 norm in free field conditions The highest noise levels are detected on the condenser coil side NOTE Avoid positioning in areas with possible reverberation of the sound waves which can adversely effect the noise levels 3 5 Transport Handle the unit by lifting it with a crane Lifting holes are positioned in the frame s base Lifting holes are positioned in the frame s base for use with lifting pipes provided by others Use spreader bars when lifting to protect the sides see Figure 16 NOTE Q Place the lifting pipes in the holes in the base indicated by LIFT HERE The capacity of the lifting gear must be adequate to lift the load in question Check the weight of the units the capacity of the lifting gear and ropes and the condition and suitability of the aforementioned equipment
71. wearing appropriate safety headgear gloves and shoes should attempt to remove or install cabinet panels CAUTION Risk of contact with hot surfaces Can cause injury The compressors pump motors and refrigerant discharge lines are extremely hot during unit operation Allow sufficient time for them to cool before working within the unit Use extreme caution and wear protective gloves and arm protection when working on or near hot compressors pump motors and discharge lines NOTICE Risk of freezing and or corrosion Can cause equipment and building damage Fluids in these systems must contain the proper antifreeze and inhibitors to prevent freezing and premature coil corrosion The water or water glycol solution must be analyzed by a competent water treatment specialist before startup to establish the inhibitor requirement The water or water glycol solution must be analyzed every six months to determine the pattern of inhibitor depletion The complexity of water caused problems and their correction makes it important to obtain the advice of a water treatment specialist and follow a regularly scheduled maintenance program Liebert HPC S LIEBERT HPC S COMPONENTS AND NOMENCLATURE 1 0 LIEBERT HPC S COMPONENTS AND NOMENCLATURE 1 2 3 4 5 6 7 8 9 10 F G 0 0 8 0 0 0 5 1 Digits 7 8 11 13 15 16 and 18 Factory Determined Digits 7 8 15 16 and 18 0 Digit 13 1 Digit 11 3 Digits 4 6 Air Cooled Chiller with Econ

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