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Liebert Mini-Mate2™ - PTS Data Center Solutions

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1. 22 Piping and Electrical 23 Rand Units ed de bett Ee PER Um ace us ocu nape anes d dad 25 185 5 O68 PI ETC 25 View Default Setpoints and Allowable 28 Loegeing a setback Blan s cto eR dee rh SS Ne Nr UE es 29 Set Up Functions Default Values and Allowable 30 Alarm Default Time Delays Ree eg Y RUP Re RU EU Y s 31 Equipment Switch Settings Unit Control Board 32 Switch Settings Wallbox 32 Cooling and Dehumidification Load Response of Hot 87 Typical Discharge 43 DIP switch Settings for Humidifier Control Board 48 Tro uble shoottrg ne CUL DER E te E SC PPS 50 iii iv PRODUCT MODEL INFORMATION M MiniMATE 2 M Microprocessor Control Dz 0 No Disconnect Switch Disconnect Switch Nominal Btuhs 1000 A 7 Air Cooled Self Contained C Chilled Water E Split Evaporator F Air Cooled with Free Cooling Water Glycol with Free Coolin
2. Default Time Delay Alarm seconds Humidifier Problem 2 High Head Pressure 2 Custom Alarm 1 0 Custom Alarm 2 6 High Temperature 30 Low Temperature 30 High Humidity 30 Low Humidity 30 Short Cycle 0 Loss of Power 0 Common Alarm Enable Each individual alarm can be selected to activate deactivate the common alarm relay If the ener gize common alarm function is set to YES the relay is energized immediately as the alarm is annunciated and de energized when the alarm condition is diverted after the alarm has been rec ognized If the alarm is completely DISABLED the alarm has no effect on the common alarm relay Use the up down arrows to scroll to a particular alarm press the Enter button to select it then press the Enter button again to select Yes or No Custom Alarms The custom alarm messages can be selected from a list of standard alarm messages allowing the operator to write his her own message A MAXIMUM OF TWO 2 ALARM MESSAGES CAN BE CUSTOMIZED The two custom alarm messages will initially display the previously programmed message but can be changed The text for custom alarms can be changed at any time by selecting CUSTOM ALARMS To change the text for a custom alarm select the alarm you would like to change 1 or 2 Using the UP DOWN ARROWS step through the list of five standard alarm messages listed below and two custom alarms Select the alarm message desired and store it by
3. Site Preparation and Installation 23 2 7 Checklist for Completed Installation l4 15 16 17 18 19 20 Proper clearance for service access have been maintained around the equipment Equipment is level and mounting fasteners are tight Piping completed to refrigerant or coolant loop if required Refrigerant charge added if required Condensate pump installed if required Drain line Connected Water supply line connected to humidifier if required All piping connections are tight Field provided pan with drain installed under all ducted cooling units Filter box installed on ducted units Ducting completed or optional grille installed Filter s installed in return air duct Line voltage to power wiring matches equipment nameplate Power wiring connections completed between disconnect switch evaporator and condensing unit including earth ground Power line circuit breakers or fuses have proper ratings for equipment installed Control wiring connections completed to evaporator and condensing unit if required including wiring to wall mounted control panel and optional controls Control panel DIP switches set based on customer requirements wiring connections are tight Foreign materials have been removed from in and around all equipment installed shipping materials construction materials tools etc Fans and blowers rotate freely without unusual noi
4. DIP Switches Microprocessor Control 35 Figure 15 Wallbox Board il Lr tr TB3 1 ed 2 i TB3 3 TB4 4 Wallbox Dip Switches 1 8 36 Microprocessor Control 4 0 SYSTEM PERFORMANCE MICROPROCESSOR CONTROLS 4 1 4 1 1 This section provides a detailed description of how the Mini Mate2 responds to operator inputs and room conditions Temperature Control Cooling Heating Required The temperature control program for the microprocessor is based on a calculated percentage requirement for cooling heating Cooling Operation Cooling Compressorized Direct Expansion and Chilled Water Cooling is ACTIVATED when the temperature control calculates a requirement for cooling of 100 It is DEACTIVATED when the cooling requirement drops below 50 The optional hot gas bypass is energized when a call for cooling occurs unless there is also a call for dehumidification Table 17 Cooling and Dehumidification Load Response of Hot Gas Bypass Situation Response Cooling only ON Dehumidification only OFF Cooling with Dehumidification OFF Heating Operation Electric Heat or Hot Water The reheat stage is ACTIVATED when the temperature control calculates a requirement of 10096 Conversely the reheat is DEACTIVATED when the heat requirement is 5096 less than the activa tion point Ground Current Detector GCD A Ground Current Detector is factory insta
5. rz Otero 5 1 2 High Head Pressure 2 oo toe BER TRE aue gd ee ede Turon es 5 1 9 H midity evel st 4o eme es ere pe ete tote o s RS ai e ee p Werden DL AL Temperaturi cele deme ele tue atte ados let tette p edunt 5 1 5 Humidifier Problem Alarm 5 1 6 lt High Water ido 065 Ut oett e eb eee aa Cycle zelo eee T RD C e YR Optional Custom Alarms ea GS eL LE EOE a s 5 2 1 Water Flow oso ult tie ated x LU e NE ald 5 2 2 Smoke Detected chet aes Me te ms Ss Wolke ah SYSTEM TESTING AND MAINTENANCE system Testing patarena PMID e esq Rau ode RI PES a pale dat 6 1 1 Environmental Control 8 nM RUE EE oh oe dyed Eu Ed 6 173 SHE AGI gs ono uocem e dr toe 6 1 4 Hur rdiBcalioh s m 2 dt e D aen e puto det orte 6 1 5 Dehumidification 452 s rs se bed esit ee ar pots he DR Se d Du 6 1 6 Exrestat Optional Lo eR te pesa RU SL Snioke Detector eed hop eeu e eli oud ele t ep e ud 6 1 8 Remote 5 s Maititenance o
6. Gee d 30 Alarm ime Delay sive sce ests upra ohne ae HES al a 30 3 1 12 Common Alarm 81 89 18 Alarm S o uote DH Re ut SMART Dee tton i uA 31 9 IE Custom Texte ns Rea eee S He Delete Eget dd e Caps d 31 3 1 15 Run Diagnostics Available on Rev 1 001 0 32 4 0 4 1 4 2 4 8 4 4 5 0 5 1 5 2 6 0 6 1 6 2 6 3 7 0 8 0 SYSTEM PERFORMANCE MICROPROCESSOR CONTROLS Temperature eee rr 4 1 1 Cooling Heating Required 4 1 2 Cooling Operation Cooling Compressorized Direct Expansion and Chilled Water 4 1 3 Heating Operation Jove IS pA X etel este ue EA SEE Ds Humidity Control RR Re Eee VERD Ee 4 2 1 Dehumidification Humidification Required 4 2 2 Dehumidification Operation Compressorized Direct Expansion DX Systems 4 2 3 Humidification Operation Load Control eee eee eee Comm 1 e e t rie ew e de EP PET au ext ALARMS Alarms Definitions and bob Custom AAT St es most pube og Decay be
7. DT t SPECF ED TS MM2CF INSTALLATION INSTRUCTIONS 1 4 TRAG TEEN 42112601 1 154232 Pal HIGH amp LOW VOLTAGE WIRE HARNESS SEE UNIT SCHEMATIC FOR WIRING 4 7 119mm BLOWER MOTOR amp CONTROLLER ACCESS COVER BLOWER amp MOTOR ASSEMBLY 9 17 25 12 438mm FAN SPEED CONTROLLER 305mm CAPILLARY TUBE FROM FAN SPEED CONTROLLER SCREW ON TO ACCESS VALVE IN DISCHARGE LINE INSIDE CEILING UNIT 4 56 14mm 5 3 BOXED AREA INDICATES A RECOMMENDED CLEARANCE 135mm OF 24 610mm BE PROVIDED FOR COMPONENT ACCESS AND REMOVAL Outdoor Air Cooled Condensing Unit Installation Location Considerations insure a satisfactory air supply locate air cooled propeller fan condensing units in an environ ment providing clear air away from loose dirt and foreign matter that may clog the coil Condens ing units must not be located in the vicinity of steam hot air or fume exhausts or closer than 18 Site Preparation and Installation 21 inches from a wall obstruction adjacent unit Avoid areas where heavy snow will accumulate at air inlet and discharge locations The condensing unit should be located for maximum security and maintenance accessibility Avoid ground level sites with public access The recommended maximum refrigerant line length is 45 feet Install a solid base capable of supporting the weight of the condensing unit Th
8. Refer to gy Quas I9 System Testing and Maintenance 47 schematic on unit Slide the rubber boot back to expose the connections Remove the two 2 power wires and the canister full wire Do not loosen the screws that secure the electrodes WARNING CANISTER AND STEAM HOSE MAY BE HOT ALLOW TIME FOR THE HUMIDIFIER TO COOL BEFORE REPLACING PARTS 7 Loosen the steam outlet hose clamps and slide the steam hose away from the canister fitting Release the canister clamp along the base of the canister 8 Remove the canister 9 Reverse previous steps to re assemble humidifier paying special attention to the following When replacing the wiring connect the red wire from terminal 1 on the interface to the red tip terminal on the canister Reconnect the power wires as before 2 on the left and 1 on the right When replacing the canister always check the fill and drain solenoids for proper operation N WARNING HAZARDOUS VOLTAGE USE EXTREME CAUTION CIRCUIT BOARD ADJUSTMENT SHOULD BE PERFORMED BY QUALIFIED PERSONNEL ONLY POWER SHOULD BE DISCONNECTED PRIOR TO THE PROCEDURE 6 3 2 Humidifier Circuit Board Adjustments The humidifier control board governs humidifier operation There are three potentiometers mounted on the board and can be used to adjust for extreme water conductivity conditions POT2 controls the amperage at which the drain will energize and is clearly marked in
9. commences and the canister operates normally 2 Ifthe conductivity of the water is low the canister fills and the water level reaches the canister full electrode before the amperage set point 1s reached The humidifier stops filling to prevent overflow Boiling should commence in time As water is boiled off the mineral concentration in the canister increases and current flow also increases The canister eventually reaches full output and goes to normal operation No drain is permitted until then 3 When full output is reached the circuit board starts a time cycle which is factory set at 60 seconds During this repeating time cycle the fill valve will open periodically to replenish the water being boiled off and maintain a steady state output at the set point The amperage variance will depend on the conductivity of the water 4 After a period of time the mineral concentration in the canister becomes too high When this occurs the water boils too quickly As the water quickly boils off and less of the electrode is exposed the current flow decreases When the current crosses the low threshold point factory set at 8596 before the end of the time cycle the drain valve opens draining the mineral laden water out and replacing it with fresh water This lowers the mineral concentration and returns the canister to steady state operation and prolongs canister life The frequency of drains depends on water conductivity 5 Over a period of time
10. temperature Heating Reheat may be tested by setting the set point for 10 F 5 C above room temperature A call for heating should register and prompt the equipment to begin heating cycle Disregard any temper ature alarms Upon completion of testing return set point to the desired temperature Humidification To check humidification set the humidity set point at R H 1096 above the room humidity reading After a short delay the canister will fill with water and steam will be produced Upon completion of testing return the humidity set point to the desired humidity Dehumidification The dehumidification performance can be tested by setting the humidity set point at R H 1096 below room relative humidity The compressor should turn on and the fan should switch to low speed Upon completion of testing return humidity set point to the desired humidity Firestat Optional The optional firestat feature is a bi metal operated sensing device with a closed switch under nor mal conditions Connected between pins 1 8 and 1 9 this device will shut down the entire unit when the inlet air temperature exceeds a preset point Smoke Detector While the smoke detector is located in the unit the optional smoke detector power supply is located in the electric panel It constantly samples return air through a tube No adjustments are required Remote Shutdown A connection point is provided for remote shutdown devices supplied by the cu
11. 3 minutes cooling from stop to start Compressor contactor not pulling in Check for 24 VAC 2 VAC at terminals P4 8 and P4 4 If voltage check contactor If no voltage at P4 8 and P4 4 check at terminals P2 3 and P2 8 If voltage check freeze stat Compressor high head pressure See below for cause Plugged filter drier Replace filter drier Low refrigerant charge Check pressure gauges See Table 5 and Table 6 for recommended pressures At low ambient temperatures proper refrigerant charge is very important on units with Lee Temp receivers Compressor high head pressure Insufficient air flow across condenser coil Remove debris from coil and air inlets Water Glycol Cooled only No fluid flowing through condenser Check fluid supply to regulating valve Adjust valve if necessary Self Contained Air Cooled only Condenser fan not operating Check fan operation 50 Troubleshooting Table 20 Troubleshooting Symptom Humidifier does not operate Possible Causes DIP switch not set to enable humidifier option Check or Remedy See DIP switch settings Table 15 HUMIDIFY not displayed at control panel Increase humidity control set point and sensitivity to require humidification Defective board Check voltage at P3 1 and P1 9 on interface board for 24 VAC 2 If no voltage check wiring and or replace board Check wir
12. Connect 3 4 in flexible rubber tubing with hose clamp both supplied with pump kit to 3 4 in hose barb fitting on pump Connect evaporator drain to 3 4 in FPT hose assembly on pump inlet using 3 4 in hard pipe with no trap in the line Provide at least 1 in clearance between the access panel and the drain line Support piping as required Connect a drain line to the pump discharge 3 8 in O D Cu compression fitting provided Connect electric leads L1 and L2 to the line voltage terminal block Connect the ground lead to the lug near the terminal block Connect wires from the Aux Pump contacts to terminals TB1 8 and TB1 9 to shutdown unit upon high water condition in the pump Reinstall the access panels Reconnect power to the unit Run the unit to make sure the pump works properly Operate the pump and check the drain line and discharge line for leaks Correct as needed Figure 6 Condensate Pump BACK OF Drain Line Field Supptied Connection 10mm P T Female Drain connection 3 4 13mm Customer Drain ik Trapped Inside Unit Connection Field Supphed Rigid Piping Support as Required Note 3 4 Flexible Rubber Tubing Assembly Supplied wh Pump Must be on Pump Piping Support as Required Site Preparation and Installation 15 Figure7 General Arrangement Diagram Split Systems AIR COOLED Split System FIELD PIPING FACTORY PIPING Field piping refers
13. Normally off unless High Head Pressure Alarm is active Custom alarm 1 Normally off unless this special customer selectable alarm is active Custom alarm 2 Normally off unless this special customer selectable alarm is active Power Normally on unless unit is turned off through the wallbox or any of the following optional devices Firestat Smoke Detector High Water Alarm or Remote Shutdown 32 Microprocessor Control Test Outputs When this feature 18 selected the unit is effectively turned off When stepping from one load to the next the previous load is automatically turned off if it is on The loads can also be toggled on off by selecting ENTER Once turned on the output will remain on for five minutes unless tog gled off or the test outputs function is exited by selecting MENU ESC Compressor is limited to 15 seconds on to prevent damage N CAUTION Testing compressor output for more than a few seconds could damage the compressor To eliminate damaging the compressor during testing do not test compressor output for more than a few seconds CAUTION Extended unit operation is the test outputs mode for troubleshooting may cause damage to the unit Do not operate unit in the test outputs mode any longer than is necessary for troubleshooting The outputs are as follows Normal Fan Normal speed fan contactor Low Speed Fan Low speed fan contactor Humidifier Humidifier contactor Coo
14. be enabled disabled refer to 3 0 Microprocessor Control and a time delay of 0 255 seconds can be set The alarms can also be programmed to either sound the alarm amp acti vate the common alarm relay OR to sound the alarm only When a new alarm occurs it is displayed on the screen and the audible alarm is activated If communicating with a Liebert Site Product the alarm is also transmitted The message PRESS ALARM SILENCE will prompt the operator to silence the alarm After the alarm is silenced the display will return to the Normal Status display Alarms can be reviewed by selecting the ACTIVE ALARMS feature The alarms can also be silenced through communications with a Lie bert Site Products Unit Many alarms will reset automatically when the alarm condition is no longer represented and only after it has been acknowledged by being Silenced The exceptions are 1 software alarms i e Loss of Power and Short Cycle alarms will reset automatically 30 seconds after being silenced or acknowledged and 2 specific alarms monitoring overload or high pressure switches may require a manual reset depending upon the model Alarms Definitions and Troubleshooting The following list provides a definition and troubleshooting suggestions for each type of alarm Refer to 8 0 Troubleshooting for additional details If you need further assistance contact your Liebert supplier THE CUSTOMER MUST SPECIFY ALARM S AT THE TIME OF ORD
15. box Carefully select a position for the box where discharge air does not directly blow on the sensors 6 Site Preparation and Installation 2 1 2 Location Considerations CAUTION Units contain water Water leaks can cause damage to sensitive equipment below Do not mount units over sensitive equipment A field supplied pan with drain must be installed beneath cooling units and water glycol cooled condensing unit Locate the evaporator unit over an unobstructed floor space if possible This will allow easy access for routine maintenance or service Do not attach additional devices such as smoke detectors etc to the housing as they could interfere with the maintenance or service When using the optional air grille kit avoid locating the evaporator unit in confined areas that affect the air flow pattern Such locations could cause short cycles down drafts and air noise Avoid locating the unit in an alcove or at the extreme end of a long narrow room Avoid installing multiple units close to each other This could result in crossing air patterns uneven loads and competing operating modes Figure1 Air Cooled Systems 1 and 5 Tons Self Contained Air Cooled Ducted Figure2 Water Glycol Cooled Systems 1 and 5 Tons Glycol System Ducted Glycol System Grille Water Cooled Ducted Water Cooled Grille Site Preparation and Installation 7 Figure3 Split system air cooled systems m Split System Ducted Spli
16. disabled until the room temperature reaches this minimum temperature setpoint 4 2 Humidity Control 4 2 1 Dehumidification Humidification Required The humidity control is based on a calculated percentage requirement for dehumidification or humidification 1 the difference between the return air humidity and the humidity setpoint As the return air humidity rises above the humidity setpoint the percent dehumidification required increases proportionally from 0 to 100 over a humidity band equal to the humidity sensitivity setting The converse is true for percent humidification requirement 4 2 2 Dehumidification Operation Compressorized Direct Expansion DX Systems Dehumidification with the standard configuration is accomplished by operating the compressor without the hot gas bypass active The fan will operate at low speed unless the cooling requirement reaches 100 At that point the low speed fan is disabled unless manually overridden by the user until the cooling requirement decreases to 0 Dehumidification will also be disabled if the heating requirement exceeds 125 It will be re enabled when the heating requirement reaches 50 423 Humidification Operation The canister humidifier is activated when the humidity control calculates a requirement of 100 humidification and it is deactivated when the humidification requirement falls below 50 4 3 Load Control Features The control system monitors the compressor and prevents it from
17. disconnected The following control keys may be used to move through the menus as prompted on the LCD dis play ON OFF I O Turns unit on or off top far left Menu Enables user to access the program menu to change control parameters alarms set back schedule etc top near left Increase UP Raises the value of displayed parameter while in a set mode setpoints time etc Arrow top near right Escape ESC Allows user to move back to a previous menu top far right Fan High Low Pressing this keypad changes the fan speed between high and low fan speed bottom far left Alarm Silence Help If an alarm is present pressing this keypad will silence the alarm If this key is pressed when no alarms are present help text will appear bottom near left Decrease DOWN Arrow Lowers the value of displayed parameter while in a set mode bot tom near right Enter After setting a control point press Enter to store the information in the micropro cessor bottom far right Figure 16 Control Active alarms are displayed on the LCD screen and sound an audible beep To silence an alarm press the Alarm Silence Help key as prompted on the display Setpoints DIP switch settings and other selections were made during factory testing of your unit and are based upon typical operating experience Other default selections were made according to options included with your unit MAKE ADJUSTMENTS TO THE FAC
18. included with the grille kit and must be installed to ensure proper air distribution Locate the return and discharge grilles as shown in the grille kit instructions Lower the grilles into place with the louvers in proper direction Note that a field supplied T bar is required between the two grilles If required grilles may be screwed directly to sub base Install disposable filter 20 x 20 1 in the return grille DO NOT OPERATE THE MINI MATE2 WITHOUT THE FILTER INSTALLED IN THE RETURN AIR GRILLE Refer to instructions shipped with kit for more details The evaporator unit should be lowered unit gasket material is compressed 1 4 6 mm f CAUTION Do not allow weight of unit to rest on the grills Piping Connections and Coolant Requirements The following pipe connections are required drain line from the evaporator coil drain pan This line also serves as the drain for the optional humidifier A water supply line to the optional humidifier if applicable Refrigerant piping connections between the evaporator unit and the outdoor condensing unit for split systems If the evaporator unit is chilled water connections to the building chilled water source are required Connection to a water or glycol loop on water glycol type systems Site Preparation and Installation 9 Drain Line CAUTION The drain line must not be trapped outside the unit or water may back up in the drain pan A 8 4 19 mm fem
19. is under war ranty it must be returned to Liebert in order to receive proper warranty credit It should be returned in the same container it was shipped in The possible cause s or condition s of the dam age should be legibly recorded on the provided return tag Proper procedures to remove and replace the failed compressor are 1 Disconnect power 2 Attach suction and discharge gauges to access fittings 3 Recover refrigerant using standard recovery procedures and equipment Use a filter drier when charging the system with recovered refrigerant NOTE Release of refrigerant to the atmosphere is harmful to the environment and unlawful Refrigerant must be recycled or discarded in accordance with federal state and local regulations 4 Remove failed compressor 5 Install replacement compressor and make all connections Pressurize and leak test the system at approximately 150 PSIG 1034kPa pressure 6 Follow manufacturer s instructions for clean out kits 7 Evacuate the system twice to 1500 microns and the third time to 500 microns Break the vacuum each time with clean dry refrigerant to 2 PSIG 13 8 kPa 8 Charge the system with refrigerant R 22 based on requirements of the evaporator condensing unit and lines Refer to the installation manual or the unit nameplate 9 Apply power and operate the system Check for proper operation Refer to Table 18 Typical Discharge Pressures for discharge pressure 46 Sys
20. on from the unit disconnect switch Table 15 Equipment Switch Settings Unit Control Board Switch OFF Position ON Position 1 Compressor Chill Water Staged Reheat SCR Reheat Not Used Must remain in OFF position Not Used Must remain in OFF position Enable Reheat Disable Reheat Enable Humidifier Disable Humidifier Enable Dehumidifier Disable Dehumidifier AJOIN Electric Reheat Gas Reheat Table 16 Switch Settings Wallbox Board Switch OFF Position ON Position 1 Disable Beeper Enable Beeper Not Used Must remain in OFF position Not Used Must remain in OFF position Not Used Must remain in OFF position Not Used Must remain in OFF position Not Used Must remain in OFF position Disable Setback Enable Setback Enable Password Disable Password AJOJN 3 1 15 Run Diagnostics Available On Rev 1 001 0 By selecting Run Diagnostics maintenance personnel can check system inputs outputs and con duct a test of the microcontroller circuit board from the wall box control review of the system inputs and the microcontroller test can be done without interrupting normal operation Show Inputs With the unit on and the fan running the input states may be displayed for the following devices High Water Alarm Normally off unless High Water Alarm is active High Head Pressure Alarm
21. percent ages This adjustment is factory set at 8596 which indicates that the unit will drain when the amperage falls off to 85 of the capacity set point Raising the value increases the frequency of drain cycles Lowering the value decreases the frequency of drain cycles The frequency should be increased for highly conductive water and decreased for less conductive water If adjustment is necessary and a change of three to four percent in either direction does not permit normal operation of the unit consult your Liebert supplier The 1 controls the duration of the drain cycle This adjustment is factory set at 60 seconds and should not be readjusted without consulting your Liebert supplier The POTS control is factory set at 100 The maximum capacity of the system is factory set sub sequently no field adjustment is possible The switch settings are used to set the capacity of the humidifier If the humidifier 18 replaced in the field the DIP switches should be set to the required settings described below Table 19 Table 19 DIP switch Settings for Humidifier Control Board Voltage SW1 Sw2 SW3 SWA Amps 208 230 On Off On Off 4 0 220 240 Off Off On Off 3 7 277 Off On Off Off 3 1 48 System Testing and Maintenance 7 0 MAINTENANCE INSPECTION CHECKLIST Make Photocopies of this form for your records Date Prepared By Model Serial Number NOTE Q Reheat element sheaths and fins are manufactured with sta
22. simultaneous display of these two alarms results in loss of the temperature input signal or the humidity is out of sensor range 15 to 8596 RH Dashes will be displayed for the temperature reading The control system will initiate 10096 cooling Check for a disconnected cable or a failed sensor NOTE Check for proper set points Does the room have a vapor barrier to seal it from outdoor humidity Are doors or windows open to outside air Humidifier Problem Alarm The Humidifier Problem Alarm will sound and display a message if any of the following humidi fier conditions occur overcurrent detection fill system fault or end of cylinder life High Water Alarm A float switch in the evaporator pan will shutdown the evaporator on a high water level Clear the drain and reset power to the unit 1n order to clear the alarm Loss of Power The Loss of Power Alarm will activate after power is restored to the unit if the unit has lost power or the disconnect switch was incorrectly turned off before the unit ON switch was pressed Liebert remote monitoring unit optional will immediately indicate loss of power Short Cycle A Short Cycle Alarm will occur if the compressor system has exceeded 10 cooling start attempts in a one hour period This can be caused by low refrigerant level or room cooling load 18 small com pared to capacity of the unit Check for leaks crimped lines and defective components If room load is low increase sensitivi
23. starts oil in the trap 1s carried up the vertical riser and returns to the compressor NOTE When installing remote condensing units below the evaporator the suction gas line should be trapped with an inverted trap the height of the evaporator This prevents refrigerant migration to the compressor during off cycles Table 5 Recommended Line Sizes O D Cu Equivalent Feet Model Tons Liquid Suction Up to 45 1and 1 5 3 8 5 8 Table 6 Connection Sizes and Torque Coupling Size OD Cu Model Tons Sizes Torque lb ft 3 8 1 and 1 5 6 10 12 5 8 1 and 1 5 11 35 45 NOTE If field supplied refrigerant piping is installed refrigerant R 22 must be added to the system Site Preparation and Installation 11 Quick Connect Fittings NOTE When hard piping is used complete all piping and evacuate lines before connecting quick connects Be especially careful when connecting the quick connect fittings Read through the following steps before making the connections 1 QEON Remove protector caps and plugs Carefully wipe coupling seats and threaded surfaces with a clean cloth Lubricate the male diaphragm and synthetic rubber seal with refrigerant oil Thread the coupling halves together by hand to insure that the threads mate properly Tighten the coupling body hex nut and union nut with the proper size wrench until the coupling bodies bottom out or until a definite resistan
24. to the use of hard piping using sweet adapter kit precharged ine sat 16 Site Preparation and Installation Figure8 General Arrangement Diagram Self Contained AIR COOLED WATER COOLED 1 GLYCOL COOLED Loa Sele ee a FIELD PIPING OPTIONAL PIPING FACTORY PIPING Components are not supplied by Liebert but are recommended Site Preparation and Installation 17 2 4 4 Electrical Connections Each unit is shipped from the factory with internal wiring completed Refer to electrical sche matic when making connections Electrical connections to be made at the installation site are Power supply to each ceiling unit N WARNING UNIT CONTAINS HAZARDOUS ELECTRICAL VOLTAGE DISCONNECT POWER SUPPLY BEFORE WORKING WITHIN LINE SIDE OF FACTORY DISCONNECT REMAINS ENERGIZED WHEN DISCONNECT IS OFF Control wiring between the evaporator unit and outdoor condensing unit if applicable Control the wiring between the control panel wallbox and the evaporator unit control board Power Connections power and control wiring and ground connections must be in accordance with the National electrical Code and local codes Refer to Unit serial tag data for electrical requirements f CAUTION Use copper wiring only Make sure that all connections are tight Voltage supplied must agree with the voltage specified on the unit name plate If a field supplied disconnect switch is re
25. turning on within a 3 minute period of being off If this on off on cycle occurs too often e g 10 times in a one hour period a Short Cycle Alarm will occur 44 Communications The control system uses a two wire RS 422 channel to communicate with Liebert Site Products via a proprietary protocol A converter board ECA2 is available to allow communications with a dumb terminal or a computer using RS 232 channel More details are provided in the Site Prod ucts and ECA2 user manual The communications channel provides both monitoring and control options including TEMPERATURE HUMIDITY Current temperature and humidity readings STATUS Cooling heating and humidify dehumidify operating status PRESENT ALARMS Alarms currently activated SETPOINTS Temperature Setpoint Temperature Sensitivity Humidity Setpoint Humidity Sensitivity High Temperature Alarm Low Temperature Alarm High Humidity Alarm Low Humidity Alarm ON OFF STATUS SILENCE ALARM 38 System Performance Microprocessor Controls 5 0 ALARMS 5 1 The microprocessor control system will audibly and visually signal all ENABLED Alarms includ ing two 2 custom alarms These special alarms can be chosen from the optional alarm list and or can have their own fully custom text The custom alarm inputs are contact closures wired from terminal TB1 1 through a normally open contact to either TB1 2 alarm 1 or TB1 3 alarm 2 The alarms can
26. unit and ductwork so that the discharge air does not short circuit to the return inlet Avoid directing the hot exhaust air toward adjacent doors or windows Normal operating sound may be objectionable if the unit is placed directly over quiet work areas Ductwork that runs through a conditioned space or 1s exposed to areas where condensation may occur must be insulated Whenever possible ductwork should be suspended using flexible hang ers Avoid mounting the duct directly to the building s structure In applications where the ceiling plenum is used as the heat rejection domain the discharge air must be directed away from the air inlet and a screen must be added to the end of the discharge duct to protect service personnel For multiple unit installation space the units so that hot exhaust air 1s not directed toward the air inlet of an adjacent unit 20 Site Preparation and Installation Figure 10 Centrifugal Condenser Fan Dimensions and Installations 2 6 2 6 1 STEP 2 54 REMOVE THESE SCREWS 1 THOSE SERENS USED I TE INSTALLATION OF MMZCE REMOVE THIS KNOCKOUT FASTEN BLOWER HARNESS CONNECTION HERE PARTS REMOVE THIS KNOCKOUT ANO PLACE ITEM 4 HERE SCREW AND WASHER BOTH SIDES DO NOT REMOVE THIS SCREW EITHER SIDE THe MAT ei E OEN LEERT DOMERSG SPECK ECAT OM R AS
27. water level in the sump Remote Monitoring and Control Remote Monitoring and Control Liebert can provide a variety of remote monitoring and control devices to enhance your Mini Mate2 system These include water detection remote monitoring of a single unit and remote con trol monitoring of multiple units Remote Sensors Remote temperature humidity sensors can be mounted in the controlled space or in ductwork and includes 30 feet of control cable Introduction 5 2 0 SITE PREPARATION AND INSTALLATION NOTE Before installing unit determine whether any building alterations are required to run piping wiring and ductwork Carefully follow all unit dimensional drawings and refer to the submittal engineering dimensional drawings of individual units for proper clearances 2 1 Installation Considerations The evaporator unit is usually mounted above the suspended ceiling in the space to be condi tioned Ducted systems may be located in a different room Refer to Figure 1 and Figure 2 for possible configurations The system may be Self Contained Air Cooled with Centrifugal Condenser mounted to the evaporator box Split System Air Cooled with Outdoor Propeller Fan Condensing Units Self Contained Chiller Water requiring connection to building chilled water loop Self Contained Water Glycol cooled requiring water or glycol loop connection T
28. 200 225 1380 1550 29 4 C Glycol Cooled 210 275 1445 1895 Maximum 330 2275 High Pressure Cut Out 360 2480 Thermostatic Expansion Valve The thermostatic expansion valve keeps the evaporator supplied with enough refrigerant to satisfy load conditions Proper valve operation can be determined by measuring superheat level If too little refrigerant is being fed to the evaporator then the super heat will be high Conversely if too much refrigerant is being supplied then the superheat will be low The correct superheat setting is between 10 and 15 F 5 6 and 8 8 C System Testing and Maintenance 43 Air Cooled Condenser Restricted airflow through the condenser coil will reduce the operating efficiency of the unit Additionally it can result in high compressor head pressure and loss of cool ing Using compressed air or commercial coil cleaner clean the condenser coil of all debris that will inhibit airflow In winter do not permit snow to accumulate around the side or underneath the condenser At the same time check for bent or damaged coil fins and repair as necessary Check all refrigerant lines and capillaries for vibration and support as necessary Carefully inspect all refrigerant lines for signs of oil leaks Coaxial Condensers Water Glycol Cooled Condensers only Each water or glycol cooled mod ule has a coaxial condenser consisting of an exterior steel tube and an interior copper tube If the water supp
29. 4 Ts osse ore e Mae Cot ufo ue ce pO e E eA 6 2 L Electric Panel sre idee REN Lb esce queo ee utet qo 0 2 2 es nx oer aos s Wa tea ote ete Re 623 Direct Drive Blower 624 Refrigerati n tee oe RG e Meese ub E UN Wt ess Replacement Procedures 0 ee eee eee tenes 6 3 1 Steam Generating Humidifier Operation 6 3 2 Humidifier Circuit Board Adjustments lesse MAINTENANCE INSPECTION CHECKLIST TROUBLESHOOTING 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 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 Figures Air Cooled Systems 1 5 Tons 7 Water Glycol Cooled Systems 1 and 5 7 Split System Air Cooled Systems 8 Unit Dimensional Data 2 es erem o eed eee ae e uenire rus Me eee eae ee 18 Init Pipinse Data oos etes mal Sen oti ae aan been ots ENTE 14 Co
30. 4 VAC 2 VAC at terminals P3 4 and P1 9 If no voltage check wiring and or replace interface board Check fan relays Fan will not operate at low speed during dehumidification Temperature requirement is too high Verify with display Cooling requirement overrides Dehumidification Cooling cycle too short Sensor response delay too short Increase sensor response delay See 3 1 9 Calibrate Sensors Display freezes and control pads do not respond Static discharge During period of low humidity static electricity can cause the control program to freeze or display incorrect information Although this is unlikely the control can be reset by cycling power from the disconnect switch Condensate pump does not operate Open or short circuit in wiring Find open or short circuit and repair power to pump Continuous Cooling Failed temperature sensor Temperature display will indicate dashes Check wiring from temperature humidity board remote sensors to the control board or from control board to wallbox Replace temperature humidity circuit board remote sensors or wallbox Continuous Cooling Dehumidification Humidification Shorted wiring or failed control board Check wiring and or replace control board 52 Troubleshooting Ensuring The High Availability Of Mission Critical Data And Applications Emerson Network Power the global leader in enabling business critica
31. ER OTHER DEVICES AND WIRING MAY BE REQUIRED AT THE FACTORY FOR SOME OF THE ALARMS Custom Alarms Custom alarm s messages are programmed at the LCD display The message displayed may be included in a list of provided alarms or it may be customized text for up to 2 alarms IF CUS TOMIZED TEXT IS USED MAINTENANCE PERSONNEL SHOULD BE INFORMED OF THE ALARM FUNCTION AND THE REQUIRED ACTION High Head Pressure Compressor head pressure is monitored with a pressure sensor switch One SPDT pressure switch is used If head pressure exceeds 360 PSIG the switch turns off the compressor contactor and sends an input signal to the control The condition 1s acknowledged by pressing the alarm silence button on the wall box which will clear if the head pressure is alleviated If the head pres sure alarm has activated three times the alarm will lock until the unit is serviced After the head pressure problem 18 fixed reset the control by disconnecting power to the evaporator unit Air Cooled Systems Check for power shut off to the condenser condenser fans not working defective head pressure control valves dirty condenser coils or crimped lines Water Glycol Systems Check water regulating valves Verify water glycol flow 1 e pumps operating and service valves open Is water tower or drycooler operating Is the coolant temperature entering the condenser at or below design conditions Is AUX relay terminals 70 amp 71 operating during coo
32. H Precision Cooling For Business Critical Continuity Liebert Mini Mate2 Installation Operation and Maintenance Manual 1 1 5 Tons 50 amp 60Hz d 1 DA 2 1 5 0 Liebert PTS EMERSON PTSdcs DATA CENTER SOLUTIONS bu x Iu Network Power Table of Contents PRODUCT MODEL INFORMATION een nnn 1 1 0 INTRODUCTION 1 1 Production Description and 3 Controls 2 b cet tte on bea Eco DURS aX cit ERR rn p s 3 1 1 2 System Components llle s 3 1 2 Optional Equipment e Nati AR eae ees 8 1 2 1 Ancillary Ship Loose Accessories 4 1 2 2 Remote Monitoring and 1 5 2 0 SITE PREPARATION AND INSTALLATION 2 1 Installation Considerations pose cen a o eoi ee eR Ee aC CEA un 6 231 Room Preparation e dave oa dre mean BoP ana eee dee Ease es 6 2 1 2 Location Considerations 7 2 2 Syste m Welghts ctas OE Paco oe 8 2 3 Equipment Inspection Upon Receipt 8 2 4 Installing the Ceiling Units 0 nee 8 2 41 Evaporator Air Distribution 5 ure soe Re RR
33. IMENSIONAL DATA Site Preparation and Installation 13 Figure5 Unit Piping Data Liquid Refrigerant Line Quick Connect Female Coupling with Access Vatve FRONT OF UNIT Chilled Water Retum Line OUT 125 13mm NPT Female Chilled Water Supply Line IN 1027 13mm NPT Female 7f8 222mm Dia Condenser Air Entrance Customer Outlet and Blower Vottage Connection Box Located for if applicable Units Hot Water Reheat Hot Water Reheat Free Colting Inlet Free Colkng Outlet 12 13mm P T Wator Gtycol Model Condenser Optionat Inlet foc rua Models o 144 6mm D Use Copper Lines For Humidifec Supply Line NOTE ROUTE HUMIDIFIER SUPPLY LINE AND ELECTRICAL SUPPLY TO CLEAR OPTIONAL FILTER BOX ACCESS DOOR 1 2 13mm P T Wiater Glycol Model Iniet 3 4 10mm N P T Fomsio Condensata Drain connection Drain i T And Must Not be Trapped The Module 14 Site Preparation and Installation 2 4 58 Condensate Pump Kit Installation All Units 1 Refer to detail instructions and drawings supplied with the pump 2 Disconnect all power to the unit 3 Remove access panels NOTE Remove shipping band from float switch in evaporator pan 9 10 11 12 Use mounting brackets if pump is not attached to ductwork Pump inlet must be at least 1 2 in below evaporator drain Mount the pump to unit exterior as shown in Figure 6
34. TORY DEFAULT SELECTIONS ONLY IF THEY DO NOT MEET YOUR SPECIFICATIONS Allowable ranges are displayed by pressing the Help key A password will be required if enabled to change setpoints time delays etc 26 Microprocessor Control The display normally shown includes the present room temperature humidity active status func tions cooling heating dehumidifying humidifying normal fan speed low fan speed and active alarms The Status Display may also be selected from the Main Menu MAIN MENU lt MENU gt Press the MENU key to display the Main Menu The Menu selections in the following order include SETPOINTS STATUS ACTIVE ALARMS TIME DATE SETBACK SETUP OPERATION SETPOINT PASSWORD SETUP PASSWORD CALIBRATE SENSORS ALARM ENABLE ALARM TIME DELAY COMMON ALARM ENABLE CUSTOM ALARMS CUSTOM TEXT DIAGNOSTICS END OF MENU Use the up down arrow to scroll through the selections then when ready to select a particular function press Enter Setpoints Setpoints and system setup parameters are kept in non volatile memory Selecting SETPOINTS from the Main Menu will display the following selections TEMPERATURE SETPOINT TEMPERATURE SENSITIVITY HUMIDITY SETPOINT HUMIDITY SENSITIVITY HIGH TEMPERATURE ALARM LOW TEMPERATURE ALARM HIGH HUMIDITY ALARM LOW HUMIDITY ALARM Scroll through this sub menu by using the up down arrow then press Enter to
35. able 1 Application Limits Evaporator and Chilled Water Units Input Voltage Range of Return Air Conditions to Unit Min Max Dry Bulb Temp Relative Humidity 5 10 65 to 85 F 10 to 29 C 20 to 8096 Unit will operate at these conditions but will not control to these extremes of conditions Table 2 Application Limits Outdoor Air Cooled Condensing Unit Input Voltage Entering Dry Bulb Air Temperature Min Max Min Max 5 10 30 34 115 46 units with Lee Temp receiver Table 3 Application Limits Water Glycol Cooled Condenser Input Voltage Entering Fluid Temperature Min Max Min Max 5 10 45 7 115 46 Operation below 65 F 18 C may result in reduced valve life and fluid noise 2 11 Room Preparation The room should be well insulated and must have a sealed vapor barrier The vapor barrier in the ceiling and walls can be a polyethylene film Paint on concrete walls and floors should contain either rubber or plastic NOTE The single most important requirement for maintaining environmental control in the conditioned room is the vapor barrier Outside or fresh air should be kept to a minimum when tight temperature and humidity control is required Outside air adds to the cooling heating dehumidifying and humidifying loads of the site Doors should be properly sealed to minimize leaks and should not contain ventilation grilles NOTE Temperature and humidity sensors are located in the wall
36. ale pipe thread connection is provided for the evaporator coil conden sate drain This line also drains the humidifier if applicable The drain line must be located so it will not be exposed to freezing temperatures The drain should be the full size of the drain connec tion The evaporator drain pan includes a float switch to prevent operation if drain becomes blocked The optional condensate pump kit is required when the evaporator is installed below the level of the gravity fed drain line NOTE Remove shipping band from the float switch in the evaporator pan before operating unit Humidifier Water Supply Line Units supplied with the optional humidifier package have a 1 4 in 6 4 mm compression fitting with ferrule at the water supply connection Supply pressure range is 10 PSIG to 150 PSIG Required flow rate is 1 gpm A shut off valve should be installed in this line to isolate the humidi fier for maintenance Assembly Instructions 1 Cuttube square and remove cutoff burr 2 Slide nut then sleeve on tube threaded end on nut facing end of tube 3 Insert tube into fitting seating it against stop shoulder and thread nut to body handtight 4 With proper wrench tighten 1 to 24 turns CAUTION Overtightening can damage fittings and or tube causing leaks Chilled Water Loop On chilled water units install manual service shut off valves at the supply and return lines of each unit These shut off valves are use
37. ce is felt Using a marker or pen make a line lengthwise from the coupling union nut to the bulkhead Tighten the nuts an additional quarter turn the misalignment of the lines shows how much the coupling has been tightened This final quarter turn is necessary to insure that the joint will not leak Refer to Table 6 for torque requirements 12 Site Preparation and Installation Figure 4 Unit Dimensional Data CUSTOMER SUPPLIED THREADED RODS FOR MODULE SUPORT FROM CEILING TYP 4 CONDENSOR BLOWER BOX LOCATION FOR SELF CONTAINED AIR COOLED UNIT ONLY SEE PAGE 13 FOR DIMENSIONAL DATA 3 8 10mm HOLES FOR MODULE RIGGING TYP 2 EACH END EVAPORATOR SUPPLY DUCTED UNT EVAPORATOR RETURN DUCTED UNIT Se 1371mm INDICATES A RECOMMENDED CLEARANCE OF 24 610mm PROVIDED FOR COMPONENT HANGING DIMENSIONS NOTE UNIT IS SPACED EVENLY IN REFERENCE TO THREADED ROD CENTERS CONDENSER INLET BRACE DUCT CONNECTION FOR SELF CONTAINED te 4 gt AIR COOLED UNIT ONLY 1 25 4mm FINGE NE TRI is laa 221 EE m 15 325 45mm cama BACK VIEW MODULE DIMENSIONAL DATA CABINET DIMENSIONS Gmm REMOVABLE FOR FILTER ACCESS AND REMOVAL INDICATES A RECOMMENDED T CLEARANCE OF 30 762mm 51mm BE PROVIDED FOR COMPONENT ACCESS AND REMOVAL TO UNIT 1 THREE WAY 25 4 UNIT DISCHARGE OPTIONAL FILTER BOX OPTIONAL GRILLE AIR DISTRIBUTION D
38. d for routine service or emergency iso lation of the unit Chilled water supply and return lines must be insulated Insulating them will prevent condensa tion of the water supply and return lines to the unit The minimum recommended water temperature is 42 F Design pressure is 300 PSIG Connection sizes are 1 2 13 mm FPT supply and return Water Glycol Loop It is recommended that manual service shut off valves be installed at the supply and return line to each unit This enables routine service and or emergency isolation of the unit Install 13mm diameter condensing fluid inlet and 13mm diameter condensing fluid outlet When the condensing fluid quality is poor it is recommended that proper filters be placed in the supply line These filters must be easily replaced and or cleaned to extend the service life of the condenser The standard maximum fluid pressure is 150 psig 1034 kPa or optional 350 psig 2413 kPa systems For applications above this pressure consult the factory The water glycol cooled system will operate 1n conjunction with a cooling tower city water or dry cooler AUTOMOTIVE ANTI FREEZE MUST NEVER BE USED IN GLYCOL SYSTEMS ALWAYS USE HVAC GLYCOL SOLUTION ONLY THAT HAS BEEN PREPARED BY INDUS TRY PRACTICES Site Preparation and Installation Regulating Valve Water Glycol cooled units include a coolant flow regulating valve which is factory adjusted and should not need field adjustment S
39. degree difference between the return air temperature and the temperature setpoint In terms of relative humidity control unnecessary dehumidification can result when overcooling occurs during a dehumidification cycle This is due to a higher than normal RH reading caused by overcooling the room about 296 RH for each degree of overcooling This drop in temperature extends the dehumidification cycle Later when the dehumidification ends and the temperature rises to the setpoint the RH reading falls The final RH reading will then be lower than actually Microprocessor Control 29 3 1 10 3 1 11 desired If the temperature drop was significant enough the percentage RH could be low enough to activate the humidifier If the absolute humidity control is selected over dehumidification may be avoided When over cooling occurs 1 causing an increase in the RH reading the humidity control program esti mates what the RH will be when the dehumidification cycle ends and temperature returns to the setpoint This allows the dehumidification cycle to end at the proper time The predictive humid ity control can greatly reduce energy consumption by minimizing both compressor reheat opera tion and elimination unnecessary operation Use the Up Down Arrow key to select the desired humidity control method Table 13 Set Up Functions Default Values and Allowable Ranges Function Default Range Restart Time Delay 0 1 0 to 9 9 min 0 manual re
40. e ae SES RE web Bale wee SS 9 2 4 0 Piping Connections and Coolant 9 2 43 Condensate Pump Kit Installation nananana anaana aee 15 2 44 Electrical Connections 0 0 eee een nett ras 18 2 5 Centrifugal Condenser Fan 19 2 6 Outdoor Air Cooled Condensing Unit Installation llle 21 2 6 1 Location Considerations cc ee ers 21 262 Connections yess ee v oc E Creer UE PA Ote eres 22 2 6 3 Electrical Connections ee has 22 2 1 Checklist for Completed 24 3 0 MICROPROCESSOR CONTROL 3 1 Feature Overview 0 ee Res 26 cot Sida rel Bh gin odes betae et Ob editi ub bote e DSL 27 3 12 STATUS os seb T eos ete ede etie dM T oderat BG Ere bd 28 Tho SActive Alarms ced Adee Als dle oe eta dak ae dte eite e lee tea ind 28 Ou inier oe orte e ba a b ues 28 90 Date Lomo te Boe Bite c epe aside es Boe Ea o CER te e Ft EA Reis Bata Se 28 9 130 Detbacke oco e Dec D E E T dois E UE een du red er eee eat 29 9d T Setup Operations rnt de Ecos ted ete tr hedera 29 98 18 Change PasswordSo Ee ERU ERE MA 30 ILY CalibrateiSensorss a aede a op e Pa to oM osea Deas 30 3 D 10 Alarm Enable hs uiae Sete te
41. e base should be at least 2 inches higher than the surrounding grade and 2 inches larger than the dimensions of the condensing unit base For snowy areas a base of sufficient height to clear snow accumulation must be installed Table 7 Unit Dimensions Inches mm Model Width A Height B Depth C PFCO13A L 40 1016 235 597 18 457 PFCO14A L 40 1016 23 5 597 18 457 PFHO14A L 40 1016 23 5 597 18 457 19 L 40 1016 23 5 597 18 457 PFCO20A L 40 1016 23 5 597 18 457 20 L 40 1016 23 5 597 18 457 PFCO26A L 40 1016 23 5 597 18 457 PFCO27A L 40 1016 23 5 597 18 457 27 L 40 1016 23 5 597 18 457 26 H 48 1219 31 787 18 457 27 1 48 1219 31 787 18 457 PFCZ26A L 48 1219 31 787 18 457 PFCZ27A L 48 1219 31 787 18 457 2 6 2 Piping Connections Details for Refrigerant R 22 Loop piping are in 2 4 2 Piping Connections and Coolant Requirements 2 6 3 Electrical Connections Refer to 2 4 4 Electrical Connections for general wiring requirements and cautions Refer to electrical schematic when making connections Power Connections The outdoor condensing unit requires its own power source and earth ground with a disconnect switch field supplied to isolate the unit for maintenance transformer is available for 277 VAC single phase applications Contro
42. er Clog An adjustable pressure differential switch emits an audible signal when high differential pres sure e g dirty filters 18 detected Ancillary Ship Loose Accessories Refrigerant Line Sweat Adapter Kit This kit includes the compatible fittings required two suction and two liquid line connections when using field supplied interconnecting refrigerant lines to outdoor condensing unit instead of the pre charged line sets Pre Charged Refrigerant Line Sets Pre charged refrigerant line sets are available in 15 and 30 foot lengths for 1 and 1 5 ton systems and are factory charged and sealed They are used to connect the evaporator to remote Air Cooled Condensing units Each set includes an insulated copper suction line and a copper liquid line with fittings 4 Introduction 1 2 2 Supply and Return Grille Kit Supply and return air grilles fit within a 2 4 ceiling tile and include a return air filter Duct Kit with Return Air Filter Box A return air filter box with duct flange 4 102mm filter and a supply air duct flange are pro vided for ducting the evaporator air Condensate Pump Kit A condensate pump is required when the evaporator is installed below the level of the gravity fed drain line Components include the pump check valve sump level sensor float switch and con trols The condensate pump kit is field mounted to the side of the evaporator housing where it automatically controls the
43. eration 2 3 Glycol solution 4 pH level Maintenance Inspection Checklist 49 8 0 TROUBLESHOOTING WARNING ZN HAZARDOUS VOLTAGE WILL BE PRESENT AT EVAPORATOR CONDENSER REHEAT AND HUMIDIFIER EVEN WITH THE UNIT TURNED OFF AT THE CONTROL PANEL WITH POWER AND CONTROLS ENERGIZED UNIT COULD BEGIN OPERATING AUTOMATICALLY AT ANY TIME TO ISOLATE UNIT FOR MAINTENANCE TURN OFF POWER AT DISCONNECT SWITCH TURN OFF POWER TO UNIT AT DISCONNECT SWITCH UNLESS YOU ARE PERFORMING TESTS TAHT REQUIRE POWER Table 20 Troubleshooting Symptom Unit will not start Possible Causes No power to unit Check or Remedy Check voltage at input terminal block Control voltage circuit breaker at transformer open Locate short and reset circuit breaker Float switch relay has closed due to high water in the condensate pan Has rubber band been removed from float switch Check drain and line Access from bottom through discharge air grille Power must be cycled at the disconnect to reset Jumper not in place Check terminal TB1 4 and TB1 5 for jumper or N C contact Check pins 1 8 and 1 9 for jumper or N C firestat contact Check pins 5 4 and 5 5 for jumper or N C smoke detector contact No cooling Cooling is not displayed at the control panel Adjust TEMP control set point and sensitivity to require cooling Short cycle prevention control Control software delays compressor
44. es Use field supplied threaded suspension rods and 8 8 16 fac tory hardware kit Recommended clearance between ceiling grids and building structural members 1s unit height plus 3 inches Install the four field supplied rods by suspending them from suitable building structural mem bers Locate the rods so that they will align with the four mounting holes in the flanges that are part of the unit base Using a suitable lifting device raise the unit up and pass the threaded rods through the four mounting holes in the flanges that are part of the unit base Attach the threaded rods to the unit flanges using the supplied nuts and grommets See Figure 4 The rubber grommets provide vibration 1solation 1 Usethe plain nuts to hold unit in place Adjust these nuts so that the weight of the unit 15 supported evenly by the four rods does not rest on the ceiling grid and to ensure the unit is level NOTE The units must be level in order to drain condensate properly 2 Usethe shake proof nuts to 5am the plain nuts Evaporator Air Distribution Filter Box The optional filter box 18 available for the unit and mounts directly to the return air opening of the evaporator The filter box is supplied with a filter measuring 16 x 20 x 4 406 mm x 508 mm x 102 mm Grille Installation The airflow grilles are directional devices and MUST be installed with the louvers properly aligned in order for unit to operate properly An air baffle is
45. g Split System with Free Cooling W Water Glycol Self Contained MMD12bE PHEOA OAOon xI DX Evaporator 2 3 3 Way Std Pressure Reg Valve Way Std pressure Reg Valve 2 Way High Pressure Reg Valve Way High Pressure High Close off Chilled Water P 208 230V 1ph 60 Hz X 277V 1ph 60 Hz S 220 240 1ph 50 Hz Canister Humidifier 0 No Humidifier 0 No Reheat E Electric Reheat S SCR Reheat Hot Water Reheat Hot Gas Reheat 0 No Hot Gas Bypass Hot Gas Bypass 0 None A Filter Clog B Smoke Detector C Firestat D Filter Clog amp Smoke Detector E Filter Clog amp Firestat Smoke Detector amp Firestat G Filter Clog Smoke Detector amp Firestat 1 0 INTRODUCTION 1 1 1 2 Production Description and Features The Mini Mate2 is a temperature humidity control system designed to be installed above a 2 x 4 ceiling grid system The unit is available as a self contained air cooled self contained water gly col self contained chilled water or as a split system evaporator with an Outdoor Prop Fan Con densing Unit Controls The Mini Mate2 system includes a wall mounted display panel that includes a liquid crystal dis play LCD screen and an 8 membrane keypad The control is menu driven for ease of u
46. g the gas and oils with exposed skin Severe burns will result Use long rubber gloves in handling contaminated parts CAUTION Do not loosen any refrigeration or electrical connections before relieving pressure Check all fuses and circuit breakers Check pressure switch operation f a compressor failure has occurred determine whether its cause is an electrical or mechani cal problem Mechanical Failure If you have determined that a mechanical failure has occurred the compres sor must be replaced If a burnout occurs correct the problem and clean the system It is impor tant to note that successive burnouts OF THE SAME SYSTEM are usually caused by improper cleaning If a severe burnout has occurred the oil will be black and acidic Electrical Failure In the event of an electrical failure and subsequent burnout of the refrigeration compressor motor proper procedures must be followed to thoroughly remove any acids that would cause a future failure There are two kits that can be used with a complete compressor burnout Sporlan System Cleaner and Alco Dri Kleener Follow the manufacturer s procedure DAMAGE TO A REPLACEMENT COMPRESSOR DUE TO IMPROPER SYSTEM CLEANING CONSTI TUTES ABUSE UNDER THE TERMS OF THE WARRANTY THEREBY VOIDING THE WAR RANTY Replacement compressors are available from your Liebert supplier and will be shipped to the job site in a reusable crate as required by the service contractor If the compressor
47. ing from control panel to board Failed humidity sensor Humidity display will indicate dashes Check wiring from temperature humidity board to the control board and from the wall box to the control board Replace wallbox or temperature humidity circuit board if remote No water flow Make sure switch is in Run position Check humidifier water supply including filter screen and check nylon overflow line if canister is full Canister fill rate is not keeping up with the steam output Check fill valve screen opening and capillary tube for obstructions Check water supply pressure minimum 10 PSIG Troubleshooting 51 Table 20 Troubleshooting Symptom Reheat will not operate Possible Causes DIP switch not set to enable reheat option Check or Remedy See DIP switch settings Table 15 HEAT not displayed at the control panel Increase temperature set point to require heating Reheat safety open defective reheat contact or defective board Check voltage at P2 1 and P1 9 on interface board for 24 VAC 2 VAC If voltage check reheat contactor and reheat safety If no voltage check wiring and or replace board Element is burned out Turn off power Check element continuity with Ohm meter Fan will not operate at low speed when selected from control panel Open wiring or failed board Verify LOW is displayed at the control panel Check for 2
48. inless steel Regular inpsections are necessary to assure proper cleanliness of the reheating element Should inspection reveal corrosion particles on the reheating element or adjoining surfaces including ducts and plenums appropriate cleaning should be performed Periodic reheating elecment replacement may be required to meet specific application requirements Monthly Filters ___ 1 Check for restriced airflow ___ 2 Check for filter ___ 3 Wipe section clean Fan Section ___ 1 Impellers free of debris ___ 2 Bearings in good condition Semi Annually Compressor Section 1l Signs of oil leaks __ 2 Vibration isolation Air Cooled Condensing Unit if applicable ___ 1 Condenser coil clean ___ 2 Motor mount tight ___ 8 Bearings in good condition ___ 4 Refrigerant lines properly supported Water or Glycol Cooled Condensing ___ 1 Water valve adjustment 9 Water flow 9 Water leaks Electric Panel Check electrical connections ___ 2 Operational sequence Notes Signature Humidifier ___ 1 Check canister for mineral deposits Check condition of electrodes 3 All hoses and fittings tight 4 Check water make up valve for leaks Refrigeration Cycle 1 Suction pressure Head pressure 2 3 Superheat 4 Evaporator coil clean 5 Insulation intact Flood Back Head Pressure Control if applicable 1 Check Refrigerant level Glycol Pump if applicable 1 Glycol leaks Pump op
49. l Compressor contactor HGBP Hot gas bypass valve Reheat Reheat contactor Common Alarm Common alarm relay NOTE Fan turned on with all loads Test Control Board By selecting this function the microcontroller will perform a self test lasting approximately 10 seconds When the test is complete the display will show the ROM checksum ROM part number and firmware vision number Microprocessor Control 33 Figure 13 Control Menu Mini Mate 2 Control Menu Setpoints Setup Setup Password Temp Setpt Enter New PSW Temp Sens Setup PSW 000 Hum Setpt Hum Sens Hi Temp Alm Lo Temp Alrm Hi Hum Alm Calibrate sensors Lo Hum Alm Temp Cal Hum Cal Temp Delay Hum Delay Status Heat 96 0 0 Dehumidify 0 Humidify 0 Alarm Enable Custom 1 Custom 2 Active Alarms High Temp No Alarms Low Temp or High Hum Alarm 01 of 01 Low Hum High Head Short Cycle Loss Pwr Menu Setpoints Status Time Active Alarms Time Alarm Time Delay Date Custom 1 ens asi Setback Date Custom 2 REF S0 ORE F 50 RH Setup Operation High Temp Setpoint Password Low Temp NO ALARMS S etup Password Setback High Hum Calibrate Sensors Wknd Time 1 Low Hum Alarm Enable Wknd Temp 1 Short Cyc Alarm Time Delay Wknd Tsens 1 Loss Pwr Common Alarm Enable Wknd Humd 1 Custom Alarms Wknd Hsens 1 D Tine Common Alarm Enable nd Temp 2 Hi Wa
50. l Connections Field supplied control wires must be connected between the evaporator and the condensing unit See Figure 9 and the electrical schematic on the units for more details Three 3 wires are required between the evaporator and condensing unit fourth wire is required on systems with hot gas bypass 22 Site Preparation and Installation Figure 11 Piping and Electrical Connections Liquid Line Quick Connect Male Coupling Suction Line Quick Connect Male Coupling Except as noted Electrical Entrance for High Voltage Connection Electrical Entrance for Low Voltage Connection Table 8 Piping and Electrical Connections Model Numbers Electrical Connections in mm Piping Connections in mm 60 Hz 50 Hz A B G PFCO014A L PFCO013A L PFH014A L 20 4 PFC019A L 2 57 5 133 7 197 8 222 5 127 7 184 PFHO20A L PFC027A L PFCO026A L PFH027A L PFC027A H FFCO026A H PFH027A H PFCZ26A L PFCZ27A L PFC037A L PFCO036A L 2 51 5 146 8 216 4 121 6 171 8 216 PFH037A L PFC042A L PFCO041A L PFH042A L PFC037A H 7 PFCZ36A L PFCZ37A L PFC042A H PFC041A H PFH042A H PFCZ41A L 2 51 6 152 8 216 4 121 7 197 8 216 PFCZ42A L 54 4 PFC053A L PFHO54A L PFCO067A L PFCO66A L PFHO67A L
51. l Technical Support Service continuity ensures network resiliency and adaptability through a family of technologies including Liebert power and cooling technologies that protect and support business critical systems Liebert solutions employ an adaptive architecture that responds to changes in criticality density and capacity Enterprises benefit from greater IT system availability operational flexibility and reduced capital equipment and operating costs Web Site www liebert com Monitoring 800 222 5877 monitoring emersonnetworkpower com Outside the US 614 841 6755 Single Phase UPS 800 222 5877 upstech emersonnetworkpower com Outside the US 614 841 6755 Three Phase UPS 800 543 2378 powertech emersonnetworkpower com For More Information 866 787 3271 Sales PTSdcs com DATA CENTER SOLUTIONS 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 2007 Liebert Corporation All rights reserved throughout the world Specifications subject to change without notice Liebert and the Liebert logo are registered trademarks of Liebert Corporation All names referred to are trademarks or registered trademarks of their respective owners 51 10530 2 02 07 Emerson Network Power The global leader in e
52. ling to turn on the drycooler Alarms 39 5 1 3 5 1 4 5 1 5 5 1 7 5 2 5 2 1 Humidity Level The humidity level alarm may be activated under the following conditions High The room return air humidity exceeds the pre set high humidity alarm set point Is the unit set up for dehumidification Check DIP switch Low The room return air humidity decreases to the high humidity alarm set point Is the unit setup for humidification Check DIP switch High and Low Simultaneously simultaneous display of two alarms results in loss of the humidity input signal DASHES WILL BE DISPLAYED IN THE HUMIDITY READING DIS PLAY Under these conditions the control system deactivates both humidification and dehu midification Check for a disconnected cable or failed sensor Temperature The temperature level alarm may be activated under the following conditions High room return air temperature increases to the high temperature alarm set point Check for proper set point value Is the room load more than the unit can handle 1 capacity too small Make sure cooling components are operating compressor or valves Low The room return air temperature decreases to the low temperature alarm set point Check for proper set point value Make sure all heating components are operating e g con tactors reheats etc Are reheats drawing the proper current refer to amp rating on name plate High and Low Simultaneously The
53. lled on all 1 ton through 3 ton Mini Mate2 units with reheat The GCD detects reheat leakage current and shuts down operation of the reheat A steady green LED indicates that the reheat 1s operating properly A red LED indicates that the reheat has failed and both the reheat element and GCD need to be replaced Current CURRENT Liebert Sensing TRANSFORMER Unit Shot Control Control Circuit BR BACKUP CONTACTOR IF PRESENT RH REHEAT CONTACTOR OR SCR CONTROL RH CONTACTOR OR BR CONTACTOR AS REQURED Reheat Assembly WARNING DO NOT REMOVE OR DISABLE THE GROUND CURRENT DETECTOR FAILURE TO LEAVE THE GCD IN PLACE COULD RESULT IN SMOKE OR FIRE System Performance Microprocessor Controls 37 SCR Electric Reheat The SCR Silicon Controlled Rectifier controller proportionally controls the stainless steel reheat fea ture to maintain the selected room temperature The rapid cycling made possible by the SCR control ler provides precise temperature control while the constant element temperature improves heater life During operation of the SCR control THE COMPRESSOR OPERATES CONTINUOUSLY The heaters are modulated to provide temperature control The display status will show when the unit 18 cooling and heating The control will automatically lock the compressor cooling in the position except when the temperature falls below the low temperature alarm setpoint Cooling will then be
54. lume air delivery any unusual restrictions within the air circuit must be avoided Note that high efficiency filters can reduce air performance and evaporator capacity Motor Replacement If the evaporator motor needs to be replaced first remove the air distribu tion plate on the bottom of the unit Removing the mounting screws allows the entire blower wheel and motor to be lifted out Refrigeration System Each month the components of the refrigeration system should be inspected for proper function and signs of wear Since in most cases evidence of malfunction is present prior to component fail ure periodic inspections can be a major factor in the prevention of most system failures Refriger ant lines must be properly supported and not allowed to vibrate against ceilings floors or the unit frame Inspect all refrigerant lines every six months for signs of wear and proper support Inspect the capillary and equalizer lines from the expansion valve Suction Pressure Suction pressure will vary with load conditions Suction pressure normally ranges from 58 psi to 75 psi 405 kPa to 517 kPa Discharge Pressure The discharge pressure will vary greatly with load and ambient conditions Table 18 The high pressure switch will shut the compressor down at its cut out setting Table 18 Typical Discharge Pressures Discharge Pressure System Design Psig kPa Air Cooled 180 275 1242 1895 Water Cooled 65 to 85 F water 18 to
55. ly 18 clean coaxial condensers do not normally require maintenance or replacement Should your system begin to operate at high head pressure with reduced capacity and all other causes have been eliminated the condenser may be obstructed or fouled and should be cleaned or replaced Regulating Valves The water regulating valve automatically regulate the amount of fluid neces sary to remove the heat from the refrigeration system permitting more fluid to flow when load conditions are high and less fluid to flow when load conditions are low The valve consists of a brass body balance spring valve seat valve disc holders capillary tube to discharge pressure and adjusting screw The water regulating valve is designed to begin opening at 180 psi 1240 kpa and be fully opened at 240 psi 1655 kpa The valve is factory set and should not need adjustment There is signifi cant difference in the way standard pressure and high pressure valves are adjusted Consult Lie bert Service Glycol Solution Maintenance It is difficult to establish a specific schedule of inhibitor mainte nance since the rate of inhibitor depletion depends upon local water conditions Analysis of water samples at time of installation and every six 6 months should help to establish a pattern of depletion A visual inspection of the solution and filter residue is often helpful in judging whether or not active corrosion is occurring The complexity of problems caused by water req
56. n Arrow to scroll through the submenu Press Enter to select a particular func tion Restart Time Delay This function delays unit restart after main power is restored to the unit If several systems are operating the time delays should be set to different values to cause a sequential start Delay can be set from 0 1 minutes 6 seconds to 9 9 minutes Setting the value to zero 0 will prevent unit restart when power 1s restored In this case the unit must be restarted manually by pressing the on off button on the keypad C F Degrees The control may be selected to show readings and setpoints in either degrees Fahrenheit F Celsius C To change the value use Enter to select this function then use the Up Down Arrow to change the value Press Enter to store the value Humidity Control Method The operator may select either relative direct or absolute predictive humidity control If rela tive 15 selected the RH control is taken directly from the RH sensor If absolute is selected the RH control is automatically adjusted whenever return air temperature deviates from the desired temperature setpoint i e predictive humidity control The LCD display will indicate percentage relative humidity for both methods of control If the absolute feature is selected the adjusted humidity reading will also be shown When utilizing the predictive humidity control feature the humidity level is automatically adjusted 2 RH for each
57. nabling Business Critical Continuity AC Power Embedded Computing I Outside Plant I Connectivity I Embedded Power Power Switching amp Controls I Dc Power Monitoring 3 Precision Cooling Environmental Systems 800 543 2778 Outside the 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 9719 111 Fax 39 049 5841 257 Asia 7 F Dah Sing Financial Centre 108 Gloucester Road Wanchai Hong Kong 852 2572220 Fax 852 28029250 EmersonNetworkPower com Racks amp Integrated Cabinets 3 Services I Surge Protection Business Critical Continuity Emerson Network Power and the Emerson Network Power logo are trademarks and service marks of Emerson Electric Co 2007 Emerson Electric Co
58. ndensate Pumpe chad ele Aus cun ore ueteri cma ates coke 15 General Arrangement Diagram Split 16 General Arrangement Diagram Self 1 17 Unit Electrical 19 Centrifugal Condenser Fan Dimensions and 21 Piping and Electrical 23 Controls teer eoe ever rete ee tat a me aa ete se ades 26 Control Men nce etic e RASEN e vate EN eese eR 34 Control Board Inside Evaporator 35 Wallbox Boards m ee S eS Ep qe a e qur a eq e dat VN 36 Hot Gas Bypass otc catia Be a e eR ete ie t e ter he BES an ee 45 Tables Application Limits Evaporator and Chilled Water Units 6 Application Limits Outdoor Air Cooled Condensing Unit 6 Application Limits Water Glycol Cooled Condenser 6 Unit Weights 2 bER TESTO E Wu LS VE aa bu RE Pa a 8 Recommended Line Sizes teen eens 11 Connection Sizes and 11 Unit Dimensions Inches
59. nections are made at the terminal block or disconnect switch in the lower left hand corner of the electric panel middle The power terminal connections are labeled L1 and L2 For 208 VAC applications change the input transformer connection as described in the electrical schematic attached to cabinet Self contained air cooled models require power con nections from the evaporator ceiling unit to the condenser fan See Figure 4 Figure 9 and pro vided electrical schematic LINE VOLTAGE SUPPLIED MUST CORRESPOND WITH THE VOLTAGE SPECIFIED ON THE UNIT NAMEPLATE Indoor Condenser Fan Ductwork The total external static pressure for the inlet and outlet ducts including grille must not exceed 0 5 inches of water Hood intake dimensions should be the same as the condensing unit duct dimensions The duct connection provided for air flow to the ceiling unit 7 x 16 4 191mm x 425mm The duct opening for air flow from the condenser fan is 12 x 12 305mm x 305mm Ductwork should be designed for 950 CFM 1614 CMH If the unit draws air from the outside of the building rain hoods must be installed In addition install a triple layer bird screen over rain hood openings to eliminate possibility of insects bird water or debris entering the unit Use flexible ductwork or nonflammable cloth collars to attach ductwork to the unit and to control vibration transmission to the building Attach the ductwork to the unit using the flanges provided Locate the
60. ondensing unit is connected to the evaporator unit by two refrigerant lines and low voltage wiring Water Glycol Cooled Model Includes the following components mounted in the main evaporator unit housing compressor evaporator coil expansion valve evaporator blower high pressure switch coaxial condenser 2 way optional 3 way regulating valve and filter drier This model is specifically designed to oper ate with city water cooling tower systems or dry cooler systems Dry cooler and pumps may be selected separately Chilled Water Model The Chilled Water model is self contained and is designed for use with an existing chilled water loop It contains a chilled water coil and a slow open close solenoid valve to control the flow of chilled water Optional Equipment Canister Humidifier The optional factory installed steam generating humidifier adds pure water vapor to the room air to control humidity Room humidity setpoints are established by the user The humidifier compo nents include a steam canister replaceable control board inlet strainer fill and drain solenoids Introduction 3 1 2 1 Electric Reheat The optional electric reheat is installed and tested at the factory The reheat feature 15 energized when required to heat room air or to control room temperature during dehumidification safety thermostat prevents the reheat from exceeding temperature limits SCR Electric Reheat The optional electric
61. pressing Enter STANDARD CUSTOM ALARM MESSAGES WATER FLOW LOSS SMOKE DETECTED LOSS OF AIR FLOW HUMIDIFIER PROBLEM FILTER CLOG Custom Text modify the two custom alarm messages select CUSTOM TXT Then select CUS TXT 1 or CUS TXT 2 Text can be up to 20 characters in length and can be either a blank space or any of the following alphanumeric characters and symbols A B C D E F G H 1J K L M N O P Q R S T U V W X Y Z 1 0 1 2 3 4 5 6 7 8 or 9 Use the UP DOWN ARROWS to select a character then press Enter The cursor will move to the next space where you may once use the UP DOWN ARROWS to select another character etc Microprocessor Control 31 LCD Contrast The level of contrast due to the viewing angle of the Liquid Crystal Display LCD can be adjusted using a potentiometer screw inside the wall box next to the display Nonvolatile Memory critical information is stored in nonvolatile memory Setpoints setup parameters and compo nent run hours are kept inside the microcontroller in EEPROM Equipment Options Switches Equipment options are selected and enabled using DIP switches 1 through 7 These are located on the control board near TB1 These switches are factory set and should not require any user changes The setting and function of the switches can be individually read on the LCD NOTE In order to update the DIP switch settings power must be cycled off then
62. quired it may be bolted to the ceiling unit but not to any of the removable panels This would interfere with access to the unit Make sure that no refrigerant lines are punc tured when mounting the disconnect switch Route the electrical service conduit through the hole provided in the cabinet and terminate it at the electric box Make connections at the factory terminal block or disconnect switch L1 L2 L3 Connect earth ground to lug provided For 208 VAC applications the low voltage transformer tap must be changed Refer to the electrical schematic Control Connections A field supplied 3 or 4 wire control connection 24 VAC is required between the evaporator and the condensing unit Control wiring must be installed in accordance with the National Electrical Code NEO Class 2 circuit Glycol cooled units also require a two wire control connection to the drycooler and pump A Class 1 circuit is required for Water Glycol units Control wiring between the evaporator and the condensing unit must not allow a voltage drop in the line of more than 1 volt 16 gauge minimum for 75 feet Do not connect additional electri cal devices to the control circuit The circuit breaker contained in the transformer housing is sized only for the factory supplied control system Additional control wiring will be required if your system includes other optional monitoring and control devices 18 Site Preparation and Installation Figure9 Uni
63. reheat is pulsed rapidly to provide precise temperature control while cooling is locked on safety thermostat prevents the reheat from exceeding temperature limits Hot Water Reheat The optional hot water reheat circulates building hot water through a y strainer solenoid valve and finned tubed heating coil to provide reheat Hot Gas Reheat Hot gas from the compressor is piped to a heating coil and valve which can only be energized dur ing compressor operation The compressor must be operating and a cooling load must be present in order to achieve reheating performance Hot Gas Bypass Self Contained Systems Hot gas from the compressor is bypassed to the evaporator coil in order to provide capacity control and reduce compressor cycling Hot Gas Bypass Split System Condensing Units This optional system bypasses hot gas around the compressor directly to suction to provide capac ity control and reduce compressor cycling System includes liquid injection valve to maintain proper suction superheat Free Cooling Coil A separate source of chilled water or cold tower water can be used to provide cooling Upon loss of the chilled water source cooling is switched to DX cooling Smoke Detector If return air smoke is detected the unit alarm panel display emits an audible signal and the unit shuts down Firestat When the return air temperature limit of approximately 125 F 51 7 C is exceeded the unit shuts down Filt
64. se Inspect all piping connections for leaks during initial operations Correct as needed Refrigerant Charge Requirements Total refrigerant charge R 22 will be required only if units are evacuated during installation or maintenance For safe and effective operation refer to pressures in 2 4 2 Piping Connections and Coolant Requirements 24 Site Preparation and Installation Total Refrigerant Units and Lines Table 9 1 and 1 5 Ton Units Charge Model No 02 MMD11A 42 1 2 MMD12A 42 1 2 MMD13W 27 0 8 MMD14W 27 0 8 MMD11E 0 09 MMD12E 0 09 MMD17A 49 1 4 MMD18A 49 1 4 MMD19W 34 1 0 MMD20W 34 1 0 MMD17E 4 11 MMD18E 4 11 Table 10 Line Sets Line Size Length Charge in ft oz kg 3 8 liq 5 8 suct 15 0 10 0 28 30 1 4 0 57 Refrigerant R 22 must be added to field refrigerant piping Site Preparation and Installation 25 3 0 MICROPROCESSOR CONTROL 3 1 The Microprocessor Control for the Liebert Mini Mate2 unit features an easy to use menu driven LCD display The menus control features and circuit board details are described in this section Detailed information concerning controls 4 0 System Performance Microprocessor Con trols and alarms 5 0 Alarms is provided Feature Overview To turn the unit ON press the ON OFF I O key after power is applied To turn the unit OFF press the ON OFF I O key before power is
65. se Figure 13 Control Menu In section 3 0 Microprocessor Control depicts the complete menu tree for the control All control set points and alarm set points are programmable System Components Air Cooled Models There are two types of air cooled systems available Self Contained with Indoor Centrifugal Condenser Blower Included Mounted inside the ceiling unit housing the self contained system includes compressor evaporator coil expan sion valve evaporator blower high pressure switch condenser coil and filter drier The cen trifugal condenser blower up to 950 CFM with variable speed motor is contained in a separate enclosure that attaches to the main unit Head pressure 1s regulated by the Fan Speed Controller FSC which automatically adjusts blower speed as required The condenser section can use air with a temperature range of 20 F to 115 F 29 C to 46 C Split System Outdoor Propeller Fan Included The evaporator section includes evaporator coil expansion valve evaporator blower and filter drier Mounted in an outdoor enclosure the prop fan condensing unit includes compressor with crankcase heater high pressure switch condenser coil propeller fan and flood back head pressure control Lee Temp The compressor crankcase heater and head pressure control allows the condensing unit to operate at an ambient temperature as low as 30 F 4 C The maximum design ambient temperature is 115 F 46 The c
66. select a particular function To change a particular value press Enter and use the UPIDOWN ARROWS to change Microprocessor Control 27 the value When the value has been changed press Enter to store the value For example to change the temperature setpoint from the main status display 1 Press Menu key to display main menu 2 Scroll to SETPOINTS using the UP DOWN ARROW key Press Enter key 3 Scroll to TEMP SETPOINT using the UP DOWN ARROW key Press Enter key 4 Usethe up down arrow to change the value Press Enter key Table 11 View Default Setpoints and Allowable Ranges Setpoint Default Range Temperature Sensitivity 2 0 F 1 9 9 F 0 6 5 6 C Humidity Setpoint 50 20 80 RH Humidity Sensitivity 5 1 30 RH High Temperature Alarm 80 F 35 95 F 2 35 C Low Temperature Alarm 65 F 35 95 F 2 35 C High Humidity Alarm 60 15 85 RH Low Humidity Alarm 40 15 84 RH Status The operator can monitor the percentage heating cooling dehumidifying and humidifying status of the unit by selecting the STATUS sub menu Active Alarms The operator can monitor the alarms status by selecting ALARMS which will display a No Alarm Present or Alarm XX of YY alert and description If more than one alarm is activated use the Up Down Arrow to scroll through the alarms list XX reference is the number of the alarm shown while the YY reference is the to
67. start C F Degrees a or F Humidity Control Rel Relative or Absolute Change Passwords The display will prompt the operator to enter a three digit password when attempting to make changes The system includes two 2 passwords one for setpoints and one for setup The system allows the password to be changed by first entering the default password set at the factory set 1 2 3 for set points and 3 2 1 for setup The password function provides system security so that only authorized personnel are allowed to make changes to the system If unauthorized changes are being made the passwords may be compromised and new ones should be selected The pass word function can be disabled by setting DIP switch 8 in the Wallbox to OFF Calibrate Sensors The temperature and humidity sensor can be calibrated by selecting the CALIBRATE SENSORS menu item The temperature sensor can be calibrated 5 F while the humidity sensor can be cal ibrated 10 RH When calibrating the humidity sensor the value shown will always be 96 RH even though absolute humidity control may be selected If absolute humidity control is selected the Normal Status Display will display the adjusted reading This reading may not agree with the relative humidity reading displayed while in calibration If the sensors are subject to frequent wide temperature and humidity swings it may be necessary to shorten the cycling by increasing the sensor
68. stomer This termi nal strip is located on the printed circuit board Terminals TB1 4 and TB1 5 are fitted with a jumper when no remote shutdown device 18 installed 42 System Testing and Maintenance 6 2 6 2 1 6 2 2 6 2 3 6 2 4 Maintenance Electric Panel The electric panel should be inspected on a semi annual basis for any loose electrical connections Filters Experience shows that filters are usually the most neglected item in an environmental control system In order to maintain efficient operation they should be checked monthly and changed as required ALWAYS TURN POWER OFF BEFORE REPLACING FILTERS Filters can be replaced by either opening the hinged door on the return air filter box or by opening the return air grille grille version only Replacement filters are commercially available in sev eral efficiencies refer to the Technical Data Manual for appropriate filter sizes Direct Drive Blower Package Monthly inspection of the blower package include motor mounts fan bearings and impellers Fan Impellers and Motor Bearings Fan impellers should be thoroughly inspected and any debris removed Check to see if they are tightly mounted on the fan shaft and do not rub against the fan housing during rotation Although the unit s motor bearings are permanently sealed and self lubricating they should be inspected monthly for signs of wear Air Distribution Since all unit models are designed for constant vo
69. sure will drop When the suction pressure reduces below the hot gas bypass valve setting the hot gas bypass valve opens diverting some of the refrigerant flow back to the compressor suction The liquid quenching valve bulb senses this increased superheat and opens allowing liquid refrigerant to mix with the discharge gas desuperheating it Proper mixing of the three refrigerant paths ensures stable operation and system performance The liquid quenching valve bulb must be located downsteam of all these connections to control superheat at the compressor inlet Superheat settings for the liquid quenching valve are chosen to maintain consistency with the system expansion valve During hot gas bypass operation higher 44 System Testing and Maintenance superheats 50 60 F 19 to 15 C may be observed at the compressor The liquid quenching valve 1s internally equalized and superheat is not adjustable Adjustment 1 Install the suction and discharge pressure gauge 2 Adjust temperature setpoint to call for cooling so that the refrigeration compressor will run continuously 3 Remove the TOP adjusting nut from the valve 4 Insert an Allen wrench in the brass hole at top of valve in adjusting port and turn CLOCKWISE if a higher evaporator temperature is required Adjust no more than 1 4 turn at a time Let the system stabilize for 15 minutes before determining if additional adjustment are necessary 5 After obtaining the suction press
70. t Electrical Connections 2 5 li fek unit disconnect switch when factory unit disconnect switch not supphexd Field suppbed field wired thermostat ware to remote wall box r Field suppked 24V NEC class 2 wiring to condensing module if applicable Electrical entrance for optional condensate pump on back of unit 1 bog l l lol l l l Fog o gd l dg hd log Entrance For Customer Fan Speed Control Low Voltage Connections Passage Holes RIGHT END LEFT END Heat rejection connection supplied 24V NEC dass 2 wiring For remote cooked units from torminalis TE2 1 8 2 2 in the FervCoil module to 1 amp 2 in the condensing module Customer remots connection fieid supplied 24V 2 wiring 0 conn TB1 1 TB1 2 amp 1 3 Factory installed disconnect ewitch optional Remote unit shutdown Replace existing jumper between terminais 1 4 amp TB1 5 with normally closed aw ich having a Entrance For High 1 minimum 75 rating use field supply Connections 24V class 1 wire servicos connection terminala Optional condensate pump aux switch connection 15 term Earth ground connection 1 8 2 Connection terminal for Entrance for customer low supplied earth grounding wire Remo
71. t System Grille 2 2 System Weights Table 6 Unit Weights Cooling Units Ib kg MMD11A 265 120 MMD11E 220 100 MMD12A 265 120 MMD12E 220 100 MMD13W 260 118 MMD14W 260 118 MMD17A 295 134 MMD17E 225 102 MMD18A 295 134 MMD18E 225 102 MMD19W 300 136 MMD20W 300 136 MMD2CF 63 29 Add 40 Ib 20 kg to units with free cooling or hot water reheat coils Weights assume reheat and humidifier package is included 23 Equipment Inspection upon receipt When the unit arrives do not uncrate equipment until it is close to its final location All required assemblies are banded and shipped in corrugated containers If you discover any damage when you uncrate the unit report it to the shipper immediately If you later find any concealed damage report it to the shipper and to your Liebert supplier 2 4 Installing the Ceiling Units WARNING BE SURE THE SUPPORTING ROOF STRUCTURE IS CAPABLE OF SUPPORTING THE WEIGHT OF THE UNIT S AND THE ACCESSORIES DURING INSTALLATION AND SERVICE SEE 2 2 SYSTEM WEIGHTS BE SURE TO SECURELY ANCHOR THE TOP ENDS OF THE SUSPENSION RODS MAKE SURE ALL NUTS ARE TIGHT The evaporator unit is usually mounted above the ceiling and must be securely mounted to the roof structure The ceiling and ceiling supports of existing buildings may require reinforcements 8 Site Preparation and Installation 2 4 1 2 4 2 Be sure to follow all applicable cod
72. tal number of alarms activated Time The controller time clock must be set to allow for the setback control The clock uses the 24 hour system i e 12 midnight is entered 24 00 To change the time press Enter to select the function then use the up down arrow to change the first character press enter to store press the up down button to change the section character press enter to store etc THERE IS A BATTERY BACK UP FOR THE DATE AND TIME FEATURES Date The controller date must be set to allow for the setback control To change the date press Enter then use the up down arrow to change the first character press enter to store press the up down button to change the second character etc 28 Microprocessor Control 3 1 6 3 1 7 Setback The microprocessor can be programmed for night and weekend setback Two 2 events can be pro grammed for a five day workweek and two 2 events can be programmed for a two day weekend The following table can be used to devise a setback plan Table 12 Logging a Setback Plan Event Weekend Weekday Time 1 Temperature1 Sensitivity 1 Humidity 1 Humidity Sensitivity 1 Time 2 Temperature 2 Sensitivity 2 Humidity 2 Humidity Sensitivity 2 Setup Operation Selecting Setpoint Setup from the Main Menu will display the following selections RESTART TIME DELAY C F DEGREES HUMIDITY CONTROL METHOD Use the Up Dow
73. tandard pressure and high pressure valves are adjusted differently Contact Liebert Service before making any adjustments Split System Air Cooled Model Refrigerant R 22 Loop split systems require two refriger ant lines an insulated copper suction line and a copper liquid line between the evaporator and the outdoor condensing unit The refrigerant lines can be piped by Using an optional Sweat Adapter Kit and hard piping between the two units Using optional pre charged line sets refrigeration piping should be installed with high temperature brazed joints Prevailing good refrigeration practices should be employed for piping supports leak testing evacuation dehydra tion and charging of the refrigeration circuits The refrigeration piping should be isolated from the building by the use of vibration isolating supports To prevent tube damage when sealing openings in walls and to reduce vibration transmission use a soft flexible material to pack around the tubes It is important to handle the pre charged lines with care so they will not get kinked or damaged Use tube benders and make all bends before making connections to either end Coil any excess tubing in a horizontal plane with the slope of the tubing toward the condensing unit When installing remote condensing units above the evaporator the suction gas line should be trapped at the evaporator This trap will retain refrigerant oil in the off cycle When the unit
74. te control panel connaction to TB3 1 2 3 4 Thermostat wire Avaliable Lisbert or others Se monitoring connection Terminals 4 1 TB4 2 are for connection Of 2 wine twisted pair communication cable available from Liebert or others 10 optional Centrifugal Condenser Fan Installation The self contained air cooled model utilizes a centrifugal blower in a housing that attaches directly to the right end of the ceiling unit Mounting holes are pre cut at the factory and fasten ers are provided In addition a wiring harness is included for the power and control connections required from the ceiling unit to the blower Route capillary tube from fan speed controller through hole in ceiling unit Screw end of capillary tube on to access valve in discharge line Pro viding ductwork for outdoor air to from the condenser is optional Site Preparation and Installation 19 Electrical Control and Power Connections Using the provided wiring harness field connections are required at the ceiling unit four 4 wire connection is required from the condenser fan to the ceiling unit Route the conduit through the hole provided in the left side of the cabinet If a field supplied disconnect switch is installed mount to the ceiling unit but no on any remov able panels DURING MOUNTING OF EXTERNAL DISCONNECT SWITCH TAKE SPECIAL CARE THAT NO REFRIGERANT LINES ARE PUNCTURED OR DAMAGED The ceiling unit power con
75. tem Testing and Maintenance 6 3 1 Steam Generating Humidifier Operation Procedures Steam generating humidifiers operate efficiently over a wide range of water quality conditions and automatically adjust to changes in the conductivity of water The system will automatically drain and refill to maintain an amperage set point and alert the operator when the humidifier canister needs to be replaced The humidifier RUN DRAIN switch is located in the humidifier assembly This switch should be in the RUN position when the humidifier is in normal operation and in the DRAIN position when a manual drain sequence is required The electronic control board for the humidifier is also located in the humidifier assembly When the unit is energized power is available to humidifier Operations involves the following steps 1 During start up when the humidity control calls for humidification the fill valve will open allowing water to enter the canister When the water level reaches the electrodes current flows and the water will begin to warm The canister fills until the amperage reaches the set point and the fill valve closes As the water warms its conductivity increases and the current flow in turn rises If the amperage reaches 115 of the normal operating amperage the drain valve opens and flushes some of the water out of the canister This reduces electrode contact with the water and lowers the current flow to the amperage set point Boiling soon
76. ter End of Menu Wknd Tsens 2 Hi Head Wknd Humd 2 Custom 1 Wknd Hsens 2 Custom 2 Wkdy Time 1 High Temp Wkdy Temp 1 Low Temp Wkdy Humd 1 High Hum Wkdy Hsens 1 Low Hum Wkdy Time 2 Short Cyc Wkdy Temp 2 Loss Pwr Wkdy Tsens 2 Wkdy Humd 2 Wkdy Hsens 2 Custom Alarms Custom Alarm 1 Custom Alarm 2 Setup Operation Restart TD C F Degrees Humidity Control Custom Text Dipswch 00000000 Custom Text 1 Pos 12345678 Custom Text 2 Setpoint Password Diagnostics Test Inputs Enter New PSW Setpt PSW 000 Test Outputs Test Microcontroller 34 Microprocessor Control Figure 14 Control Board Inside Evaporator P P2 P3 P4 P5 TB2 4 TB2 3 TB2 2 TB2 1 Hot Gas Bypass High Head Alarm Connection Heat Rejection Heat Rejection TB1 9 TB1 8 TB1 7 TB1 6 TB1 5 TB1 4 TB1 3 TB1 2 TB1 1 Condensate Pump Aux Alarm Condensate Pump Aux Alarm Common Alarm Connection Common Alarm Connection Remote Shutdown Remote Shutdown Customer Alarm Connection 2 Customer Alarm Connection 1 Customer Alarm Connection Common TB3 4 TB3 3 TB3 2 TB3 1 Connection to Terminal 4 Wallbox Connection to Terminal 3 Wallbox Connection to Terminal 2 Wallbox Connection to Terminal 1 Wallbox 4 2 4 1 Site Monitoring Connection Site Monitoring Connection P16 Remote Sensor Connection 281
77. the electrode surface will become coated with a layer of insulating material which causes a drop in current flow As this happens the water level in the canister will slowly rise exposing new electrode surface to the water to maintain normal output Eventually the steady state water level will reach the canister full electrode and indicate so by activating the canister full alarm At this point all of electrode surface has been used up and the canister should be replaced 6 Afterthe entire electrode surface has been coated the output will slowly decrease This allows for maintenance scheduling During these last hours of electrode life the mineral concentration can increase and arcing can occur If the electrodes start to arc turn off the humidifier immediately and replace the canister with the identical part Replacing the humidifier canister The proper procedure to replace the humidifier canister is 1 Turn off the humidifier by lowering the humidity set point below the ambient humidity level Record the original set point Place the RUN DRAIN switch in the DRAIN position to drain the water from the canister Return the RUN DRAIN switch to the RUN position after the canister has drained Turn OFF the power at the main unit Remove the cover from the humidifier cabinet Locate the power wires to the steam canister They are connected to the canister with 1 4 quick connects Make note of the wiring configuration before removing any wires
78. time delay If the cycling by increasing the sensor time delay If the sensors are located too close to the air discharge they will likely experience rapid swings in measurement Another method in reducing compressor cycling is to increase the temperature and or humidity sensitivity Alarm Enable Each alarm can be disabled or enabled Use the Up Down Arrow to select a particular alarm press Enter to select either enable or disable Then press Enter again to store the change When the alarm is disabled it will NOT report to either the wallbox beeper or the common alarm relay THE HIGH WATER ALARM WILL AUTOMATICALLY SHUT THE UNIT OFF EVEN IF THE ALARM IS DISABLED SIMILARLY OPTIONAL FACTORY INSTALLED SMOKE DETEC TORS ARE WIRED TO SHUT THE EVAPORATOR UNIT OFF REGARDLESS OF THE ENABLE DISABLE STATUS Alarm Time Delay Each individual alarm can be programmed with a time delay Table 14 causing the unit to delay a specified amount of time 0 255 seconds before recognizing the alarm The alarm condition must be present for the full amount of the time delay before the alarm will sound If the alarm condition is diverted prematurely the alarm will not be recognized and the time delay time will 30 Microprocessor Control 3 1 12 3 1 13 3 1 14 automatically reset FOR SOFTWARE ALARMS SUCH AS LOSS OF POWER AND SHORT CYCLE THE TIME DELAY SHOULD BE LEFT AT THE FACTORY DEFAULT OF 0 Table 14 Alarm Default Time Delays
79. ty to reduce cycle Optional Custom Alarms Loss of Water Flow The Loss of Water Flow Alarm will occur if no water flow is detected in the chilled water or con denser water supply line An external flow switch is required for this alarm Check for service valves closed pumps not working etc 40 Alarms 5 2 2 Smoke Detected Smoke is detected in the return air by an optional Liebert Smoke Detector The evaporator unit will automatically shut down upon smoke detection Locate source of smoke and follow appropri ate emergency procedures Alarms 41 6 0 SYSTEM TESTING AND MAINTENANCE 6 1 6 1 1 This section describes system testing maintenance and replacement procedures Use copies of the Maintenance Inspection Checklist to record preventive maintenance inspections N WARNING UNIT CONTAINS HAZARDOUS ELECTRICAL VOLTAGE DISCONNECT POWER SUPPLY BEFORE WORKING WITHIN LINE SIDE OF FACTORY DISCONNECT REMAINS ENERGIZED WHEN DISCONNECT IS OFF System Testing Environmental Control Functions The performance of all control circuits can be tested by changing the set points which actuates each of the main functions Cooling To test the cooling function set the set point to a temperature of 10 F 5 C below room tempera ture call for cooling should register and prompt the equipment to begin cooling cycle Disre gard any temperature alarms Upon completion of testing return set point to the desired
80. uires expert advice from a water treatment specialist plus a regular maintenance program schedule It is important to note that improper use of water treatment chemicals can cause more severe prob lems than simply using none Proper inhibitor maintenance must be performed in order to prevent corrosion of the glycol sys tem Consult your glycol manufacturer for proper testing and maintenance procedures Do not mix products from different manufacturers Hot Gas Bypass Optional Operation When applying hot gas bypass with split system condens ing units bypassing discharge gas to the compressor suction line offers more flexibility than con ventional hot gas bypass to the evaporator unit The hot gas bypass valve is installed between the compressor discharge piping and suction piping bypassing the condenser and evaporator coils The discharge gas mixes with the suction gas rais ing the suction temperature and pressure and decreasing the mass flow through the evaporator The higher suction temperatures could cause compressor overheating therefore a separate liquid quenching valve is provided to mix refrigerant from the system liquid line with the discharge gas before mixing with the suction gas entering the compressor During normal operation when the evaporator is under full load the hot gas bypass equalizer pressure will remain high enough to keep the valve port closed If the evaporator load decreases the evaporator temperature and pres
81. ure required reinstall cap tightly making sure there are leaks 6 Let the evaporator operate for approximately 10 to 15 minutes to make sure the suction pressure is within the range desired 7 There may be a fluctuation of approximately 3 to 6 PSIG 21 to 41 kPa on the evaporator due to the differential on the hot gas bypass 8 Return temperature setpoint to the desired setting Figure 16 Hot Gas Bypass 6 3 External Equalizer Discharge Bypass a Hot Gas ll Solenoid Vatve Replacement Procedures Compressor Replacement Infrequently a fault in the motor insulation may result in a motor burnout if system is properly installed motor burnout rarely occurs Primarily this type of fail ure 18 due to mechanical or lubrication problems where the burnout 1s a secondary consequence Early detection can prevent a large percentage of the problems that can cause compressor fail ures Periodic maintenance inspections by alert service personnel i e identification of abnormal operation can be a major factor in reducing maintenance costs It is easier and more cost effective to implement the necessary preventative steps that ensure proper system operation rather than System Testing and Maintenance 45 ignore a problem until it results in compressor failure and costly replacement When trouble shooting a compressor problem check all electrical components for proper operation CAUTION Avoid touching or contactin

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