Emerson Liebert CW User manual

Precision Cooling
For Business-Critical Continuity™
Liebert® CW™
User Manual–26-181 kW, 7.5-52 Tons, Upflow and Downflow, 50/60Hz
DATA CENTER SOLUTIONS
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(866) 787-3271
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TABLE OF CONTENTS
IMPORTANT SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
SAVE THESE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.0
LIEBERT CW NOMENCLATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
2.0
INSTALLATION GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2.1
Room Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2
Air Distribution—Downflow Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3
Air Distribution—Upflow Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4
Connections and System Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.5
Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.6
Location Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3.0
LIEBERT CW DIMENSIONS AND WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
4.0
EQUIPMENT INSPECTION AND HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.1
Packaging Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.2
Unpacking the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.2.1
4.2.2
4.2.3
4.2.4
Removing the Unit from the Skid With a Forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Moving the Unit to the Installation Location with Piano Jacks . . . . . . . . . . . . . . . . . . . . . . .
Removing Piano Jacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing Liebert CW from Skid Using Rigging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26
27
27
28
5.0
EC FAN—LOWERING AND REMOVING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.1
Lowering the EC Fans into the Floor Stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.2
Removing the EC Fans. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.0
ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.1
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7.0
PIPING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
7.1
Fluid Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
7.1.1
7.1.2
7.1.3
7.2
Condensate Piping—Field-Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Humidifier Supply Water—Optional Infrared . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Humidifier Supply Water—Optional Steam Generating Humidifier . . . . . . . . . . . . . . . . . . . 47
Chilled Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
7.2.1
Requirements of Systems Using Water or Glycol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
8.0
PIPING SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
9.0
CHECKLIST FOR COMPLETED INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
9.1
Moving and Placing Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
9.2
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
9.3
Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
9.4
Other . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
i
10.0
INITIAL STARTUP PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
10.1
Additional Considerations for Upflow Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
11.0
COMPONENT OPERATION AND MAINTENANCE, CHECKS AND ADJUSTMENTS . . . . . . . . . . . . 63
11.1
System Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
11.1.1 Environmental Control Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
11.1.2 Electric Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
11.2
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
11.3
Blower Package—Centrifugal Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
11.3.1 Fan Impellers and Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
11.3.2 Belts—Except with EC Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
11.3.3 Electronic Variable Speed Drive (Inverter). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
11.4
Blower Package—EC Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
11.4.1 Fan Impellers and Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
11.4.2 Protective Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
11.5
Humidifier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
11.5.1 Infrared Humidifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
11.5.2 Cleaning Humidifier Pan and Float Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
11.5.3 Changing Humidifier Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
11.6
Steam Generating Humidifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
11.7
Condensate Drain and Condensate Pump Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
11.7.1 Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
11.7.2 Condensate Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
11.8
Facility Fluid and Piping Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
12.0
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
13.0
HVAC MAINTENANCE CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
COMPLIANCE WITH EUROPEAN UNION DIRECTIVES . . . . . . . . . . . . . . . . . . . . . . INSIDE BACK COVER
FIGURES
Figure 1
Figure 2
Upflow ducting configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cabinet and floor planning dimensions for downflow chilled water models CW026 - CW084
with forward-curved fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Figure 3
Cabinet and floor planning dimensions for downflow chilled water models CW106 and CW114
with forward-curved fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Figure 4
Cabinet and floor planning dimensions for downflow chilled water models CW089, CW106
and CW114 with EC fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Figure 5
Cabinet and floor planning dimensions for downflow chilled water models CW146 and CW181
with EC fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 6
Cabinet and floor planning dimensions for upflow chilled water models CW026-CW084 . . . . . . 11
Figure 7
Cabinet and floor planning dimensions for upflow chilled water models, CW106 and
CW114 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Figure 8
Floor stand dimensions, optional steam, hot water reheat and humidifier piping entrances
for CW026 - CW84 models with forward-curved fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Figure 9
Floor stand dimensions for CW106 and CW114 models with forward-curved fans . . . . . . . . . . . 14
Figure 10 Floor stand and floor planning dimensions, downflow models CW026 - CW041 with
EC fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
ii
Figure 11 Floor stand and floor planning dimensions for downflow models CW051 and CW060 with
EC fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 12 Floor stand and floor planning dimensions, downflow models CW076 and CW084 with
EC fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 13 Floor stand and floor planning dimensions, downflow models CW089, CW106 and CW114
with EC fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 14 Floor stand and floor planning dimensions, downflow models CW146 and CW181 with
EC fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 15 Plenum dimensions for upflow chilled water models CW026 - CW084 . . . . . . . . . . . . . . . . . . . . .
Figure 16 Plenum dimensions for upflow chilled water models CW106 and CW114 . . . . . . . . . . . . . . . . . .
Figure 17 Blower duct and deck dimensions for CW106 and CW114 upflow chilled water models . . . . . . .
Figure 18 Filter plenum dimensions, downflow models CW146 and CW181 with EC fans . . . . . . . . . . . . .
Figure 19 Equipment recommended for handling the Liebert CW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 20 Removing packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 21 Remove the unit from the skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 22 Moving the unit to its installation location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 23 Locate center of gravity marker and place slings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 24 Using rigging to lift Liebert CW off skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 25 EC fan lowering procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 26 EC fan lowering and removal procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 27 Electrical field connections for downflow chilled water models CW026 - CW084. . . . . . . . . . . . .
Figure 28 Electrical field connections for downflow chilled water models CW089, CW106 and CW114 . . .
Figure 29 Electrical field connections (high voltage) for upflow chilled water models CW026 - CW084 . . .
Figure 30 Electrical field connections (low voltage) for upflow chilled water models CW026 - CW084 . . .
Figure 31 Electrical field connections (high voltage) for upflow chilled water models CW106
and CW114 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 32 Electrical field connections (low voltage) for upflow chilled water models CW106 and
CW114 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 33 Electrical field connections for downflow chilled water models CW146 and CW181 . . . . . . . . . .
Figure 34 Gravity drain for downflow and upflow units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 35 Chilled water downflow general arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 36 Piping connections for downflow chilled water models CW026 - CW084 with
forward-curved fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 37 Piping connections for downflow chilled water models CW106 and CW114 with
forward-curved fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 38 Primary connection locations, downflow models CW026 - CW041 with EC fans . . . . . . . . . . . . .
Figure 39 Primary connection locations, downflow models CW051 and CW060 with EC fans. . . . . . . . . . .
Figure 40 Primary connection locations, downflow models CW076 - CW084 with EC Fans . . . . . . . . . . . .
Figure 41 Primary connection locations, downflow models CW089, CW106 and CW114 with EC fans . . .
Figure 42 Primary connection locations, downflow models CW146 and CW181 with EC fans. . . . . . . . . . .
Figure 43 Chilled water upflow general arrangement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 44 Piping connections for upflow chilled water models CW026 - CW084 . . . . . . . . . . . . . . . . . . . . . .
Figure 45 Piping connections for upflow chilled water CW106 and CW114 . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 46 Correct orientation of float switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 47 Steam generating humidifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 48 Run/drain switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 49 Steam generating humidifier control board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
iii
16
17
18
19
20
21
22
23
25
25
26
27
28
29
31
33
35
36
37
38
39
40
41
46
50
51
52
53
54
55
56
57
58
59
60
67
68
69
73
TABLES
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
Unit dimensions and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Maximum harmonic current distortion, IEEE-519-1992 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Typical TDD for CW106, CW114 and CW146 at 460V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Typical TDD for CW181 at 460V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Humidifier canister part numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Faults—canister generator humidifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Steam generating humidifier capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
DIP switch settings for steam generating humidifier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Blower troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Chilled water troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Humidifier—steam generator troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Humidifier—infrared troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Reheat troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
iv
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
This manual contains important safety instructions that should be followed during the installation
and maintenance of the Liebert CW™. Read this manual thoroughly before attempting to install or
operate this unit.
Only properly trained and qualified personnel should move, install or service this equipment.
Adhere to all warnings, cautions and installation, operating and safety instructions on the unit and in
this manual. Follow all operating and user instructions.
! WARNING
Arc flash and electric shock hazard. Disconnect all electric power supplies and wear protective
equipment per NFPA 70E before working within electric control enclosure. Failure to comply
can cause serious injury or death.
Customer must provide earth ground to unit, per NEC, CEC and local codes, as applicable.
Before proceeding with installation, read all instructions, verify that all the parts are included
and check the nameplate to be sure the voltage matches available utility power.
The Liebert iCOM microprocessor does not isolate power from the unit, even in the Unit Off
mode. Some internal components require and receive power even during the Unit Off mode of
Liebert iCOM control.
The line side of the disconnect switch on the front of the unit contains live high-voltage.
The only way to ensure that there is NO voltage inside the unit is to install and open a remote
disconnect switch. Refer to unit electrical schematic.
Follow all local codes.
! WARNING
Risk of high-speed moving parts. Can cause injury or death.
Disconnect all local and remote electric power supplies before working in the unit.
Do not operate this unit with any or all cabinet panels removed.
Do not operate upflow units without installing a plenum, ductwork or guard over the blower
opening(s) on the top surface of the unit cabinet.
Ductwork must be connected to the blower(s), or a plenum must be installed on the blower
deck for protection from rotating blower wheel(s) on upflow units.
! WARNING
Risk of top-heavy unit falling over. Can cause equipment damage, injury or death.
Read all of the following instructions before attempting to move the unit, lift it, remove
packaging or prepare the unit for installation.
! CAUTION
Risk of contact with hot surfaces. Can cause injury.
The humidifiers and reheats are extremely hot during unit operation. Allow sufficient time for
them to cool before working within the unit cabinet. Use extreme caution and wear protective
gloves and arm protection when working on or near hot discharge lines, humidifiers and
reheats.
! CAUTION
Risk of sharp edges, splinters and exposed fasteners. Can cause injury.
Only properly trained and qualified personnel wearing appropriate safety headgear, gloves,
shoes and glasses should attempt to move the unit, lift it, remove packaging or prepare the
unit for installation.
1
NOTICE
Risk of clogged or leaking drain lines. Can cause equipment and building damage.
This unit requires a water drain connection. Drain lines must be inspected regularly and
maintenance must be performed to ensure that drain water runs freely through the drain
system and that lines are clear and free of obstructions and in good condition with no visible
sign of damage or leaks. This unit may also require an external water supply to operate.
Improper installation, application and service practices can result in water leakage from the
unit. Water leakage can result in severe property damage and loss of critical data center
equipment.
Do not locate unit directly above any equipment that could sustain water damage.
Emerson recommends installing leak detection equipment for unit and supply lines.
NOTICE
Risk of a leaking coil due to freezing and/or corrosion. Can cause equipment and serious
building damage.
Cooling coils and piping systems that are connected to open cooling towers or other open
water/glycol systems are at high risk for freezing and premature corrosion. Fluids in these
systems must contain the proper antifreeze and inhibitors to prevent freezing and premature
coil corrosion. The water or water/glycol solution must be analyzed by a competent water
treatment specialist before startup to establish the inhibitor requirement. The water or
water/glycol solution must be analyzed every six months to determine the pattern of inhibitor
depletion. The complexity of water-caused problems and their correction makes it important
to obtain the advice of a water treatment specialist and follow a regularly scheduled
maintenance program.
NOTICE
Risk of overhead interference. Can cause unit and/or building damage.
The unit may be too tall to fit through a doorway while on the skid. Measure the unit and
doorway heights and refer to the installation plans to verify clearances prior to moving the
unit.
NOTICE
Risk of damage from forklift. Can cause unit damage.
Keep tines of the forklift level and at a height suitable to fit below the skid and/or unit to
prevent exterior and/or underside damage.
NOTICE
Risk of improper storage. Can cause unit damage.
Keep the Liebert CW upright, indoors and protected from dampness, freezing temperatures
and contact damage.
2
Liebert CW Nomenclature
1.0
LIEBERT CW NOMENCLATURE
CW
026
CW = Liebert CW
Floor Mount
Chilled Water
Unit
D
C
S
D = Downflow
U = Upflow with Front
Return
Nominal Capacity, kW
026
038
041
051
060
076
084
089
106
114
146
181
A
2
A = 460/3/60
B = 575/3/60
C = 208/3/60
D = 230/3/60
2 = 380/3/60
F = 380/3/50
G = 415/3/50
M = 380-415V/3/50 Hz
C = Chilled Water
S = Forward-Curved Centrifugal
Fan with Standard Motor
V = Forward-Curved Centrifugal
Fan with Variable Speed Drive
1 = EC Motorized Impeller
3
1234
A
XXXX
A-Z = Standard
configuration
S = SFA
2 = 2-Way Valve, Standard Pressure
3 = 3-Way Valve, Standard Pressure
1 = 2-Way Valve, High Pressure
T = 3-Way Valve, High Pressure
Installation Guidelines
2.0
INSTALLATION GUIDELINES
2.1
Room Preparation
• Verify that the floor is level, solid and sufficient to support the unit. See Table 1 for unit weights.
• Confirm that the room is properly insulated and has a sealed vapor barrier.
• For proper humidity control, keep outside or fresh air to an absolute minimum (less than 5% of
total air circulated in the room).
• Do not install Liebert CW units in an alcove or at the end of a long, narrow room.
• Install the units as close as possible to the largest heat load.
• Allow at least the minimum recommended clearances for maintenance and service. See
Figures 2 through 17 for dimensions.
• Emerson recommends installing an under-floor water detection system. Contact your local Emerson representative for information.
2.2
Air Distribution—Downflow Units
• Verify that the raised floor has been properly sized for the unit’s airflow and the room is free of
airflow restrictions.
• Perforated floor tiles in the raised floor should ensure minimal pressure loss.
• The raised floor must provide 7-1/2" (191mm) of clearance.
• Ensure that there is adequate clearance above the unit for service, such as replacing filters.
• Optional plenums are available for downflow unit ducting.
• If installing units with electrically commutated fans (EC fans), there must be 24" minimum clearance below the unit to lower the fans. Fans may also remain the in unit if desired.
• A filter plenum is required for Liebert CW146 and CW181 units.
NOTE
The floor stand used with EC units is not symmetrical and its orientation to the Liebert CW is
critical to lowering the EC fans. Unless the floor stand is installed in the correct position, the
blowers will not lower into the floor stand.
4
Installation Guidelines
2.3
Air Distribution—Upflow Units
Various configurations are available:
• Front return
• Rear return
• Bottom return (not available on CW106 and CW114 models)
For in-room applications with supply and return grilles, several feet of clearance must be maintained
at the intake and discharge of the unit. For a bottom return, at least 6-8 inches of unrestricted underfloor height is needed.
Upflow rear-return configurations use a filter box attached to the back of the Liebert CW. Allow 25"
(635 mm) on one side of the unit for access to the rear return filter box. Refer to the filter box installation sheet, which can be found inside the rear return filter box package.
For ducted applications, duct flanges are supplied on the blower outlets. Follow the SMACNA-Duct
Construction Standard for single-, dual-, or triple-blower systems. Do not run ductwork off the perimeter flange on the top of the unit. This flange is for positioning and attaching the optional air discharge plenum with grille. Attaching a duct to this flange may reduce airflow to inadequate levels.
! WARNING
Risk of high-speed moving parts. Can cause injury or death. Disconnect all local and remote
electric power supplies and make sure blowers and pulleys have stopped rotating before
working in the unit.
Do not operate upflow units without installing a plenum, ductwork or guard over the blower
opening(s) on the top surface of the unit cabinet.
Ductwork must be connected to the blower(s), or a plenum must be installed on the blower
deck for protection from rotating blower wheel(s) on upflow units.
Figure 1
Upflow ducting configurations
2
2
1
2
1
1
1 Straight section of duct off of unit to be 1.5 to 2.5 times
the longest blower dimension.
2 Typical ducting shown; ducting may run to either side. DPN001156
Rev. 0
* Follow standard practices on all duct work.
NOTE
Drain traps are qualified to a return duct static of negative 1.5 i.w.g. (-1.5 i.w.g).
5
Installation Guidelines
2.4
Connections and System Setup
• Plan the routing of wiring, piping and ductwork to the unit. See Figures 27 through 33 and
Figures 35 through 45 for unit connection locations.
• The unit requires a drain, which must comply with all applicable codes. This drain line may contain boiling water. See 7.1.1 - Condensate Piping—Field-Installed for details.
• Three-phase electrical service is required for all models. Electrical service must conform to
national and local electrical codes. See the equipment nameplate for details.
• If seismic requirements apply, consult your local Emerson representative for information about a
seismic-rated floor stand.
2.5
Operating Conditions
• The Liebert CW should be operated in a conditioned space within the operating envelope
ASHRAE recommends for data centers: Maximum temperature of 77°F (25°C) DB and 55% RH or
maximum WB of 65.5°F (18.6°C).
• Return air to the unit must be no cooler than the ASHRAE recommendation of 68°F (20°C) DB
and 40% RH or minimum WB of 54°F (12.2°C) for proper unit operation. Operating below this can
decrease equipment reliability.
Refer to the ASHRAE publication, “Thermal Guidelines for Data Processing Environments.”
2.6
Location Considerations
For a downflow unit, the unit can sit on an accessible, elevated flooring system. It may be necessary to
furnish additional pedestal support below the unit to ensure maximum structural support. A separate
floor stand for the unit may be used as support, independent of the elevated floor and installed prior
to the flooring system.
For downflow and upflow units, provide approximately 34" (864mm) service clearance on the left,
right and in front of the unit whenever possible. The minimum space required for service is
18" (457mm) on the left end, 18" (457mm) on the right end and 24" (610mm) in front of the unit. This
space is necessary to permit routine maintenance, such as replacing filters and adjusting the fan
speed. On downflow chilled water units and upflow CW106 and CW114 models, left- and right-end
minimum clearances are 0" (0 mm), with the exception of rear return.
Avoid installing units in an alcove or at the extreme end of a room that has a high aspect ratio (long
narrow room). Also avoid installing units too close together. This tends to reduce the effectiveness of
the air distribution as compared to units located 30-40 feet (9-12m) apart.
6
Liebert CW Dimensions and Weights
3.0
LIEBERT CW DIMENSIONS AND WEIGHTS
Figure 2
Cabinet and floor planning dimensions for downflow chilled water models CW026 - CW084 with
forward-curved fans
Projection of
Display Bezel
3/4" (19mm)
Overall
J
ension
Overall Dim
A
Dimen
sio
C
D
2"
(50.8mm)
B
Air R
etu
Air Return
Opening
n
2"
(50.8mm)
r n Op
Overall
Projection of
Display Bezel
3/4" (19mm)
J
on
Dimensi
C
inet
Unit Cab
F
Plenum
Overall
1"
(25.4mm)
ening
K
1"
(25.4mm)
72"
(1829mm)
A
Overall
Dimen
sio
Unit an
d Plenu n
m
1"
(25.4mm)
rn
Air Retu
Opening
Air R
etu
B
rn Op
ening
2"
(50.8mm)
Pre-Filter
Plenum
Shaded areas indicate
a recommended clearance
of 36" (914mm) for component
access and filter removal.
9"
(228mm)
72"
(1829mm)
1"
(25.4mm)
Un E
it B
as
e
F
it
Un
e
s
Ba
UNIT DIMENSIONAL DATA
1"
(25.4mm)
3"
(76.2mm)
9" (228mm)
Reheat or Humidifier Piping
Opening (Optional Steam &
G Hot Water Only)
MODELS WITH PRE-FILTERS
9"
(228mm)
H
Reheat or Humidifier Piping
Opening (Optional Steam &
G Hot Water Only)
Air Discharge
Opening
L
20"
(508mm)
20"
(508mm)
20"
(508mm)
M
1"
(25.4mm)
Standard Piping
E
& Electrical Opening
Fl
oo
Floor Cutout Dimensions
for Units with Forward-Curved
(FC) Fans
Table 1
3"
(76.2mm)
1"
(25.4mm)
Air Discharge
Opening
1" (25.4mm)
1"
(25.4mm)
F
1" (25.4mm)
18"
(457mm)
rL
ev
e
E
Standard Piping
& Electrical Opening
31" (787.4mm)
Fl
oo
l
Floor Cutout Dimensions
for Units with EC Fans
DPN001659
Rev. 1
rL
ev
el
Unit dimensions and weights
Dimensions, inches (mm)
Net
L
M
Weight
(EC Only) (EC Only) lb (kg)
B
C
D
E
F
G
H
(FC Only)
46
(1168)
46
(1168)
46
(1168)
70
(1778)
35
(889)
35
(889)
35
(889)
35
(889)
32
(813)
32
(813)
32
(813)
32
(813)
48
(1219)
48
(1219)
48
(1219)
72
(1829)
33
(883)
33
(883)
33
(883)
8
(203)
8
(203)
8
(203)
37
(940)
37
(940)
37
(940)
35-5/8 31
(905) (787)
35-5/8 31
(905) (787)
35-5/8 31
(905) (787)
28
(711)
28
(711)
28
(711)
2-7/8
(73)
2-7/8
(73)
2-7/8
(73)
760
(345)
795
(361)
855
(388)
8
33
(883) (203)
74
70
35
32
72
33
8
CW060
(1880) (1778) (889) (813) (1829) (883) (203)
99
95
35
32
97
33 15-1/4
CW076
(2515) (2413) (889) (813) (2464) (883) (387)
99
95
35
32
97
33 15-1/4
CW084
(2515) (2413) (889) (813) (2464) (883) (387)
61
(1549)
61
(1549)
78-3/4
(2000)
78-3/4
(2000)
35-5/8
(905)
35-5/8
(905)
35-5/8
(905)
35-5/8
(905)
51
(1295)
51
(1295)
60-3/4
(1543)
60-3/4
(1543)
2-7/8
(73)
2-7/8
(73)
8-7/8
(225)
8-7/8
(225)
1090
(494)
1115
(524)
1320
(599)
1420
(644)
Model
A
50
(1270)
50
CW038
(1270)
50
CW041
(1270)
74
CW051
(1880)
CW026
7
J
K
31
(787)
31
(787)
31
(787)
31
(787)
Liebert CW Dimensions and Weights
Figure 3
Cabinet and floor planning dimensions for downflow chilled water models CW106 and CW114
with forward-curved fans
G
Overall
n
Dimensio
Projection Of
Display Bezel
3/4" (19mm)
Overa
C
D
turn
Air Re g
n
Ope in
2" (50.8mm)
A
ll Dime
nsion
B
Air R
eturn
Open
in
g
G
ll
Ov e r a
n
io
s
n
e
Dim
2"
(50.8mm)
Projection Of
Display Bezel
3/4" (19mm)
76"
(1930mm)
1"
(25.4mm)
2"
(51mm)
C
a
Unit C
A
Overall
Dimens
ion
Unit an
d Plenu
m
binet
Plenum
Overall
H
turn
Air Re
g
Openin
Air Re B
turn O
pe n
ing
2"
(50.8mm)
Pre-Filter
Plenum
E
Unit Base
Shaded area indicates
a recommended
clearance of 36" (914mm)
for component access
and filter removal
9"
(228mm)
1"
(25.4mm)
F
Unit Base
76"
(1930mm)
UNIT DIMENSIONAL DATA
20"
(508mm)
Air Discharge Opening
1" (25.4mm)
77"
(1955.8mm)
MODELS WITH PRE-FILTERS
26"
(660.4mm)
28"
(711mm)
*Note: "Electrical Opening" is also
used for drain connection of
optional steam generating
1" (25.4mm)
canister humidifier
E
Standard Piping
Opening
10"
(254mm)
24"
(609.6mm)
* Electrical
Opening
1"
(25.4mm)
6" ( 1 5
16-1/4"
2.4mm (412.75mm)
)
*This drawing pertains to CW106 & CW114
with forward-curve blowers only.
DPN001660
Rev. 0
FLOOR CUTOUT DIMENSIONS
Dimensions, inches (mm)
A
B
C
D
E
F
G
H
I
Net
Weight
lb (kg)
CW106
122
(3099)
118
(2997)
35
(889)
31
(787)
120
(3048)
33
(838)
35-5/8
(905)
30
(762)
34
(864)
1785
(810)
CW114
122
(3099)
118
(2997)
35
(889)
31
(787)
120
(3048)
33
(838)
35-5/8
(905)
30
(762)
34
(864)
1925
(873)
Chilled Water
Model
8
Liebert CW Dimensions and Weights
Figure 4
Cabinet and floor planning dimensions for downflow chilled water models CW089, CW106 and
CW114 with EC fans
118" Opening
(2997mm)
Notes: Filters are accessible
from front of unit only.
35"
33" (889mm)
(838mm)
30-3/4"
(781mm)
Opening
Electrical connections
can be made from the
bottom of unit.
TOP VIEW
3/4"
(19mm)
Bezels
122"
(3099mm)
36"
(914mm)
24"
(610mm)
76"
(1930mm)
Striated area indicates the
recommended minimum
clearance for component access.
Shaded area indicates the
required minimum clearance
below the unit to lower the
fans. Fans may also remain
in unit if desired.
120"
(3048mm)
1-1/2"
(38mm)
FRONT VIEW
DPN001614
Rev. 1
Model
Weight
lb (kg)
CW089
1925 (873)
CW106
1785 (810)
CW114
1925 (873)
9
Liebert CW Dimensions and Weights
Figure 5
Cabinet and floor planning dimensions for downflow chilled water models CW146 and CW181
with EC fans
117-11/16" (2989mm)
Opening
45"
(1143mm)
Plenum
42"
(1067mm)
Opening
3/4"
(20mm)
BEZELS
18"
(457mm)
Filter Plenum
76"
(1930mm)
Base Unit
94"
(2388mm)
Total Height
Liebert
CW146
and CW181
45"
(1143mm)
47"
(1194mm)
120"
(3044mm)
122"
(3099mm)
1"
(25mm)
typical
1-1/2"
(38mm)
Note: Typical CW166 and CW181
with EC fans unit orientation shown.
Filter Plenum
(shipped separately)
Filters are removed
through the
front of the plenum.
Reference DPN001693
for the electrical
and plumbing
requirements.
CW146 or CW181
base unit
48"
(1219mm)
Striated area indicates
the recommended
minimum clearance
for component access.
24"
(610mm)
Shaded area indicates the required minimum clearance
below the unit to lower the fans into the floo r. Fans may
also remain in their shipped position.
Model
Weight
lb (kg)
CW146
2520 (1143)
CW181
2520 (1143)
10
DPN001707
Rev. 2
Liebert CW Dimensions and Weights
Figure 6
Cabinet and floor planning dimensions for upflow chilled water models CW026-CW084
Display Bezel
Projection
3/4" (19mm)
(905)
35-5/8"
ra
Ove ll
n
Dimensio
Overall
9)
35" (88
1"
(25.4mm)
A
Dimens
io
L
Duct Flanges on 2 Blowers
n
H
K
J
72"
(1829mm)
J
M
Front of Unit
Duct Flanges on 1 Blower
H
K
J
Front of Unit
1" (25.4mm) flange
for plenum connection
Shaded area indicates
a recommended
clearance of 36" (914mm)
for component access
and filter removal
Un
Note: Flanges
provided on
blower(s)
outlet for
supply air
ducting.
B
it B
as
e
"
33 m )
m se 1"
8
a
3
(8 it B (25.4mm)
Un
1"
(25.4mm)
UNIT DIMENSIONAL DATA
33" m)
8m 22"
(83
5-1/2"
(139.7mm)
(559mm)
/8"
1-1 mm)
.6
(28
Air Return
Opening
D
Ai
G
Air Return
Opening
C
B
Fl
oo
FLOOR CUTOUT
DIMENSIONS
Models with Bottom Return
F
rL
n
ur
et
R
r
g
nin
e
Op
A return air grille may
be ordered in place of
the duct flange. See
specification sheet for
option supplied.
E
MODELS WITH PRE-FILTERS
ev
e
DPN001661
Rev. 0
l
Dimensions, inches (mm)
Model
# of
Blowers
CW026
1
CW038
1
CW041
1
CW051
2
CW060
2
CW076
2
CW084
2
A
50
(1270)
50
(1270)
50
(1270)
74
(1880)
74
(1880)
99
(2515)
99
(2515)
B
48
(1219)
48
(1219)
48
(1219)
72
(1829)
72
(1829)
97
(2464)
97
(2464)
C
46
(1168)
46
(1168)
46
(1168)
70
(1778)
70
(1778)
95
(2413)
95
(2413)
D
44
(1118)
44
(1118)
44
(1118)
68
(1727)
68
(1727)
68
(1727)
68
(1727)
E
3
(76)
3
(76)
3
(76)
3
(76)
3
(76)
6 1/2
(165)
6 1/2
(165)
F
5
(127)
5
(127)
5
(127)
4
(102)
4
(102)
5
(127)
5
(127)
11
G
18
(457)
18
(457)
18
(457)
20
(508)
20
(508)
18
(457)
18
(457)
H
15-7/8
(403)
15-7/8
(403)
15-7/8
(403)
15-7/8
(403)
15-7/8
(403)
15-7/8
(403)
15-7/8
(403)
J
18-5/8
(473)
18-5/8
(473)
18-5/8
(473)
14-5/8
(371)
14-5/8
(371)
18-5/8
(473)
18-5/8
(473)
K
2-3/16
(55)
2-3/16
(55)
2-3/16
(55)
2-3/16
(55)
2-3/16
(55)
3-1/4
(82)
3-1/4
(82)
L
17-3/8
(454)
17-3/8
(454)
17-3/8
(454)
20-3/8
(517)
20-3/8
(517)
20-5/8
(524)
20-5/8
(524)
M
_
_
_
11-1/4
(286)
11-1/4
(286)
12-5/8
(321)
12-5/8
(321)
Net
Weight
lb (kg)
760
(345)
795
(361)
855
(388)
1090
(494)
1155
(524)
1320
(599)
1420
(644)
Liebert CW Dimensions and Weights
Figure 7
Cabinet and floor planning dimensions for upflow chilled water models, CW106 and CW114
Projection of
Display Bezel
3/4 (19mm)
2"
(51mm)
35" Overall
(889mm)
32"
(813mm)
Plenum
Flange
122" Overall
(3099mm)
118"
(2997mm)
Plenum
Flange
2"
(51mm)
76"
(1930mm)
1" (25mm) Flange
for Decorative
Plenum Alignment
Flanges provided
on blower outlets for
supply air ducting
Air grille
supplied on
units with front
return air only
Shaded areas indicate
a recommended clearance
of 36" (914mm) for component
access and filter removal.
120" Base
(3048mm)
1"
(25mm)
33" Base
(838mm)
UNIT DIMENISONAL DATA
Filter Access
(Both Ends)
24-1/4" (616mm)
117-1/2"
(2985mm)
Shaded area indicates a recommended
clearance of 25" (635mm) for rear return
filter removal on one end of the unit.
4"
(102mm)
2-1/4"
(57mm)
22" (546mm)
DUCT CONNECTION DATA
MODELS WITH REAR RETURN
12
Air Return
Opening
DPN001662
Rev. 0
Liebert CW Dimensions and Weights
Figure 8
Floor stand dimensions, optional steam, hot water reheat and humidifier piping entrances for
CW026 - CW84 models with forward-curved fans
1"
(25.4mm)
33"
(838mm)
3
8"
(76.2mm)
(203mm)
Optional Steam/Hot Water
Reheat or Humidifier
Piping Entrance
Location
E
A + 2" (50.8mm) =
Overall Width of Unit
STANDARD
PIPING AND
ELECTRICAL
ENTRANCE
LOCATION
Air Discharge
Opening
2"
(50.8mm)
D
1"
(25.4mm)
B
Length of
Vane = D - 1/8" (3mm)
LEG SUPPORT SUPPLIED
ON 18, 21 & 24" HIGH MODELS
16-1/4"
(413mm)
A
J
C
H ±1-1/2" (38mm) *
Optional Turning Vane
Field-Installed in
Fan Discharge Opening
For Rear or Front Air
Discharge
62" (1574.8mm)
56-3/4" (1441.5mm)
CROSS-BRACING LOCATION FOR 72" FRAMES ONLY
DPN001676
Rev. 0
* Leveling feet are provided with ± 1-1/2" (38mm) adjustment from nominal height H.
Height in. (mm)
H* Nominal
J
9 (229)
12 (305)
15 (381)
18 (458)
21 (553)
24 (610)
6-1/2 (165)
9 (229)
12 (305)
15 (381)
18 (458)
21 (553)
Dimensions, inches (mm)
Model
Overall Width Of Unit
A
B
C
D
E
CW026, CW038,
CW041
50 (1270)
48 (1219)
0
0
36 (914)
8 (203)
CW051, CW060
74 (1880)
72 (1829)
0
0
60 (1524)
8 (203)
CW076, CW084
99 (2515)
97 (2464) 48-1/2 (1232) 48-1/2 (1232) 77-3/4 (1975) 15-1/4 (362)
13
Liebert CW Dimensions and Weights
Figure 9
Floor stand dimensions for CW106 and CW114 models with forward-curved fans
D
K
Air Discharge
Opening
1"
(25.4mm)
A + 2" (50.8mm) =
Overall Width of Unit
E
G
Standard
Piping and
Electrical
Entrance
Location
1"
(25.4mm)
B
Leg supports
supplied on models
18", 21" and 24" high
F
Length Of
Vane=E-1/8"(3mm)
A
C
H ± 1-1/2" (38mm) *
J
Electrical
Opening
*Leveling feet are provided with ± 1 1/2" (38mm) adjustment from nominal height H.
*This drawing pertains to CW106 & CW114 with forward curve blowers only.
Optional turning vane field-installed
in fan discharge opening for rear
of front air discharge
DPN001677
Rev. 0
Height, in. (mm)
H* Nominal
J
9 (229)
6 1/2 (165)
12 (305)
9 (229)
15 (381)
12 (305)
18 (458)
15 (381)
21 (553)
18 (458)
24 (610)
21 (533)
Dimensions, inches (mm)
Model
Overall Width
of Unit
A
B
C
D
E
F
G
K
CW106
CW114
122
(3099)
120
(3048)
60
(1524)
60
(1524)
33
(838)
100-3/4
(2559)
16-1/4
(413)
8-1/4
(210)
11
(279)
14
Liebert CW Dimensions and Weights
Figure 10 Floor stand and floor planning dimensions, downflow models CW026 - CW041 with EC fans
14"
(356mm)
1" (25mm)
3/4"
(19mm)
Piping access area
31-1/2"
(800mm)
3/4"
(19mm)
46-1/2" (1181mm)
Support Feet Centers
3/4"
(19mm)
48" (1219mm)
See Note 4
3/4"
(19mm) typ
33" (838mm)
7/8"
(23mm)
3" (76mm) typ
A*
49-1/2" (1257mm)
NOTES:
1) This floor stand should be used when EC fans are will be
lowered into a raised floo r. The standard Liebert CW
floor stand can be used if the fans will remain in their
34-1/2" (876mm)
original, raised position.
Overall Depth
2) All paneled sides of unit overhang the floor stand by 1" (25mm).
3) The floor stand used with EC units is not symmetrical, and its orientation to the
Liebert CW is critical for lowering the EC fans. Unless the floor stand is installed in
the correct position, the blowers will not lower into the floor stand.
4) The jack and jack support are shipped loose and are intended to be placed into position
under each fan and utilized to lower or raise that fan as needed.
DPN002029
REV 0
* Leveling feet are provided with ± 1-1/2" (38mm) adjustment from nominal height “A.”
Dimension A*
Height in (mm)
24 (610)
30 (762)
36 (914)
42 (1067)
48 (1219)
15
Liebert CW Dimensions and Weights
Figure 11 Floor stand and floor planning dimensions for downflow models CW051 and CW060 with EC
fans
A
A
Front View
Note: Drawing Not To Scale.
Tolerance on all piping locating
dimensions ± 1/2" (13mm).
All Dimensions From
Right Rear Corner Of Unit
Including Panels
X
Section A-A
0
Y
31" (787mm)
Typical Air
Discharge Area
24-7/16" (620mm)
Typical Air
Discharge Area
24-1/8"
(613mm)
Air Discharge
Area
HUM
CD
LV
CWP
35"
(889mm)
B
HV
Front of Unit
74" (1880mm)
* Field pitch Condensate Drain line a minimum of 1/8" (3.2 mm) per foot (305 mm).
All units contain a factory-installed condensate trap. Do not trap external to the unit.
Drain line may contain boiling water. Select appropriate drain system materials.
The drain line must comply with all local codes.
DPN002035
** Optional Condensate Pump to be field-installed under unit.
Rev. 0
Point
CD
HUM
CWP
Description
Condensate Drain*
W/Optional Condensate Pump**
X, in (mm)
Y, in (mm)
60-7/8 (1547)
27-3/4 (705)
Connection Size / Opening, in (mm)
3/4 (19) FPT
1/2 (13) Cu Sweat
Humidifier Supply Line
59-1/8 (1502)
28-5/8 (727)
1/4 (6) Cu Sweat
Chilled Water Piping Slot (Center)
66-9/16 (1691)
31-1/4 (794)
11 x 3 (279 x 76)
Supply & Return Piping Diameter
—
—
CW051: 1-5/8 (41)
CW060: 2-1/8 (54)
HV
High Volt Electrical Connection
59-3/8 (1509)
30-3/4 (781)
3 (76)
LV
Low Volt Electrical Connection
60-7/8 (1547)
29-1/4 (743)
7/8 (22)
B
Blower Outlet Opening
4 (101)
33 (838)
51 x 31 (1295 x 787)
16
Liebert CW Dimensions and Weights
Figure 12 Floor stand and floor planning dimensions, downflow models CW076 and CW084 with EC fans
25"
(635mm)
1"
(25mm)
Piping access area
3/4"
(19mm)
32"
(813mm)
Center Feet
31-1/2"
(800mm)
3/4"
(19mm)
47-3/4"
(1213mm)
95-1/2" (2426mm)
Support Feet Centers
3/4"
(19mm)
97" (2464mm)
See Note 4
7/8"
(23mm)
typ
1"
(25mm)
typ
3"
(76mm) typ
98-1/2" (2502mm)
NOTE:
1) This floor stand should be used when EC fans are intended to be lowered under
a raised floor. The standard Liebert CW floor stand can be used “if” the fans are to
remain in their original raised position.
2) All paneled sides of unit overhang floorstand 1” (25mm).
3) The floor stand used with EC units is not symmetrical and its orientation to the
Liebert CW is critical for lowering the EC fans. Unless the floor stand is installed in
the correct position, the blowers will not lower into the floor stand.
4) Jack and jack support are shipped loose and are intended to be placed into position
under each fan and utilized to lower or raise that fan as needed.
*Leveling feet are provided with ± 1-1/2” (38mm) adjustment from nominal height “A”.
Dimension A*
Height, in (mm)
24 (610)
30 (762)
36 (914)
42 (1067)
48 (1219)
17
33" (838mm)
A*
35" (889mm)
Overall Depth
DPN002027
Rev. 0
Liebert CW Dimensions and Weights
Figure 13 Floor stand and floor planning dimensions, downflow models CW089, CW106 and CW114 with
EC fans
1"
(25mm)
20-1/4"
(514mm)
Piping access
area
3/4"
(19mm)
32"
(813mm)
Center Feet
31-1/2"
(800mm)
3/4"
(19mm)
59-1/4"
(1505mm)
118-1/2"
(3010mm)
Support Feet Centers
3/4"
(19mm)
Typ
7/8"
(22mm)
Typ
120"
(3048mm)
3"
(76mm) TYP
1"
(25mm)
TYP
See Note 4
33"
(838mm)
A*
121-1/2"
(3086mm)
Overall Width
NOTES
1. This floor stand should be used when EC fans are intended to be lowered into
the floor stand. The standard Liebert CW floor stand can be used†“if” the fans
are to remain in their original raised position.
2. All paneled sides of unit overhang floorstand 1" (25mm).
3. The floor stand used with EC units is not symmetrical and its orientation to the
Liebert CW is critical for lowering the EC fans. Unless the floor stand is installed
in the correct position, the blowers will not lower into the floor stand.
4. Jack and jack support are shipped loose and are intended to be placed into
position under each fan and utilized to lower or raise that fan as needed.
* Leveling feet are provided with ±1-1/2" (38mm) adjustment from nominal height†“A.”
18
35"
(889mm)
Overall Depth
Height, in. (mm)
A*
24 (610)
30 (762)
36 (914)
42 (1067)
DPN001629
Rev. 3
Liebert CW Dimensions and Weights
Figure 14 Floor stand and floor planning dimensions, downflow models CW146 and CW181 with EC fans
1"
(25mm)
20-1/4"
(514mm)
Piping access
area
3/4"
(19mm)
43-1/2"
(1105mm)
44"
(1118mm)
CENTER FEET
59-1/4"
(1505mm)
3/4"
(19mm)
3/4"
(19mm)
TYP
118-1/2"
(3010mm)
Support Feet Centers
120"
(3048mm)
See Note 4
1"
(25mm)
TYP
7/8"
(23mm)
TYP
45"
(1143mm)
A*
3" (76mm)
121-1/2" (3086mm)
Overall Depth
NOTE:
1. This floor stand should be used when EC fans are intended to be lowered into
the floor stand. The standard Liebert CW floor stand can be used if the fans
are to remain in their original, raised position.
2. All paneled sides of unit overhang floor stand 1" (25mm).
3. The floor stand used with EC units is not symmetrical, and its orientation to the
Liebert CW is critical for lowering the EC fans. Unless the floor stand is installed
in the correct position, the blowers will not lower into the floor stand.
4. The jack and jack support are shipped loose and are intended to be placed into
position under each fan and used to lower or raise one fan at a time as needed.
* Leveling feet are provided with ±1-1/2" (38mm) adjustment from nominal height†“A.”
19
47"
(1194mm)
Overall Depth
Height in (mm)
A*
24 (610)
30 (762)
36 (914)
42 (1067)
48 (1219)
DPN001696
Rev. 3
Liebert CW Dimensions and Weights
Figure 15 Plenum dimensions for upflow chilled water models CW026 - CW084
NOTE: Flanges
provided on blower(s)
outlet for supply air ducting
when solid panel plenum
is used.
1" (25mm)
D
C
J
1"
(25mm)
2"
(50mm)
18" (457mm)
H
1"
(25mm)
Both top duct openings and
front grille are shown. See
specification sheet for
specific application.
E
B
A
F
2"
(50mm)
1"
(25mm)
D
C
2"
(50mm)
1"
(25mm)
Flange is standard on all units
except downflow models
where it must be specified
if required.
DPN001678
Rev. 0
Plenum Height in. (mm)
H
J
20 (508)
1 (25)
22-3/4 (578)
2-3/8 (60)
34-3/4 (883)
2-3/8 (60)
Plenum Dimensions, in. (mm)
Model
A
B
C
D
E
F
Grill Free Area
ft2 (m2)
CW026, CW038,
CW041
50 (1270)
34 (864)
46 (1168)
32 (813)
44 (1118)
3 (76)
4.29 (.40)
CW051, CW060
74 (1880)
34 (864)
70 (1778)
32 (813)
60 (1524)
7 (178)
5.85 (.54)
CW076, CW084
99 (2515)
34 (864)
95 (2413)
32 (813)
70 (1778)
14-1/2 (368)
6.83 (.63)
20
Liebert CW Dimensions and Weights
Figure 16 Plenum dimensions for upflow chilled water models CW106 and CW114
NOTE: Flanges
provided on blower(s)
outlet for supply air ducting
when solid panel plenum
is used.
1"
(25mm)
D
C
L
18" (457mm)
K
1"
(25mm)
H
J
G
B
Both top duct openings an
front grille are shown. See
specification sheet for
specific application.
E
F
E
A
1" (25mm)
D
C
2" (50mm)
2" (50mm)
1" (25mm)
Flange is standard on all units
except downflow models
where it must be specified
if required.
DPN001679
Rev. 0
Plenum Height, in.(mm)
K
L
20 (508)
1 (25)
22-3/4 (578)
2-3/8 (60)
34-3/4 (883)
2-3/8 (60)
Plenum Dimensions, in. (mm)
Model
A
B
C
D
E
F
G
H
J
Grille Free
Area, ft2 (cm2)
CW106,
CW114
122
(3099)
34
(864)
118
(2997)
32
(813)
44
(1118)
3-1/2
(89)
4
(102)
7
(178)
16
(406)
10.14
(.94)
21
Liebert CW Dimensions and Weights
Figure 17 Blower duct and deck dimensions for CW106 and CW114 upflow chilled water models
Top of Unit
122" Ref (3099mm)
Blower Deck
Duct Flanges on Three Blowers
A
D
C
E
C
E
F
B
76"
(1930mm)
Ref.
35"
(889mm)
Ref.
C
Front of Unit
Blower Duct Flange Location
Front or Rear Air Supply
DPN001663
Rev. 0
Dimensions, in. (mm)
Model
Blower
Supply
Motor Hp
A
B
C
D
E
F
Top Front
10-15
27-1/2
(699)
3-1/2
(89)
18-11/16
(475)
16-3/16
(411)
10
(254)
4-1/2
(114)
Top Rear
10-15
27-1/2
(699)
12-5/16
(313)
18-11/16
(475)
16-3/16
(411)
10
(254)
4-1/2
(114)
30
(762)
3-1/2
(89)
14-3/4
(375)
16-3/16
(411)
10
(254)
4-1/2
(114)
30
(762)
12-5/16
(313)
14-3/4
(375)
16-3/16
(411)
10
(254)
4-1/2
(114)
15x15
CW106
CW114
Top Front
15x11
Top Rear
10-15
20
10-20
22
Liebert CW Dimensions and Weights
Figure 18 Filter plenum dimensions, downflow models CW146 and CW181 with EC fans
117-11/16"
(2989mm) Opening
42"
(1067mm)
Opening
3/4"
(20mm)
Bezels
45"
(1143mm)
Plenum
18"
(457mm)
Filter Plenum
94"
(2388mm)
Total Height
76"
(1930mm
Base Unit
120" (3044mm)
1-1/2"
(38mm)
122" (3099mm)
1"
45"
(25mm)
(1143mm)
typ
47"
(1194mm)
Filters are removed
through the front
of the plenum
Filter Plenum
(Shipped Separately)
CW146 or
CW181 base unit
48"
(1219mm)
Striated area indicates
recommended minimum
clearance for component
access
24"
(610mm)
Shaded area indicates the minimum clearance
below the unit to lower the fans into the floor. Fans may
remain in their shipped position.
23
DPN001707
Rev. 2
Equipment Inspection and Handling
4.0
EQUIPMENT INSPECTION AND HANDLING
Upon arrival of the unit and before unpacking it, verify that the labeled equipment matches the bill of
lading. Carefully inspect all items for damage, either visible or concealed. For initial access use a
7/32" Allen wrench for panel removal. Damage should be immediately reported to the carrier and a
damage claim filed with a copy sent to Emerson Network Power or to your sales representative.
4.1
Packaging Material
All material used to package this unit is recyclable. Please save for future use or
dispose of the material appropriately.
R
SAFETY INFORMATION
! WARNING
Risk of top-heavy unit falling over. Can cause equipment damage, injury or death.
Read all of the following instructions before attempting to move the unit, lift it, remove
packaging or prepare the unit for installation.
! WARNING
Risk of improper moving. Unit can tip over and cause equipment damage, injury or death.
Use only lifting equipment that is rated for the unit weight by an OSHA-certified rating
organization. Unit weights are listed in Table 1 of this manual.
Use the center of gravity indicators (see Figure 23) on the unit to determine the position of
the slings. The center of gravity varies depending on the unit size and selected options.
The slings must be equally spaced on either side of the center of gravity indicator.
! CAUTION
Risk of sharp edges, splinters and exposed fasteners. Can cause injury.
Only properly trained and qualified personnel wearing appropriate safety headgear, gloves,
shoes and glasses should attempt to move the unit, lift it, remove packaging or prepare the
unit for installation.
NOTICE
Risk of overhead interference. Can cause unit and/or building damage.
The unit may be too tall to fit through a doorway while on the skid. Measure the unit and
doorway heights and refer to the installation plans to verify clearances prior to moving the
unit.
NOTICE
Risk of forklift running into the unit. Can cause unit damage.
Keep the tines of the forklift level and at a height to fit below the skid and unit to prevent
damage.
NOTICE
Risk of improper storage. Can cause unit damage.
Keep the Liebert CW upright, indoors and protected from dampness, freezing temperatures
and contact damage.
24
Equipment Inspection and Handling
Figure 19 Equipment recommended for handling the Liebert CW
Forklift
Pallet
Jack
Spreader Bars and Slings
Piano Jacks
If possible, transport the Liebert CW with a forklift or pallet jacks. If that is not possible, use a crane
with slings and spreader bars.
• If using a forklift or pallet jack, make sure that the forks (if adjustable) are spread to the widest
distance that will fit under the skid.
Ensure the fork length is suitable for the unit length.
• When moving the packaged Liebert CW with a forklift, lift the unit from either end of the skid
that has the indicated labeling no higher than 4" (102mm) off the floor. Ensure that the opposite
end still touches the floor.
• The unit is to be pulled by the forklift—If the unit must be lifted higher than 4" (102mm) great
care must be exercised: Personnel who are not directly involved in moving the unit must be kept
20' (5m) or farther from the lift point of the unit.
• Always refer to the location of the center of gravity indicators when lifting the Liebert CW (see
Figure 23).
4.2
Unpacking the Unit
Remove outer packaging when ready to install the unit.
1. Remove the exterior stretch wrap packaging material from the unit, exposing the protective
corner and side packaging planks.
2. Remove the corner and side packaging planks from the unit, exposing the bag over the unit.
3. Remove the bag from the unit when ready to remove the skid and install the unit.
Figure 20 Removing packaging
Step 1
Step 2
Step 3
196713
Rev. 0
25
Equipment Inspection and Handling
4.2.1
Removing the Unit from the Skid With a Forklift
1. Align a forklift with either the front or rear side of the unit (see Figure 21).
! WARNING
Risk of improper moving. Unit can tip over and cause equipment damage, injury or death.
Use the center of gravity indicators on the unit to determine the entry points for the tines (see
Figure 23). The center of gravity varies depending on the unit size and selected options.
The forklift’s tines must be equally spaced on either side of the center of gravity indicator. The
forklift’s tines must be locked to the widest possible spread that will fit under the unit.
2. Insert the tines of the forklift completely under the base of the Liebert CW.
! WARNING
Risk of improper moving. Unit can tip over and cause equipment damage, injury or death.
Ensure that the tines are level—not angled up or down.
The tines must be at a height that will allow proper clearance under the unit.
Ensure that the tines extend beyond the opposite side of the unit.
3. Remove the brackets holding the Liebert CW to the skid.
4. Lift the unit off the skid—no more than 4" (1052mm)—and remove the skid.
Figure 21 Remove the unit from the skid
Step 1
Step 2
Step 3
Step 4
196713
Rev. 0
26
Equipment Inspection and Handling
4.2.2
Moving the Unit to the Installation Location with Piano Jacks
1. With the Liebert CW elevated, position piano jacks at each end of the unit (see Figure 22).
2. Lower the unit to a height suitable for the piano jacks and place protective material between the
Liebert CW and the piano jacks.
3. Secure the unit to the piano jacks and remove the forklift.
4. Use the piano jacks to move the unit for installation. At least two people are required to move the
Liebert CW with the piano jacks.
Figure 22 Moving the unit to its installation location
Step 1
Step 2
Step 3
196713
Rev. 0
4.2.3
Removing Piano Jacks
1. Lower the unit as much as the piano jacks will allow.
2. Undo all strapping holding the piano jacks to the unit.
3. Use a pry bar or similar device to lift one end of the unit just enough to allow removal of the piano
jack from that end.
4. Repeat Step 3 to remove the piano jack on the opposite end.
5. Remove all material that might have been used to protect the unit from the piano jacks and
strapping.
27
Equipment Inspection and Handling
4.2.4
Removing Liebert CW from Skid Using Rigging
! WARNING
Risk of top heavy unit tipping over. Can cause cause equipment damage, injury or death.
Use only lifting equipment that is rated for the unit weight by an OSHA-certified rating
organization. Unit weights are listed in Table 1 of this manual.
Use the center of gravity indicators (see Figure 23) on the unit to determine the position of
the slings. The center of gravity varies depending on the unit size and selected options.
The slings must be equally spaced on either side of the center of gravity indicator.
1. Locate the center of gravity indicator—the center of gravity varies according to a unit’s size and
options.
2. Space the slings equidistant on either side of the center of gravity indicator (see Figure 23).
Figure 23 Locate center of gravity marker and place slings
Slings Equidistant
from Each Side of
Indicator
Illustration shows
rigging for one possible
center of gravity on the
Liebert CW. The center of
gravity varies with the
model’s options and size.
Center
of Gravity
Indicator
Equal
Space
Equal
Space
196713
Rev.0
3. Place the slings between the bottom rails of the Liebert CW and the top of the skid.
NOTE
Unit is shown without packaging. These instructions may be applied with or without the outer
packaging in place, with the panels attached or with the panels removed.
4. Use spreader bars or a similar device and padding to ensure the Liebert CW will not be damaged
when the unit is lifted (see Figure 23). Lifting will force the slings toward the Liebert CW and
the slings may damage the unit unless it is properly protected.
5. Move the Liebert CW to its installation location.
6. Remove the brackets securing the Liebert CW to the shipping skid.
NOTE
Depending on final installation location, the skid may need to remain under the unit.
Therefore, the lag bolts and brackets would not yet be removed.
7. Lift the Liebert CW off the skid.
8. Move the skid from under the unit.
9. If the unit is at its installation location, lower it to the floor and remove the slings and spreader bars.
If the Liebert CW must be moved, refer to 4.2.2 - Moving the Unit to the Installation Location with Piano Jacks.
28
Equipment Inspection and Handling
Figure 24 Using rigging to lift Liebert CW off skid
196713
Rev. 0
29
EC Fan—Lowering and Removing
5.0
EC FAN—LOWERING AND REMOVING
Liebert CW downflow models CW106, CW114 and CW181 can be equipped with EC fans that can be
operated either in their fully raised position or lowered into the floor stand for increased efficiency
from reduced air resistance.
The fans are also removable, easing maintenance and replacement.
! WARNING
Risk of very heavy 145 lb. (65.7kg) fan modules dropping downward suddenly. Can cause
injury or death. Support fan modules before removing mounting hardware.
Use caution to keep body parts out of the fan modules pathway during repositioning.
Only properly trained and qualified personnel should work on this equipment.
! CAUTION
Risk of handling heavy and lengthy parts. Can cause personal injury and equipment damage.
Cabinet panels can exceed 5ft. (1.5m) in length and weigh more than 35lb. (15.9kg). Follow
relevant OSHA lifting recommendations and consider using a two-person lift for safe and
comfortable removal and installation of cabinet panels. Only properly trained and qualified
personnel wearing appropriate safety headgear, gloves and shoes should attempt to remove or
install cabinet panels.
NOTE
The Liebert CW unit should be used with the fans either in their original raised position or
with the fans in their fully lowered position. Suspension of fans in an intermediate position
will directly affect product performance and is not recommended.
5.1
Lowering the EC Fans into the Floor Stand
1. Remove the middle and bottom panels from the front of the unit.
2. For ease of fan lowering, Emerson recommends removing the infrared humidifier using the
approved infrared humidifier removal procedure.
3. Position the factory-supplied jack and jack support under the fan to be lowered.
4. Raise the jack to safely support the fan before removing any hardware.
NOTE:
A properly positioned jack will be centered between the first and second set of tabs on the jack
support. The jack will be biased towards the front of the unit.
5. For Liebert CW models CW089-CW114, remove the two guide rails and store them; they will be
needed if the fan module is removed.
6. Remove the six 1/2" hex head screws, and, on CW026-CW114 models, remove the “Z” bracket(s)
using the socket wrench. Retain the hardware for later steps.
7. Using the jack, slowly lower the fan module until it rests on the frame of the unit.
NOTICE
Risk of equipment snagging cables and wiring. Can cause unit damage.
Monitor the position of the fan harnesses and other parts while lowering the fan to be sure
that they are not caught or pinched.
8. Secure the fan module in the fully lowered position by re-installing the “Z” bracket(s), using the
retained hex-head screws (not applicable on CW146 and CW181).
For CW051 and CW060 models, the fan module is secured to the center frame support. The “Z”
brackets will be used to secure the fan at the outer attachment point.
NOTE
Not all hardware retained will be used to secure the fans in the lowered positioned.
30
EC Fan—Lowering and Removing
Figure 25 EC fan lowering procedure
1
3
2
Tabs
1
Detail A
Jack Location
B
Section
Not Shown
B
3
A
Fan Deck
Section
Not Shown
5
5
4
"Z" Bracket
Section B-B
Top View of Fan Deck
See Step 55
31
"Z" Bracket
Wiring Loop
DPN002037
Page 1, Rev. 0
EC Fan—Lowering and Removing
5.2
Removing the EC Fans
The EC fans in Liebert CW units can be removed for easier maintenance or for replacement.
! WARNING
Risk of very heavy 145 lb. (65.7kg) fan modules dropping downward suddenly. Can cause
injury or death. Support fan modules before removing mounting hardware.
Use caution to keep body parts out of the fan modules pathway during repositioning.
Only properly trained and qualified personnel should work on this equipment.
NOTE
The Liebert CW unit should be used with the fans either in their original raised position or
with the fans in their fully lowered position. Suspension of fans in an intermediate position
will directly affect product performance and is not recommended.
If the fan to be removed has been lowered into the floor stand, first raise the fan; if the fans are
already in the raised position, skip to Step 6. To raise a lowered fan:
1. Remove the middle and bottom panels from the front of the unit.
2. Remove the infrared humidifier to ease fan removal.
3. Remove any securing hardware and position the jack support and jack supplied with the unit
under the fan module. A properly positioned jack will be biased toward the front of the fan motor.
4. Use the jack to raise the fan module slowly out of the floor stand and into the unit.
NOTICE
Risk of equipment snagging cables and wiring. Can cause unit damage.
Monitor the position of the fan harnesses and other parts while raising the fan to be sure that
they are not caught or pinched while the fan is being raised.
5. CW089, CW106 and CW114 models: Insert the two fan guide rails supplied with the unit or
equivalent, field-supplied device into position. The rails can be installed by latching onto the
channel in the back of the unit and secured with one #8-18 x 1/2" self-threading screw in the front
channel hole provided.
CW146 and CW181 models will need to utilize a field-supplied device in place of the fan guide
rails.
6. On CW026 - CW114 models, wiring is in the rear. Unplug the power connectors to the fan
module and constrain the harness out of the way. Remove the protective shields by removing
hardware.
The CW146 and CW181 models’ wiring is in the front of the unit and does not have connectors.
The harness must be unconnected from the motor overloads in the electric panel and removed
with the fan module.
7. Remove the front vertical supports as needed to remove the fan module.
8. Using the rails, slide the blower out through the front of the unit. Reverse directions to reinstall
replacement fan module.
32
EC Fan—Lowering and Removing
Figure 26 EC fan lowering and removal procedure
2
See Step 3
See Steps 1 and 2
3
6
6
8
7
5
See Step 8
See Steps 4 - 7
33
Electrical Connections
6.0
ELECTRICAL CONNECTIONS
6.1
Electrical Connections
Three-phase electrical service is required for all models. Electrical service must conform to national
and local electrical codes. Refer to equipment nameplate regarding wire size and circuit protection
requirements. Refer to electrical schematic when making connections. Refer to Figures 27
through 33 for electrical service entrances into unit.
A manual electrical disconnect switch should be installed in accordance with local codes and distribution system. Consult local codes for external disconnect requirements.
! WARNING
Risk of electric shock. Can cause injury or death. Disconnect local and remote power supplies
before working within.
Use voltmeter to make sure power is turned off before making any electrical connections.
Before proceeding with installation, read all instructions, verify that all the parts are included
and check the nameplate to be sure the voltage matches available utility power.
50Hz Models Only: Reinstall all terminal covers before connecting power to the unit. Failure
to install these covers exposes high-voltage terminals.
Follow all local codes.
! WARNING
Risk of improper wiring, piping, moving, lifting and handling. Can cause equipment damage,
injury or death.
Installation and service of this equipment should be done only by personnel who have been
properly trained and qualified in the installation of air conditioning equipment
! WARNING
Risk of overheated electrical connection terminals. Can cause equipment damage, smoke and
activation of smoke alarm and fire suppression system that can lead to injuries or death from
building evacuation accidents.
Use copper wiring only. Make sure that all connections are tight.
NOTICE
Risk of improper electrical supply connection. Can cause equipment damage.
See the transformer label for primary tap connections. The installer must change the
transformer primary taps if the applied unit voltage is other than the pre-wired tap voltage.
34
Electrical Connections
Figure 27 Electrical field connections for downflow chilled water models CW026 - CW084
Field-supplied disconnect switch when factory-installed
unit disconnect switch is not provided.
Factory-installed unit disconnect switch (optional).
Monitoring panel.
Electric service connection block
Earth ground connection (60Hz).
Connection terminal for field-supplied
earth grounding wire.
Earth ground bar (on 50Hz only).
Connection terminals with factory ground
from each high-voltage component for
field-supplied earth grounding wire.
Site monitoring connection. Terminals
77 ( - ) and 78 ( + ) are for connection
of a 2 wire, twisted pair, communication
cable (available from Liebert or others)
to optional Sitescan and are factoryconnected to the interface board on the unit.
Not available when Liebert IntelliSlots are used.
Three-phase electric service
not by Liebert.
Factory-wired to components on
electric panel
Three-phase connection. Electric service
connection terminals when factory disconnect
switch is NOT supplied
Three-phase connection. Electric
service connection terminals when
factory disconnect switch is supplied.
Factory-installed disconnect switch (optional ).
Liebert IntelliSlot Housings.
Optional Monitoring and
Communication cards
inserted here.
Three phase electric service not by Liebert
Electric conduit knockouts on bottom of
wire raceway. Knockouts sizes 1-3/8"
(35mm) or 1-3/4" (45mm) or 2-1/2"(64mm).
Electrical handy box factory-installed with cover
C
D
Common alarm connection. Field-supplied 24V
Class 2 wiring to common alarm pigtails 75 + 76
which are factory connected to common alarm
relay (R3).
Remote unit shutdown. Replace existing
jumper between Terminals 37 + 38
with normally closed switch having a
minimum 50VA rating. Use field-supplied
24V Class 2 wire.
Unit-to-Unit Communication
Connections. C & D ports,
CAT5E Ethernet connections.
Special alarm connections. Field-supplied
24V. Class 2 wire for special alarms.
Smoke detector alarm connections.
Field-supplied 24V. Class 2 wire to
remote alarm circuits. Factory-wired
terminals from optional smoke detector
are #91-comm., #92-NO, and #93-NC.
NOTE: Refer to specification sheet for full load amp. and wire size amp. ratings.
35
DPN001670
Rev. 0
Electrical Connections
Figure 28 Electrical field connections for downflow chilled water models CW089, CW106 and CW114
Factory-installed unit disconnect switch (optional).
Monitoring panel
Field-supplied disconnect switch
when factory-installed unit
disconnect switch is not provided.
Three-phase electric service
not by Liebert.
Electric service connection block
Common alarm connection.
Field-supplied 24V. Class 1
wiring to common alarm
Pigtails 75 + 76 which
are factory-connected
to common alarm relay (R3).
Earth ground connection (60 Hz).
Connection terminal for field-supplied
earth grounding wire
Electrical handy box
factory-installed with cover
Factory-wired to components on
electric panel
Three-phase connection. Electric
service connection terminals when
factory disconnect switch is not supplied.
Remote unit shutdown. Replace
existing jumper between Terminals
37 + 38 with normally closed switch
having a minimum 50VA rating. Use
field-supplied 24V Class 1 wire.
Earth ground bar (on 50 Hz only).
Connection terminals with factory ground
from each high-voltage component for
field-supplied earth grounding wire.
Three-phase connection. Electric
service connection terminals when
factory disconnect switch is supplied.
Factory-installed disconnect switch
(optional).
Special alarm connections.Field-supplied
24V. Class 1 wire for special alarms
37
38
24
50
51
55
56
77
78
91
92
93
Three-phase electric service
not by Liebert.
Electric conduit knockouts on bottom of
wire raceway. Knockout sizes 1-3/8"
(35mm) or 1-3/4" (45mm) or 2-1/2" (64mm)
Site monitoring connection. Terminals
77 (-) and 78 (+) are for connection
of a 2-wire, twisted pair, communication
cable (available from Liebert or others)
to optional Liebert SiteScan and are factoryconnected to the interface board on the
unit. Not available when Liebert IntelliSlots
are used.
Liebert IntelliSlot Housings.
Optional monitoring and
communication cards inserted here.
Smoke detector alarm connections
Field supplied 24V. Class 1 wire to
remote alarm circuits. Factory-wired
terminals from optional smoke detector
are #91-comm., #92-NO, and #93-NC
Unit-to-Unit Communication
Connections. C & D ports,
CAT5E Ethernet connections
C
D
NOTE: Refer to specification sheet for full load amp. and wire size amp. ratings.
36
DPN001671
Rev. 0
Electrical Connections
Figure 29 Electrical field connections (high voltage) for upflow chilled water models CW026 - CW084
Field-supplied disconnect switch when factory-installed
unit disconnect switch is not provided
Factory-installed unit disconnect switch (optional).
Monitoring panel
Three-phase electric service
not by Liebert.
Factory-wired to components
on electric panel.
Electric service connection block
Earth ground connection (60Hz)
Connection terminal for field-supplied
earth grounding wire
Three-phase connection. Electric service
connection terminals when factory
disconnect switch is NOT supplied
Earth ground bar (50Hz only)
Connection terminals with
factory ground from each
high-voltage component for
field-supplied earth grounding wire.
Three-phase connection. Electric
service connection terminals when
factory disconnect switch is supplied
Factory-installed disconnect switch
(optional ).
Three-phase electric service
not by Liebert.
Electric conduit knockouts on bottom
of wire raceway. Knockouts sizes 1-3/8"
(35mm) or 1-3/4" (45mm) or 2-1/2"(64mm).
NOTE: Refer to specification sheet
for full load amp. and wire size
amp. ratings.
DPN001672
Rev. 0
37
Electrical Connections
Figure 30 Electrical field connections (low voltage) for upflow chilled water models CW026 - CW084
Liebert IntelliSlot Housings.
Back of
Optional monitoring and
Electric Box
communication cards inserted here.
Unit-to-Unit communication
connections.
C & D ports, CAT5E Ethernet
connections
Electrical Handy Box
factory-installed
with cover
Remote unit shutdown. Replace existing
jumper between Terminals 37 & 38
with normally closed switch having a
minimum 50VA rating. Use field-supplied
24V Class 2 wire.
37
38
24
50
Site monitoring connection. Terminals
77 (-) and 78 (+) are for connection
of a 2 wire, twisted pair, communication
cable (available from Liebert or others)
to optional Liebert Sitescan and are
factory-connected to the interface board
on the unit. Not available when Liebert
Intellislots are used.
77
78
91
92
93
57
55
56
Smoke detector alarm connections.
Field-supplied 24V. Class 2 wire to
remote alarm circuits. Factory-wired
terminals from optional smoke detector
are #91-comm., #92-NO, and #93-NC.
Special alarm connections. Field-supplied
24V. Class 2 wire for special alarms.
Common alarm connection. Field-supplied 24 V.
Class 2 wiring to common alarm pigtails 75 + 76
which are factory-connected to common alarm relay (R3).
NOTE: Refer to specification sheet for full load
amp. and wire size amp. ratings
38
DPN001673
Rev. 0
Electrical Connections
Figure 31 Electrical field connections (high voltage) for upflow chilled water models CW106 and CW114
Three-phase electric
service not by Liebert.
Field-supplied disconnect switch when factory-installed
unit disconnect switch is not provided
Factory-installed unit disconnect switch (optional).
Monitoring panel.
Three-phase electric
service not by Liebert.
Electrical conduit knockouts
in top of electrical box.
Knockout sizes 1-3/8" (35mm),
1-3/4" (45mm) or 2-1/2" (64mm)
Factory-wired to
components
on electric panel
Three-phase connection. Electric
service connection terminals
when factory disconnect switch
is NOT supplied.
Electric service connection block.
Earth ground connection (60Hz).
Connection terminal
for field-supplied
earth grounding wire
Earth ground bar (on 50Hz only).
Connection terminals with factory ground
from each high voltage component for
field supplied earth grounding wire.
Three-phase connection.
Electric service connection
terminals when optional
factory disconnect switch
is supplied.
NOTE: Refer to specification sheet
for full load amp. and wire size amp. ratings
DPN001674
Rev. 0
39
Electrical Connections
Figure 32 Electrical field connections (low voltage) for upflow chilled water models CW106 and CW114
Monitoring
Panel
Disconnect
Switch
Common alarm connection. Fieldsupplied 24V Class 1 wiring to
common alarm pigtails 75 + 76
which are factory connected to
common alarm relay (R3).
Electrical handy box
factory-installed with cover
Knockout for low-voltage
wiring connections in
top frame member.
Knockout size 7/8" (22mm)
Remote unit shutdown.
Replace existing jumper
between Terminals 37 + 38 with
normally closed switch
having a minimum 50VA rating. Use
field-supplied 24V Class 1 wire.
Special alarm connections
Field-supplied 24V
Class 1 wire for special alarms
37
38
24
50
51
55
56
77
78
91
92
93
Site monitoring connection. Terminals 77 (-) and 78 (+)
are for connection of a 2-wire, twisted pai r, communication
cable (available from Liebert or others) connected to the
interface board on the to optional Liebert SiteScan and
are factory unit. Not available when Liebert Intellislots are used.
Liebert Intellislot housings.
Optional monitoring and
communication cards inserted here.
Unit-to-Unit Communication
Connections. C & D ports,
CAT5E Ethernet connections
C
Smoke detector alarm connections
Field-supplied 24V Class 1 wire to
remote alarm circuits. Factory-wired
terminals from optional smoke detector
are #91-comm., #92-NO, and #93-NC.
D
NOTE: Refer to specification sheet
for full load amp. and wire size amp. ratings.
DPN001675
Rev. 0
40
Electrical Connections
Figure 33 Electrical field connections for downflow chilled water models CW146 and CW181
4
3
Fuses/Circuit
Breakers
10
Liebert IntelliSlot
Housing
11
A
B
C
D
9
Contactors
1
4 50Hz
Main Fan
Overloads
Liebert iCOM
Control Board
2
Note: Typical orientation of components shown. Component location varies by option and unit.
Refer to text on pages 41
and 42 for description of
numbered items.
A
B
C
D
DPN001699
Page 1, Rev. 2
Standard Electrical Connections for Downflow Chilled Water Models CW146 and CW181
Refer to Figure 33.
1. Primary high-voltage—2-1/2" (64mm); 1-3/4" (44mm); 1-3/8" (35mm) diameter concentric
knockouts in bottom of box.
2. Primary low-voltage entrance—Three knockouts, 1-1/8" (28mm) diameter, in bottom of box.
3. Three-phase electrical service—Terminals are on high-voltage terminal block (disregard if
unit has optional disconnect switch). Three-phase service not by Emerson.
4. Earth ground—Terminal for field-supplied earth grounding wire.
5. Remote unit shutdown—Replace existing jumper between Terminals 37 and 38 with
field-supplied, normally closed switch that has a minimum 75VA, 24VAC rating. Use
field-supplied Class 1 wiring.
6. Customer alarm inputs—Terminals for field-supplied, normally open contacts, having a
minimum 75VA, 24VAC rating, between Terminals 24 and 50, 51, 55, 56. Use field-supplied
Class 1 wiring. Terminal availability varies by unit options.
7. Liebert SiteScan®—Terminals 77(-) and 78(+) for a 2-wire, twisted pair, communication cable
(available from Emerson) to optional Liebert SiteScan.
8. Common alarm—On any alarm, normally open dry contact is closed across Terminals 75 and 76
for remote indication. 1A, 24VAC maximum load. Use Class 1 field-supplied wiring.
41
Electrical Connections
Optional Electrical Connections for Downflow Chilled Water Models CW146 and CW181
Refer to Figure 33.
9. Factory-installed disconnect switch
10. Secondary disconnect switch and earth ground
11. Three-phase electrical service—Terminals are on top of disconnect switch. Three-phase
service not by Emerson.
12. Smoke sensor alarm—Factory-wired dry contacts from smoke sensor are 91-common, 92-NO
and 93-NC. Supervised contacts, 80 and 81, open on sensor trouble indication. This smoke sensor
is not intended to function as, or replace, any room smoke detection system that may be required
by local or national codes. 1A, 24VAC maximum load. Use Class 1 field-supplied wiring.
13. Reheat and humidifier lockout—Remote 24VAC required at Terminals 82 and 83 for lockout
of reheat and humidifier.
14. Condensate alarm (with condensate pump option)—On pump high-water indication, normally
open dry contact is closed across Terminals 88 and 89 for remote indication. 1A, 24VAC maximum
load. Use Class 1 field-supplied wiring.
15. Remote humidifier—On any call for humidification, normally open dry contact is closed across
Terminals 11 and 12 to signal field-supplied remote humidifier. 1A, 24VAC maximum load. Use
Class 1 field-supplied wiring.
16. Reversing Starter Power Supply Notification—Normally open contact Terminals 106 and
107 will close when Power Supply 1 is engaged; 110 and 111 will close when Power Supply 2 is
engaged.
17. Total Harmonic Distortion (THD) Reducing Transformer
EC motor and variable frequency drives create current harmonics that will distort the voltage waveform of their supply and might affect other equipment on the same power source. The degree of distortion is dependent on the “stiffness” of the supply power and the total current distortion caused by all
non-linear loads on the system.
The IEEE-519-1992 is the IEEE Recommended Practices and Requirements Guideline for Harmonic
Control in Electrical Power Systems. It defines the maximum voltage distortion limits allowed to be
reflected back onto the utility distribution system. It is a guideline meant to minimize the effects of
electrical pollution created by one utility customer from affecting a different customer. The guideline
requires total voltage harmonic distortion (THD) to not exceed 5% and that the individual current distortions and total current distortion (TDD) must conform to the table below. It is NOT a guideline for
individual connected loads, but a guideline for total building or plant. Many apply the voltage distortion criteria to all substations (maximum 5% THD) and apply the current distortion criteria exclusively to the utility metering point (PCC).
Table 2
Maximum harmonic current distortion, IEEE-519-1992
Individual Harmonic Limits
I SC / IL
< 11
< 20
4.0
2.0
1.5
5.0
20 < 50
7.0
3.5
2.5
8.0
50 < 100
10.0
4.5
4.0
12.0
100 < 1000
12.0
5.5
5.0
15.0
7.0
6.0
20.0
> 1000
11 h 17
15.0
17 h 23
TDD
ISC = Maximum Short circuit current @ PCC.
IL = Total load current @ PCC.
TDD = Total Current Distortion
Typically, if the variable speed fan load is less than 10% of the current capacity at the point of common coupling (PCC), your installation will meet IEEE-519 guidelines. In this case there should be no
interference issues with other electrical equipment. Typically, the worst-case PCC is the emergency
backup generator plant but could be the transformer that powers the cooling load. If the PCC is a
UPS, consult your UPS supplier for recommendations. For customers who have variable speed loads
that exceed this rule of thumb, it may be necessary to minimize the harmonic impact these variable
42
Electrical Connections
speed loads have on the system voltage. In these instances, an undesirable effect is a difficulty in
switching from generator supply to utility supply. The purpose of the Liebert CW THD mitigating
transformer is to cancel current harmonics generated by the EC fan. This device is a passive device,
not a harmonic filter or trap, thus it will not cause unintended harmonic resonance problems. This
device will not improve harmonics caused by other systems on the power network.
The Liebert CW THD mitigation device is an optional feature that can be ordered with the Liebert
Precision Cooling unit
Table 3 shows the Total Current Distortion levels as measured on a single CW114 unit and is typical
of what can be expected in the field on CW106, CW114 and CW146 units.
Table 3
Typical TDD for CW106, CW114 and CW146 at 460V
Event Current Harmonic List — 100% Fan Speed
Unfiltered Test Results – 3 Blowers
Order
(A)
(%)
1
13.89
5
3.29
7
Filtered Test Results - Transformer + 3 Blowers
Order
(A)
(%)
100.0%
1
13.00
100.0%
23.7%
5
0.44
3.4%
1.94
14.0%
7
0.33
2.5%
11
1.29
9.3%
11
0.13
1.0%
13
0.92
6.6%
13
0.11
0.9%
17
0.79
5.7%
17
0.66
5.1%
Broad Spectrum TDD
31.7%
Broad Spectrum TDD
9.1%
Event Harmonic List — 60% Fan Speed
Unfiltered Test Results – 3 Blowers
Filtered Test Results - Transformer + 3 Blowers
Order
(A)
(%)
Order
(A)
(%)
1
4.77
100.0%
1
4.37
100.0%
5
1.96
41.1%
5
0.38
8.6%
7
1.15
24.2%
7
0.31
7.0%
11
0.34
7.1%
11
0.05
1.2%
13
0.35
7.3%
13
0.05
1.2%
17
0.23
4.9%
17
0.23
5.2%
Broad Spectrum TDD
49.9%
Broad Spectrum TDD
43
14.1%
Electrical Connections
Table 4 shows the Total Current Distortion level as measured on a single CW181 unit and is typical
of what can be expected in the field on CW181.
Table 4
Typical TDD for CW181 at 460V
Event Current Harmonic List — 100% Fan Speed
Unfiltered Test Results – 3 Blowers
Filtered Test Results - Transformer + 3 Blowers
Order
(A)
(%)
Order
(A)
(%)
1
13.89
100.0%
1
13.00
100.0%
5
3.29
23.7%
5
0.44
3.4%
7
1.94
14.0%
7
0.33
2.5%
11
1.29
9.3%
11
0.13
1.0%
13
0.92
6.6%
13
0.11
0.9%
17
0.79
5.7%
17
0.66
5.1%
31.7%
Broad Spectrum TDD
Broad Spectrum TDD
9.1%
Event Harmonic List — 60% Fan Speed
Unfiltered Test Results – 3 Blowers
Filtered Test Results - Transformer + 3 Blowers
Order
(A)
(%)
Order
(A)
(%)
1
4.77
100.0%
1
4.37
100.0%
5
1.96
41.1%
5
0.38
8.6%
7
1.15
24.2%
7
0.31
7.0%
11
0.34
7.1%
11
0.05
1.2%
13
0.35
7.3%
13
0.05
1.2%
17
0.23
4.9%
17
0.23
49.9%
Broad Spectrum TDD
Broad Spectrum TDD
5.2%
14.1%
Optional Low-Voltage Terminal Package Connections for Downflow Chilled Water Models
CW146 and CW181
Refer to Figure 33.
18. Remote unit shutdown—Two additional contact pairs available for unit shutdown (labeled as
37B & 38B, 37C & 38C). Replace jumpers with field-supplied, normally closed switch that has a
minimum 75VA, 24VAC rating. Use Class 1 field-supplied wiring.
19. Common alarm—On any alarm, two additional normally open dry contacts are closed across
Terminals 94 and 95 and 96 and 97 for remote indication. 1A, 24VAC maximum load. Use Class 1
field-supplied wiring.
20. Main fan auxiliary switch—On closure of main fan contactor, normally open dry contact is
closed across Terminals 84 and 85 for remote indication. 1A, 24VAC maximum load. Use Class 1
field-supplied wiring.
21. Liebert Liqui-tect® shutdown and dry contact—On Liebert Liqui-tect activation, normally
open dry contact is closed across Terminals 58 and 59 for remote indication (Liebert Liqui-tect
sensor ordered separately). 1A, 24VAC maximum load. Use Class 1 field-supplied wiring.
NOTE
Refer to specification sheet for total unit full load amps, wire size amps and maximum
overcurrent protective device size.
44
Piping
7.0
PIPING
All fluid connections to the unit, with the exceptions of the condensate drain and live steam, are sweat
copper. Factory-installed piping brackets must not be removed. Field-installed piping must be
installed in accordance with local codes and must be properly assembled, supported, isolated and
insulated. Avoid piping runs through noise-sensitive areas, such as office walls and conference rooms.
All piping below the elevated floor must be located so that it offers the least resistance to air flow.
Careful planning of the piping layout under the raised floor is required to prevent the air flow from
being blocked. When installing piping on the subfloor, it is recommended that the pipes be mounted in
a horizontal plane rather than stacked one above the other. Whenever possible, the pipes should be
run parallel to the air flow.
Refer to specific text and detailed diagrams in this manual for other unit-specific piping requirements.
7.1
Fluid Connections
NOTICE
Risk of clogged or leaking drain lines. Can cause equipment and building damage.
This unit requires a water drain connection. Drain lines must be inspected regularly and
maintenance must be performed to ensure that drain water runs freely through the drain
system and that lines are clear and free of obstructions and in good condition with no visible
sign of damage or leaks. This unit may also require an external water supply to operate.
Improper installation, application and service practices can result in water leakage from the
unit. Water leakage can result in severe property damage and loss of critical data center
equipment.
Do not locate unit directly above any equipment that could sustain water damage.
Emerson recommends installing leak detection equipment for unit and supply lines.
7.1.1
Condensate Piping—Field-Installed
! CAUTION
Risk of boiling water. Can cause injury.
The unit requires a drain line that may contain boiling water. Only properly trained and
qualified personnel wearing appropriate safety equipment should service the drain line or
work on parts near or connected to the drain line.
•
•
•
•
•
Do not reduce drain lines
Do not expose drain line to freezing temperatures
Drain line may contain boiling water. Use copper or other suitable material
Drain line must comply with local building codes
Emerson recommends installing under-floor leak detection equipment
Gravity Drain
• 3/4" NPT drain connection is provided on units without optional factory-installed condensate
pump
• Pitch drain line toward drain a minimum of 1/8" (3mm) per 1 foot (305mm) of length
• Drain is trapped internally. Do not trap external to equipment
• Drain line must be sized for 2 gpm (7.6 l/m) flow
• Drain line must comply with all applicable codes
NOTICE
Risk of improper installation. Can cause unit and/or building damage.
The drain line must not be trapped outside the unit or water may back up in the drain pan
and leak out of the unit on to the building floor(s) below
45
Piping
Figure 34 Gravity drain for downflow and upflow units
DOWNFLOW CW UNIT
UPFLOW CW UNIT
INTERNAL
DRAIN
UNIT
EXTERNAL
DRAIN
INTERNAL
DRAIN
UNIT
EXTERNAL
DRAIN
CONTINUOUS DOWNWARD SLOPE
CORRECT
CORRECT
UNIT
CONTINUOUS DOWNWARD SLOPE
INTERNAL
DRAIN
EXTERNAL
DRAIN
INTERNAL
DRAIN
UNIT
EXTERNAL
DRAIN
DO NOT EXTERNALLY
TRAP THE UNIT
INCORRECT
DO NOT EXTERNALLY
TRAP THE UNIT
INCORRECT
INTERNAL
DRAIN
UNIT
EXTERNAL
DRAIN
INTERNAL
DRAIN
UNIT
EXTERNAL
DRAIN
THESE ARE EXTERNAL TRAPS ALSO, ALTHOUGH
UNINTENTIONAL. LINES MUST BE RIGID ENOUGH
NOT TO BOW OVER TOP OF OTHER OBJECTS.
THESE ARE EXTERNAL TRAPS ALSO, ALTHOUGH
UNINTENTIONAL. LINES MUST BE RIGID ENOUGH
NOT TO BOW OVER TOP OF OTHER OBJECTS.
INCORRECT
INCORRECT
46
DPN001556
Rev. 0
Piping
Condensate Pump
• 1/2" copper sweat connection is provided on units with optional factory-installed condensate
pump
• Condensate Pump (60Hz): Condensate pump is rated for approximately 400 gph at 10 feet total
head
• Condensate Pump (50Hz): Condensate pump is rated for approximately 315 gph at 10 feet total
head
• Size piping based on available condensate head
• Condensate pump discharge (drain) line must comply with all applicable codes
NOTE
For units with a field-installed condensate pump, the unit is shipped from the factory with the
condensate pump option, unmounted in the unit, which must be installed in the field. The unit
has an internally mounted trap. The drain line from the unit to the condensate pump does not
require a trap. The discharge (drain) line from the pump must comply with all applicable
codes.
7.1.2
Humidifier Supply Water—Optional Infrared
• 1/4" supply line; maximum water pressure is 150 psi (1034kPa)
• Size humidifier supply line for 1 gpm (3.8 l/m), with a minimum water pressure of 20 psi (138kPa)
• Do not supply de-ionized water to the humidifier
7.1.3
Humidifier Supply Water—Optional Steam Generating Humidifier
• Water conductivity of 200-500 micro-siemens required for optimum operation.
• 1/4" supply line
Leak Checking of Unit and Field Piping
Liebert unit fluid systems are factory-checked for leaks and may be shipped with a nitrogen holding
charge. Liebert unit fluid circuits should be checked for leaks at installation as described below.
NOTE
During leak checking of field-installed piping, Emerson recommends that the unit be isolated
using field-installed shutoff valves. When Liebert CW units are included in a leak test, use of
fluid for pressure testing is recommended. When pressurized gas is used for leak testing a
Liebert CW unit, the maximum recommended pressure is 30 psig (2 bars) and tightness of the
unit should be verified by pressure decay over time, (<2 psig/hour [0.3 bars/hour]) or sensing a
tracer gas with suitable instrumentation. Dry seals in fluid valves and pumps may not hold a
high gas pressure.
47
Piping
7.2
Chilled Water Piping
7.2.1
Requirements of Systems Using Water or Glycol
These guidelines apply to the field leak checking and fluid requirements for field piping systems, including Liebert chilled water, hot water, condenser (water or glycol), GLYCOOL and drycooler circuits.
General Guidelines
• Equipment damage and personal injury can result from improper piping installation, leak checking, fluid chemistry and fluid maintenance.
• Follow local piping codes, safety codes.
• Properly trained and qualified personnel must install and inspect system piping.
• Contact a local water consultant regarding water quality, corrosion protection and freeze protection requirements.
• Install manual shutoff valves at the supply and return line to each indoor unit and drycooler to
permit routine service and emergency isolation of the unit.
NOTICE
Risk of frozen fluids. Can cause equipment damage and building damage.
Freezing system fluids can rupture piping. Complete system drain-down cannot be ensured.
When the field piping or unit may be exposed to freezing temperatures, charge the system
with the proper percentage of glycol and water for the coldest design ambient.
Automotive antifreeze is unacceptable and must NOT be used in any glycol fluid system.
NOTICE
Risk of corrosion. Can cause equipment damage.
Read and follow individual unit installation instructions for precautions regarding fluid
system design, material selection and use of field-provided devices. Liebert systems contain
iron and copper alloys that require appropriate corrosion protection. Contact a local water
consultant regarding water quality, corrosion and freeze protection requirements.
Water chemistry varies greatly by location, as do the required additives, called inhibitors,
that reduce the corrosive effect of the fluids on the piping systems and components. The
chemistry of the water used must be considered, because water from some sources may
contain corrosive elements that reduce the effectiveness of the inhibited formulation.
Preferably, surface waters that are classified as soft and are low in chloride and sulfate ion
content should be employed. Proper inhibitor maintenance must be performed in order to
prevent corrosion of the system. Consult glycol manufacturer for testing and maintenance of
inhibitors.
Commercial ethylene glycol (Union Carbide Ucartherm, Dow Chemical Dowtherm SR-1 and
Texaco E.G. Heat Transfer Fluid 100), when pure, is generally less corrosive to the common
metals of construction than water itself. It will, however, assume the corrosivity of the water
from which it is prepared and may become increasingly corrosive with use if not properly
inhibited.
48
Piping
NOTICE
Risk of corrosion. Can cause equipment damage.
Read and follow individual unit installation instructions for precautions regarding fluid
system design, material selection and use of field-provided devices. Liebert systems contain
iron and copper alloys that require appropriate corrosion protection.
Contact a water consultant about water quality, corrosion and freeze protection requirements.
Water chemistry varies greatly by location, as do the required additives, called inhibitors, that
reduce the corrosive effect of the fluids on the piping systems and components. The chemistry
of the water used must be considered, because water from some sources may contain corrosive
elements that reduce the effectiveness of the inhibited formulation. Preferably, surface waters
that are classified as soft and are low in chloride and sulfate ion content should be employed.
Proper inhibitor maintenance must be performed to prevent corrosion of system components.
Consult glycol manufacturer for testing and maintenance of inhibitors.
Commercial ethylene glycol (Union Carbide Ucartherm, Dow Chemical Dowtherm SR-1 and
Texaco E.G. Heat Transfer Fluid 100), when pure, is generally less corrosive to the common
metals of construction than water itself. It will, however, assume the corrosivity of the water from
which it is prepared and may become increasingly corrosive with use if not properly inhibited.
Leak Checking of Unit and Field Piping
Liebert unit fluid systems are factory-checked for leaks and may be shipped with a nitrogen holding
charge. Liebert unit fluid circuits should be checked for leaks at installation as described below.
NOTE
During leak checking of field-installed piping, Emerson recommends that the unit be isolated
using field-installed shutoff valves. When Liebert CW units are included in a leak test, use of
fluid for pressure testing is recommended. When pressurized gas is used for leak testing a
Liebert CW unit, the maximum recommended pressure is 30 psig (2 bars) and tightness of the
unit should be verified by pressure decay over time, (<2 psig/hour [0.3 bars/hour]) or sensing a
tracer gas with suitable instrumentation. Dry seals in fluid valves and pumps may not hold a
high gas pressure.
Manual shutoff valves should be installed at the supply and return lines to each unit. This provides
for routine service and emergency isolation of the unit.
The lowest water temperature to be supplied by the chiller will determine whether insulation is
needed to prevent condensation on the supply and return lines. To prevent water damage to flooring
and subflooring, install a water detection system, such as a Liqui-tect or floor drains with wet traps.
49
Piping Schematics
8.0
PIPING SCHEMATICS
Figure 35 Chilled water downflow general arrangement
Airflow
Bleed
Valve
Valve
Actuator
Chilled
Water
Return
AB
Chilled
Water
Supply
A
3-Way
Chilled
Water
Valve
B
Ball
Valve
(Optional)
Shutoff *
Valves
Chilled
Water
Return
Airflow
3-WAY VALVE
Flow Switch
(Optional)
Hose*
Bibs
Chilled Water Coil
Bleed
Valve
Valve
Actuator
Chilled Water Coil
Chilled
Water
Supply
2-Way Chilled
Water Valve
Shutoff *
Valves
2-WAY VALVE
Ball Valve
(Optional)
Hose*
Bibs
FACTORY PIPING
FIELD PIPING
*Components are not supplied by Liebert but
are recommended for proper circuit operation
and maintenance.
50
DPN001657
Rev. 1
Piping Schematics
Figure 36 Piping connections for downflow chilled water models CW026 - CW084 with forward-curved
fans
Monitoring
Panel
NOTE: Install all piping
per local codes.
Condensate Drain. Field-pitch a min. of
1/8" (3mm) per ft. (305mm). 3/4" NP T for units
without factory installed condensate pump. Do
not install an external trap. 1/2" OD CU for units
with factory-installed condensate pump
1/4" OD CU Humidifier Supply Line (Steam Gen./Infrared)
C - Steam Reheat Supply Line
D - Hot Water Reheat Supply Line
E - Steam Reheat Return Line
(Field-install factory-supplied steam
trap with vacuum breaker)
F - Hot Water Reheat Return Line
1/2" NPT Male Steam Humidifier Supply Line
1/2" NPT Male Steam Humidifier Return Line
OPTIONAL REHEAT SCHEMATICS
Supply
B - Chilled Water Return Line.
- Chilled Water Supply Line on units with High Pressure
2 Way Valve Only
A - Chilled Water Supply Line
- Chilled Water Return Line on units with High Pressure
2-Way Valve Only
Return
Y-Strainer
Actuator
Steam Humidifier
Steam Trap
Return
Supply
Y-Strainer
Hot Water Reheat Coil
Optional Hot Water Reheat (2-Way Valve)
Optional Steam Humidifier
Actuator
Actuator
Supply
Return
Y-Strainer
Return
Steam Trap
Supply
Steam Reheat Coil
Y-Strainer
Hot Water Reheat Coil
Optional Hot Water Reheat (3-Way Valve)
Optional Steam Reheat
DPN001666
Rev. 0
Models
A
(OD Cu)
B
(OD Cu)
C
(NPT Male)
D
(OD Cu)
E
(NPT Male)
F
(OD Cu)
CW026
1-1/8
1-1/8
1/2
5/8
1/2
5/8
CW038
1-3/8
1-3/8
1/2
5/8
1/2
5/8
CW041
1-5/8
1-5/8
1/2
5/8
1/2
5/8
CW051
1-5/8
1-5/8
1/2
7/8
1/2
7/8
CW060
2-1/8
2-1/8
3/4
7/8
3/4
7/8
CW076
2-1/8
2-1/8
3/4
7/8
3/4
7/8
CW084
2-1/8
2-1/8
3/4
7/8
3/4
7/8
51
Piping Schematics
Figure 37 Piping connections for downflow chilled water models CW106 and CW114 with forward-curved
fans
Monitoring
Panel
NOTE: Install all piping
per local codes.
3/4" NPT Steam Generating Canister Humidifier
Drain. Field-pitch a minimum of 1/8" (3mm)
per ft. (305mm). Do not install an external trap.
1/4" OD CU Humidifier Water Supply Line
Condensate Drain. Field-pitch a min. of
1/8" (3mm) per ft. (305mm). 1-1/8" NP T for units
without factory-installed condensate pump. Do
not install an external trap. 1/2" OD CU for units
with factory-installed condensate pump
1/2" NPT Male Steam Humidifier Return Line
1/2" NPT Male Steam Humidifier Supply Line
B - Chilled Water Return Line.
3-Way Valve Only
A - Chilled Water Supply Line
- Chilled Water Return Line
on units with High Pressure
2-Way Valve Only
B - Chilled Water Return Line
- Chilled Water Supply Line
on units with High Pressure
2-Way Valve Only
C-D - Steam/Hot Water Reheat Supply Line
E-F - Steam/Hot Water Reheat Return Line
OPTIONAL REHEAT SCHEMATICS
Supply
Return
Actuator
Y-Strainer
Steam Humidifier
Steam Trap
Return
Supply
Y-Strainer
Hot Water Reheat Coil
Optional Hot Water Reheat (2-Way Valve)
Optional Steam Humidifier
Actuator
Actuator
Supply
Return
Y-Strainer
Return
Supply
Y-Strainer
Steam Reheat Coil
Steam Trap
Hot Water Reheat Coil
Optional Steam Reheat
Optional Hot Water Reheat (3-Way Valve)
DPN001667
* This drawing pertains to CW106 & CW 114 with forward curve blowers onl y.
Rev. 0
Piping Connection Sizes, inches
Model
Numbers
A
OD Cu
B
OD Cu
C
NPT Male
D
OD Cu
E
NPT Male
F
OD Cu
CW106
2-1/8
2-1/8
3/4
7/8
3/4
7/8
CW114
2-5/8
2-5/8
3/4
7/8
3/4
7/8
52
Piping Schematics
Figure 38 Primary connection locations, downflow models CW026 - CW041 with EC fans
A
A
Front View
Note: Drawing Not To Scale.
All Dimensions From
Right Rear Corner of Unit
with Panels Assembled
Tolerance on all piping locating
dimensions ± 1/2" (13mm).
X
Section A-A
0
Y
31" (787mm)
Air Discharge Area
28-1/16"
(714mm)
Air Discharge Area
CD
35"
(889mm)
HUM
LV
CWP
B
HV
Front of Unit
50" (1270mm)
* Field pitch Condensate Drain line a minimum of 1/8" (3.2 mm) per foot (305 mm).
All units contain a factory-installed condensate trap. Do not trap external to the unit.
Drain line may contain boiling water. Select appropriate drain system materials.
The drain line must comply with all local codes.
DPN002036
** Optional Condensate Pump to be field-installed under unit.
Rev. 0
Point
CD
HUM
CWP
Description
Condensate Drain*
W/Optional Condensate Pump**
Humidifier Supply Line
Chilled Water Piping Slot (Center)
X, in (mm)
Y, in (mm)
Connection Size / Opening, in (mm)
35-7/8 (911)
24-3/8 (619)
35 1/2 (902)
28-1/4 (718)
1/4 (6) Cu Sweat
42 11/16 (1085)
31-1/4 (794)
10-1/2 x 3-1/16 (267 x 78)
3/4 (19) FPT
1/2 (13) Cu Sweat
CW026: 1-1/8(29)
—
—
CW038: 1-3/8(32)
CW041: 1-5/8(41)
HV
High Volt Electrical Connection
35-1/2 (902)
31-1/4 (794)
2 1/2 (64)
LV
Low Volt Electrical Connection
36-3/4 (934)
29-1/4 (743)
7/8 (22)
B
Blower Outlet Opening
4 (101)
33 (838)
28-1/16 x 31 (714 x 787)
53
Piping Schematics
Figure 39 Primary connection locations, downflow models CW051 and CW060 with EC fans
A
A
Front View
Note: Drawing Not To Scale.
Tolerance on all piping locating
dimensions ± 1/2" (13mm).
All Dimensions From
Right Rear Corner Of Unit
Including Panels
X
Section A-A
0
Y
31" (787mm)
Typical Air
Discharge Area
24-7/16" (620mm)
Typical Air
Discharge Area
24-1/8"
(613mm)
Air Discharge
Area
HUM
CD
LV
CWP
35"
(889mm)
B
HV
Front of Unit
74" (1880mm)
* Field pitch Condensate Drain line a minimum of 1/8" (3.2 mm) per foot (305 mm).
All units contain a factory-installed condensate trap. Do not trap external to the unit.
Drain line may contain boiling water. Select appropriate drain system materials.
The drain line must comply with all local codes.
DPN002035
** Optional Condensate Pump to be field-installed under unit.
Rev. 0
Point
CD
HUM
CWP
X, in (mm)
Y, in (mm)
60-7/8 (1547)
27-3/4 (705)
Humidifier Supply Line
59-1/8 (1502)
25-5/8 (727)
1/4 (6) Cu Sweat
Chilled Water Piping Slot (Center)
66-9/16 (1691)
31-1/4 (794)
11 x 3 (279 x 76)
—
—
Description
Condensate Drain*
W/Optional Condensate Pump**
Supply & Return Piping Diameter
Connection Size / Opening, in (mm)
3/4 (19) FPT
1/2 (13) Cu Sweat
CW051: 1-5/8 (41)
CW060: 2-1/8 (54)
HV
High Volt Electrical Connection
59 3/8 (1509)
30-3/4 (781)
3 (76)
LV
Low Volt Electrical Connection
60-7/8 (1547)
29-1/4 (743)
7/8 (22)
B
Blower Outlet Opening
4 (101)
33 (838)
51 x 31 (1295) x 787)
54
Piping Schematics
Figure 40 Primary connection locations, downflow models CW076 - CW084 with EC Fans
Note: Drawing Not To Scale.
A All Dimensions From
Rear Corner Of Unit
Including Panels
X
A
Front View
Tolerance on all piping locating
dimensions ± 1/2" (13mm).
Section A-A
0
Y
31" (787mm)
Typical Air Discharge Area
HV
CWP
28" (711mm)
Typical Air Discharge Area
35"
(889mm)
LV
HUM
B
CD
Front Of Unit
99" (2514mm)
* Field pitch Condensate Drain line a minimum of 1/8" (3.2 mm) per foot (305 mm).
All units contain a factory installed condensate trap. Do not trap external to the unit.
Drain line may contain boiling water. Select appropriate drain system materials.
The drain line must comply with all local codes.
DPN002034
Rev. 0
Point
CD
HUM
CWP
Description
X, in (mm)
Y, in (mm)
Connection Size / Opening, in (mm)
Condensate Drain*
75-7/16 (1916)
30-3/4 (781)
3/4 (19) FPT
W/Optional Condensate Pump
75-7/16 (1916)
30-3/4 (781)
1/2 (13) Cu Sweat
Humidifier Supply Line
80-3/8 (2042)
31-3/8 (797)
1/4 (6) Cu Sweat
Chilled Water Piping Slot (Center)
91-7/16 (2323)
31-3/8 (797)
101-5/16 x 2-15/16 (277 x 74)
Supply & Return Piping Diameter
—
—
2-1/8 (54)
HV
High Volt Electrical Connection
84 (2134)
30-3/4 (781)
3 (76)
LV
Low Volt Electrical Connection
81-7/16 (2068)
32 (813)
7/8 (22)
B
Blower Outlet Opening
9-7/8 (251)
33 (838)
60-13/16 x 31 (1544 x 787)
55
Piping Schematics
Figure 41 Primary connection locations, downflow models CW089, CW106 and CW114 with EC fans
NOTE: Drawing not to scale.
Tolerance on all
piping dimensions
is ±1/2" (13mm).
A
A
FRONT VIEW
All dimensions from
rear corner of unit
including panels
X
SECTION A-A
O
Y
CWR 3
CWS 3
28-1/16"
(712mm)
Typical Air
Discharge Area
31"
(787mm)
Typical Air
Discharge Area
LV1
E1
CWS 2
CD
HUM
35"
(889mm)
LV2
B
E2
FRONT OF UNIT
DPN001628
Rev. 4
CWR 2
122" (3099mm)
Point
CD
Description
X, in. (mm)
Y, in. (mm)
Connection Size / Opening
Condensate Drain *
103-1/2 (2629)
28 (711)
1-1/4" FPT
W/ Optional Pump
103-1/2 (2629)
28 (711)
1/2" Cu Sweat
Humidifier Supply Line
107-1/2 (2731)
29 (737)
1/4" Cu Sweat
CWS 2
2-Way Chilled Water Supply
118-1/2 (3010)
31 (787)
CW106: 2-1/8"; CW089, CW114: 2-5/8"
CWS 3
3-Way Chilled Water Supply
115-1/2 (2934)
22 (559)
CW106: 2-1/8"; CW089, CW114: 2-5/8"
CWR 2
2-Way Chilled Water Return
112-1/2 (2858)
31 (787)
CW106: 2-1/8"; CW089, CW114: 2-5/8"
CWR 3
3-Way Chilled Water Return
115-1/2 (2934)
31 (787)
CW106: 2-1/8"; CW089, CW114: 2-5/8"
E1
Electrical Conn. (High Volt)
35 (889)
31 (787)
2"
E2
Electrical Conn. (High Volt)
34 (864)
29 (737)
2"
LV1
Electrical Conn. (Low Volt)
35-1/2 (902)
26-1/2 (673)
1-3/8"
LV2
Electrical Conn. (Low Volt)
33-1/2 (851)
26-1/2 (673)
1-3/8"
4 (102)
33 (838)
94 x 31" (2388mm x 787mm)
HUM
B
*
Blower Outlet
Field-pitch condensate drain line a minimum of 1/8" (3.2 mm) per foot (305 mm). All units contain a factory-installed
condensate trap. Do not trap external to the unit. Drain line may contain boiling water. Select appropriate drain system
materials. The drain line must comply with all local codes.
56
Piping Schematics
Figure 42 Primary connection locations, downflow models CW146 and CW181 with EC fans
NOTE: Drawing not to scale.
Tolerance on all
piping dimensions
is ±1/2" (13mm).
FRONT VIEW
All dimensions from
rear corner of unit
including panels
SECTION A-A
X
A
A
O
Y
41"
(1041mm) TYP
AIR DISCHARGE
AREA
CWR
29-3/8"
(746mm) TYP
AIR DISCHARGE
AREA
47"
(1194mm)
CD
LV1
LV2
LV3
HUM
CWS
B
E1 E2
FRONT OF UNIT
122" (3099mm)
DPN001693
Rev. 2
Point
CD
X
Inches (mm)
Y
Inches (mm)
Connection Size
/ Opening
Condensate Drain *
110 (2794)
35 (889)
1-1/4" FPT
W/ Optional Pump
110 (2794)
35 (889)
1/2" Cu Sweat
Humidifier Supply Line
101 (2565)
43 (1092)
1/4" Cu Sweat
2-Way Chilled Water Supply
117 (2972)
37 (940)
3-1/8"
3-Way Chilled Water Supply
117 (2972)
37 (940)
3-1/8"
2-Way Chilled Water Return
117 (2972)
30 (762)
3-1/8"
3-Way Chilled Water Return
117 (2972)
30 (762)
3-1/8"
E1
Electrical Conn. (High Volt)
113 (2870)
43 (1092)
2"
E2
Electrical Conn. (High Volt)
110 (2794)
43 (1092)
2"
LV1
Electrical Conn. (Low Volt)
2-1/2 (64)
36 (914)
7/8"
LV2
Electrical Conn. (Low Volt)
2-1/2 (64)
37-1/2 (953)
7/8"
LV3
Electrical Conn. (Low Volt)
2-1/2 (64)
39 (991)
7/8"
B
Blower Outlet
4-1/2 (114)
44 (1118)
93" x 41" (2362mmx1041mm)
HUM
CWS
CWR
*
Description
Field-pitch condensate drain line a minimum of 1/8" (3.2 mm) per foot (305 mm). All units contain a factoryinstalled condensate trap. Do not trap external to the unit. Drain line may contain boiling water. Select appropriate
drain system materials. The drain line must comply with all local codes.
57
Piping Schematics
Figure 43 Chilled water upflow general arrangement
Air Flow
Chilled
Water
Supply
Bleed
Valve
Chilled
Water
Return
Valve
Actuator
Shutoff *
Valves
Chilled Water Coil
A
AB
B
Flow
Switch
(Optional
Hose*
Bibs
3-Way
Chilled
Water
Valve
lve
Ball Va
al)
(Option
3-WAY VALVE
Air Flow
Chilled
Water Supply
Chilled
Water
Return
Valve
Actuator
Bleed
Valve
2-Way
Chilled
Water
Valve
Chilled Water Coil
Shutoff *
Valves
2-WAY VALVE
Ball Valve
(Optional)
Hose*
Bibs
FACTORY PIPING
FIELD PIPING
*Components are not supplied by Liebert
but are recommended for proper
circuit operation and maintenance.
58
DPN001658
Rev. 0
Piping Schematics
Figure 44 Piping connections for upflow chilled water models CW026 - CW084
UNIT FIELD PIPING LOCATIONS
Piping stubbed out inside unit end compartment for field
connection through 2 5/8" x 10 3/4" (66 x 273mm)
opening as shown. Piping may also exit through bottom
or top of end compartment by field cutting an opening in
a suitable location (except bottom return air units).
1" (25mm) Rear Panel
1-1/32" (26mm)
2-5/8" (66mm)
10-3/4"
(273mm
7-1/2"
(191mm)
PLENUM FIELD PIPING LOCATIONS
For separate steam or hot water plenum in UPFLOW (UH)
units, piping may exit through bottom, top or sides by field
cutting an opening in a suitable location.
A - Chilled Water Supply Line.
(Line is stubbed down, field
install elbow for side
connection).
B - Chilled Water Return Line.
(Line is stubbed down, field
install elbow for side
connection).
1/4" OD CU Humidifier Water
Supply Line.
Condensate Drain. Field pitch a min. of
1/8" (3mm) per ft. (305mm). 3/4" NP T
for units without factory installed
condensate pump. Do not install an
external trap.
1/2" OD CU for units with factory
installed condensate pump.
Piping outlet location on units
w/rear return option.
Unit Left
End Panel
NOTE: Install all piping
per local codes.
Plenum Left
End Panel
1/2" NPT Female Steam
Humidifier Supply Line
1/2" NPT Female Steam
Humidifier Return Line
C - Steam Reheat Supply Line
F - Hot Water Reheat Return
Line
E - Steam Reheat Return Line
(Field-install factory-supplied
steam trap with vacuum breaker)
D - Hot Water Reheat
Supply Line
OPTIONAL REHEAT SCHEMATICS
Supply
Return
Actuator
Steam Humidifier
Return
Supply
Steam Trap
Hot Water Reheat Coil
Y-Strainer
Optional Hot Water Reheat (2-Way Valve)
Optional Steam Humidifier
Actuator
Actuator
Supply
Return
Y-Strainer
Return
Steam Trap
Supply
Steam Reheat Coil
Hot Water Reheat Coil
Y-Strainer
Optional Hot Water Reheat (3-Way Valve)
Optional Steam Reheat
DPN001668
Rev. 0
Factory-Provided Piping Connection Sizes, inches
Models
A, OD Cu
B, OD Cu
C, NPT Female
D, OD Cu
E, NPT Female
F, OD Cu
CW026
1-1/8
1-1/8
1/2
5/8
1/2
5/8
CW038
1-3/8
1-3/8
1/2
5/8
1/2
5/8
CW041
1-5/8
1-5/8
1/2
5/8
1/2
5/8
CW051
1-5/8
1-5/8
3/4
7/8
3/4
7/8
CW060
2-1/8
2-1/8
3/4
7/8
3/4
7/8
CW076
2-1/8
2-1/8
3/4
7/8
3/4
7/8
CW084
2-1/8
2-1/8
3/4
7/8
3/4
7/8
59
Piping Schematics
Figure 45 Piping connections for upflow chilled water CW106 and CW114
UNIT FIELD PIPING LOCATIONS
Piping stubbed out inside unit end compartment for field
connection through 13" x 6-1/2" (330 x 165mm) opening as
shown. Piping may also exit through bottom of end
compartment by field cutting an opening in a suitable
location.
A - Chilled Water Supply Line.
2-5/8" O.D. CU on 3 way
front return units only.
1/4" OD Cu Humidifier Water
Supply Line
Condensate Drain. Field-pitch a min. of
1/8" (3mm) per ft. (305mm). 1-1/4" NP T for units
without a factory-installed condensate pump.
1/2" OD Cu for units with factory-installed
condensate pump. Do not install an external trap.
1" (25mm)
Rear Panel
A- Chilled Water Supply Line
2-5/8" O.D. Cu on all units
except 3-way front return
B - Chilled Water Return Line
2-5/8" O.D. CU
7-1/2" (191mm)
Note: Install all piping per local codes
3" (76mm)
Unit Left
End Panel
DPN001669
Rev. 0
13" (330mm)
60
Checklist for Completed Installation
9.0
CHECKLIST FOR COMPLETED INSTALLATION
9.1
Moving and Placing Equipment
___ 1. Unpack and check received material.
___ 2. Proper clearance for service access has been maintained around the equipment.
___ 3. Equipment is level and mounting fasteners are tight.
___ 4. If the equipment has been disassembled for installation, unit must be reassembled per
instructions.
9.2
Electrical
___ 1. Supply voltage and phase matches equipment nameplate.
___ 2. Wiring connections completed between disconnect switch and unit.
___ 3. Power line circuit breakers or fuses have proper ratings for equipment installed.
___ 4. All internal and external high- and low-voltage wiring connections are tight.
___ 5. Confirm that unit is properly grounded to an earth ground.
___ 6. Control transformer setting matches incoming power.
___ 7. Electrical service conforms to national and local codes.
___ 8. Check blowers for proper rotation.
9.3
Piping
___ 1. Piping completed to coolant.
___ 2. Piping has been checked for leaks.
___ 3. Piping is properly sized, sloped, trapped as shown in the piping schematics
___ 4. Check piping inside and outside of equipment for proper support.
___ 5. Ensure that factory clamps have been reinstalled
___ 6. Drain line connected and pitched per local code.
___ 7. Water supply line connected to humidifier
9.4
Other
___ 1. Ducting complete (if required), maintain access to filters.
___ 2. Filters installed.
___ 3. Check fasteners that secure reheats, humidifier and motors-some may have become loose
during shipment.
___ 4. Verify water detection is properly installed around all units.
___ 5. Control panel DIP switches are set based on user requirements.
___ 6. Blower drive system rotates freely and belts are properly aligned and tensioned
___ 7. All fans are free of debris.
___ 8. Remove rubber band from float in optional infrared humidifier.
___ 9. Installation materials and tools have been removed from equipment (literature, shipping
materials, construction materials, tools, etc.)
___ 10. Locate blank startup sheet, ready for completion by installer or startup technician.
61
Initial Startup Procedure
10.0 INITIAL STARTUP PROCEDURE
Locate the startup form supplied with the unit documents. Complete the form during startup and
mail it to your local Emerson Network Power sales office after startup is completed. Contact your
Emerson supplier if you have any questions or problems during installation, startup or operation.
! WARNING
Risk of electric shock. Can cause injury or death. Disconnect all local and remote electrical
power supplies before working within the unit.
Potentially lethal voltages exist within this equipment during operation. Observe all cautions
and warnings on the unit and in this manual. Failure to do so could result in serious injury or
death. Only properly trained and qualified service and maintenance personnel should work
with this equipment.
! WARNING
Risk of fire suppression and alarm system activation. Can cause injury or death during
building evacuation and mobilization of emergency fire and rescue services.
Startup operation of optional electric reheat elements may activate facility alarm and fire
suppression system. Prepare and take appropriate steps to manage this possibility. Activating
reheat during initial startup may burn off particulates from electric reheat elements.
Check the steam generating humidifier electrode plugs to ensure that they are pressed firmly
onto the pins. Loose connections will cause the cylinder and plugs to overheat.
Before beginning initial startup checks, make certain that unit was installed according to the
instructions in this manual. All exterior panels must be in place.
1. Disconnect all power to the environmental control unit.
2. Tighten all electrical wiring connections on electric panel and at all major components, such as
compressors and motors that may have loosened during shipping.
3. Remove all line voltage fuses except the main fan fuses at the far right of the electric panel and
the control voltage fuses at the far left of the electric panel. For units supplied with circuit
breakers, open them instead of removing fuses.
4. Turn on electrical input power and check the line voltage on the main unit disconnect switch. Line
voltage must be within 10% of the nameplate voltage.
5. Turn ON the main unit disconnect switch and check the secondary voltage at transformer T1.
Voltage at T1 must be 24VAC, ±2.5VAC (check at TB1-1 and TB1-8). T1 voltage must not exceed
28VAC. Change the primary tap if necessary.
6. Push the ON button. Blower will start and the ON lamp will light.
7. If you do not want your unit to operate at factory default settings, manually set temperature
setpoints and sensitivity, alarms and other control functions. Refer to the Liebert iCOM manual,
SL-18835, available at the Liebert Web site, www.liebert.com
8. Turn Off the main unit disconnect and main breaker. The unit On button should be Off.
9. Replace all fuses removed during Step 3 (or reset the circuit breakers).
10. Restore electrical power to the unit; turn ON the main unit disconnect switch.
11. Check the current draw on all line voltage components and match with the serial tag.
12. Push the ON button, putting the unit into operation.
13. Check for unusual noises and vibration.
14. Check all water lines for leaks.
15. Test all unit functions for proper operation.
Return the completed startup form to your local Emerson Network Power sales office.
10.1
Additional Considerations for Upflow Units
These units are manufactured with factory-supplied adjustable motor sheaves. Due to variations in
applications, a fixed motor pulley may be desired and can be substituted for the adjustable sheave
after obtaining and confirming the desired airflow. This will reduce vibration and wear on the belts
and pulleys. Consult the factory for more information.
62
Component Operation and Maintenance, Checks and Adjustments
11.0 COMPONENT OPERATION AND MAINTENANCE, CHECKS AND ADJUSTMENTS
11.1
System Testing
! WARNING
Risk of electric shock. Can cause injury or death. Disconnect all local and remote electrical
power supplies before working within the unit.
Potentially lethal voltages exist within this equipment during operation. Observe all cautions
and warnings on unit and in this manual. Failure to do so could result in serious injury or
death. Only qualified service and maintenance personnel should work with this equipment.
11.1.1 Environmental Control Functions
The performance of all control circuits can be tested by actuating each of the main functions. This is
done by temporarily changing the setpoints.
Cooling
To test the cooling function, set the setpoint to a temperature 10°F (5°C) below room temperature. A
call for cooling should be seen and the equipment should begin to cool. A high-temperature alarm may
come on. Disregard it. Return setpoint to the desired temperature.
Proportional Cooling
The Liebert iCOM is capable of responding to changes in room conditions. These systems utilize
either a two or three-way valve activated by a proportioning motor. Refer to the Liebert iCOM user
manual, SL-18835, available at the Liebert Web site, www.liebert.com, for large or small display
operation and settings.
The Liebert iCOM will respond by positioning the valve proportionally to match the needs of the
room. Full travel of the valve takes place within the range of the sensitivity setting.
11.1.2 Electric Panel
The electric panel should be inspected for any loose electrical connections.
! WARNING
Risk of electric shock. Can cause injury or death. Disconnect all local and remote electrical
power supplies before working within the unit.
Be sure that power to the unit is shut down before attempting to tighten any fittings or
connections.
Control Transformer and Fuses
The control system is divided into four (4) separate circuits. Fuses located on the transformer/fuse
board individually protect the control voltage circuits. If any of the fuses are blown, first eliminate
shorts, then use spare fuses supplied with unit. Use only type and size of fuse specified for your unit.
The small isolation transformer on the main control board supplies 24 volts to the electronics. The
transformer is internally protected. If the internal protector opens, the transformer/fuse board must
be replaced. Also check the control voltage fuse on the main control board before replacing the transformer/fuse board.
Fan Safety Switch
For Liebert CW units, the Fan Safety Switch is in the low-voltage compartment and consists of a diaphragm switch and interconnecting tubing to the blower scroll. The Fan Safety switch is wired
directly to the control circuit to deactivate the unit and activate the alarm system if airflow is interrupted.
63
Component Operation and Maintenance, Checks and Adjustments
Firestat
The optional firestat is a bimetal operated sensing device with a Normally Closed switch. This device
will shut down the entire unit when the inlet air temperature exceeds a preset point. It is connected
between terminals 1 and 2 at plug P39.
Smoke Detector
The optional smoke detector power supply is located on the base of the upflow units and at the top of
downflow units. It is constantly sampling return air through a tube. No adjustments are required.
Water Detection Sensor
! WARNING
Risk of fire or explosion. Can cause injury or death.
Do not use near flammable liquids or for flammable liquid detection.
Emerson manufactures a variety of water-detection systems, including point, zone and cable systems.
Follow the instructions supplied with your selected device for proper installation, adjustment and
maintenance.
Remote Shutdown
A connection point is provided for customer-supplied remote shutdown devices. Terminals 37 & 38 on
the terminal strip are jumpered when no remote shutdown device is installed. Refer to the unit’s electrical schematic and the unit’s installation manual.
11.2
Filters
Filters are usually the most neglected item in an environmental control system. To maintain efficient
operation, they should be checked monthly and changed as required. Because replacement intervals
vary with environmental condition and filter type, each unit is equipped with a filter clog switch. This
warns of restricted airflow through the filter compartment by activating the Change Filter alarm.
• Turn power Off before replacing filters.
• Liebert CW filters can be replaced from either end by opening the end doors. On CW089, CW106
and CW114 units, filters can be replaced from the front. Liebert CW models CW146 and CW181
contain filters in a filter plenum that permits removing the filters from the front. Removing the
middle filters will allow you to remove the filters on the end. Install the new end filters first, then
the middle ones.
• Replacement filters are commercially available in several efficiencies. For Liebert CW units, refer
to the technical data manual, SL-18056, or other documentation for filter sizes.
• After replacing the filter(s), test the operation of the filter clog switch. Turn the adjusting screw
counter clockwise to trip the switch—this will energize the Change Filter alarm. To adjust the
switch:
1. With the fan running, set the switch to energize the light with clean filters. The unit panels must
all be in place and closed to accurately find this point.
2. Turn the adjusting knob one turn clockwise, or to the desired filter change point.
64
Component Operation and Maintenance, Checks and Adjustments
11.3
Blower Package—Centrifugal Fans
Periodic checks of the blower package include: belt, motor mounts, fan bearings and impellers.
These units are manufactured with factory-supplied adjustable motor sheaves. Due to variations in
applications, a fixed motor pulley may be desired and can be substituted for the adjustable sheave
after obtaining and confirming the desired airflow. This will reduce vibration and wear on the belts
and pulleys. Consult the factory for more information.
11.3.1 Fan Impellers and Bearings
Fan impellers should be periodically inspected and any debris removed. Check to see if they are
tightly mounted on the fan shaft. Rotate the impellers and make sure they do not rub against the fan
housing.
Bearings used on the units are permanently sealed and self-lubricating. They should be inspected for
signs of wear when belts are adjusted. Shake the pulley and look for movement in the fan shaft. If any
excessive movement is noticed, bearings should be replaced. However, the cause of the wear must be
determined and corrected before returning the unit to operation.
11.3.2 Belts—Except with EC Fans
The drive belt should be checked monthly for signs of wear and proper tension. Pressing in on belts
midway between the sheave and pulley should produce from 1/2" to 1" (12 to 25mm) of movement.
Belts that are too tight can cause excessive bearing wear.
Belt tension is adjusted by raising or lowering the fan motor base. To adjust the motor, loosen (but do
not remove) the four motor mounting bolts. Turn adjustment bolt(s) on motor mounting base to adjust
belt tension or to raise motor to remove belts. Tighten motor bolts after adjustment. If belt appears
cracked or worn, it should be replaced with a matched belt (identically sized). With proper care, a belt
should last several years.
11.3.3 Electronic Variable Speed Drive (Inverter)
On large Liebert CW chilled water models, an optional, variable speed drive inverter is available.
This packaged unit is factory-set and should not require field adjustment. The variable speed drive
saves power by reducing blower speed to match unit load. If you suspect a problem with the inverter,
first make sure that the INTELLIGENT CONTROL method is selected at the microprocessor.
1. Turn off all power to the unit at the disconnect.
2. Open the unit accent panel and electric box cover.
3. Find the main fan motor wires. These are connected to the motor overload relay in the
high-voltage section of the electric box.
a. Mark motor wires to ensure they can be reconnected in the same order.
b. Disconnect motor wires at the load side of the motor overload relay.
c. Close the electric box cover.
4. Remove the right front vertical panel to gain access to the variable speed drive.
5. With the panel removed, restore power to the unit by turning the disconnect on.
6. Place the right front vertical panel back on the unit.
7. Reconnect the motor wires to the overload and close the electric box cover and unit accent panel.
8. Restore power at the disconnect.
11.4
Blower Package—EC Fans
11.4.1 Fan Impellers and Bearings
Fan impellers should be periodically inspected and any debris removed. Check to see if the impellers
can rotate freely and if the fan guards are still properly mounted for sufficient protection against accidentally touching the impeller. Bearings used on the units are maintenance free. Consult the factory
for more information.
65
Component Operation and Maintenance, Checks and Adjustments
11.4.2 Protective Features
Monitoring functions protect the motor against overtemperature of electronics, overtemperature of
motor and incorrect rotor position detection. With any of these failures, an alarm will display through
the Liebert iCOM and the motor stops electronically. There is no automatic restart. The power must
be switched off for a minimum of 20 seconds once the motor is at a standstill.
The motor also provides locked rotor protection, undervoltage/phase failure detection and motor current limitation. These conditions will display an alarm through the Liebert iCOM.
! WARNING
Risk of electric shock. Can cause injury or death. Disconnect all local and remote electrical
power supplies before working within the unit.
When connecting the motor to the mains, dangerous voltages occur. Do not open the motor
within the first 5 minutes after disconnection of all phases.
Dangerous external voltages can be present at main fan terminal KL2 even with the motor
being turned off.
! CAUTION
Risk of hot surfaces. Can cause injury.
Wear thermally insulated gloves and a long-sleeved shirt when touching the electronics
housing or allow time for the housing to cool before replacing parts.
The electronics housing can get hot and can cause severe burns
! CAUTION
Risk of improper moving, lifting and handling. Can cause equipment damage or injury.
Only properly trained and qualified personnel should work on this equipment. Fan modules
weigh in excess of 100 pounds each and may require more than one person or a mechanical
lifting device to raise or lower the fan(s) safely. Use proper lifting techniques and wear
protective clothing, gloves, shoes and head gear to avoid injury and dropping the fan module
during removal.
NOTICE
Risk of improper installation. Can cause equipment damage. Only a properly trained and
qualified technician should install or open this motor.
Use 60/75°C copper wire only. Use Class 1 wires only.
11.5
Humidifier
11.5.1 Infrared Humidifier
During normal humidifier operation, deposits of mineral solids will collect in the humidifier pan and
on the float switch. These must be cleaned periodically to ensure proper operation. Frequency of
cleaning must be locally established because it depends on humidifier usage and local water quality.
A spare pan is recommended to reduce maintenance time at unit. The Liebert autoflush system can
greatly increase the time between cleanings, but does not eliminate the need for periodic checks and
maintenance (see the Liebert iCOM user manual, SL-18835, available at the Liebert Web site,
www.liebert.com, for autoflush setup). To help reduce excessive scaling in locations with difficult
water quality, the use of Vapure is recommended (contact your local Emerson representative).
66
Component Operation and Maintenance, Checks and Adjustments
11.5.2 Cleaning Humidifier Pan and Float Switch
Before turning off unit:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
With the unit operating, remove call for humidification at the Liebert iCOM control.
Let the blower operate 5 minutes to allow the humidifier and water to cool.
If the unit has a condensate pump, turn the unit Off at the Liebert iCOM control.
Pull out the humidifier standpipe in pan.
Inspect the O-ring (replace if necessary).
Let the pan drain and the condensate pump operate (if applicable).
Disconnect power from the unit.
Disconnect the drain coupling from the bottom of the pan.
Remove the thermostat from the bottom of the pan and retaining screws from sides of pan.
Slide pan out.
Loosen scale on the side and bottom of the pan with a stiff nylon brush or plastic scraper.
Flush with water.
Carefully clean the scale from the float switch (make sure to reinstall correctly; see Figure 46).
Reinstall the pan, thermostat, standpipe, drain coupling and screws into the humidifier.
Operate the humidifier and check for leaks.
Figure 46 Correct orientation of float switch
Correct Switch Orientation
Incorrect Switch Orientation
DPN000996
Rev. 0
67
Component Operation and Maintenance, Checks and Adjustments
11.5.3 Changing Humidifier Lamps
NOTE
Touching quartz lamps with bare hands will severely shorten bulb life. Skin oils create hot
spots on lamp surface. Wear clean cotton gloves when handling lamps.
1. Remove the humidifier pan (see 11.5.2 - Cleaning Humidifier Pan and Float Switch, Steps 1
through 10).
2. Disconnect power from the unit.
3. At the humidifier, remove the screws and cover from the high-voltage compartment.
4. Disconnect one end of the purple jumper wires.
5. Using a continuity meter, locate the burned-out lamp.
6. Remove the lamp brackets under the lamps.
7. Loosen the two screws securing the lamp lead wires to the junction block.
8. Pull the bulb straight down and discard it.
9. Wrap the lead wires once around the new lamp’s metal ends. This will support the lamp and allow
for thermal expansion. Insert the lead wires into the junction block and torque the screws to 30
in-lb.
10. Reassemble by reversing Steps 1 through 9.
Figure 9 Infrared humidifier lamps
Infrared Bulbs
11.6
Steam Generating Humidifier
The humidifier drains and refills to maintain a current setpoint and alert the operator when the
humidifier canister needs to be replaced. The humidifier is located in the lower section of upflow
units. In downflow units, the humidifier is in the middle section.
Figure 47 Steam generating humidifier
68
Component Operation and Maintenance, Checks and Adjustments
Operation
NOTE
Numbers and percentages within parentheses in the following paragraphs refer to circuit
board settings for downflow models CW106 and CW114.
1. During startup, when the humidity control calls for humidification, the fill valve opens and allows
water to enter the canister. When the water level reaches the electrodes, current flows and the
water begins to warm. The canister fills until the amperage reaches the setpoint and the fill valve
closes. As the water warms, its conductivity increases and the current flow, in turn, rises. If the
current reaches 115% of the normal operating current, the drain valve opens and drains some of
the water out of the canister. This reduces electrode contact with the water and lowers the
current flow to the amperage setpoint. Boiling soon commences, and the canister operates
normally.
2. If the conductivity of the water is low, the canister fills and the water level reaches the canister
full electrode before the current setpoint is 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 (84)
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 setpoint.
4. After many cycles, 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 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 (usually between 500 and 1500 hours depending on water quality), 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 and
opening the humidifier contactor. At this point, all of the electrode surface has been used up and
the canister must be replaced.
6. After the entire electrode surface has been coated, the output will slowly begin to fall off. This
usually occurs in the last several hours of electrode life and should allow enough time to schedule
maintenance. During these last hours, the mineral concentration can increase. If the mineral
concentration is too high, arcing can occur. If the electrodes start to arc, turn off the humidifier
immediately and replace the canister with the identical part.
Controls
The humidifier RUN/DRAIN switch is located in the unit low-voltage compartment for most models
(in the humidifier assembly for models CW106 and CW114). This switch should be in the RUN position when the humidifier is in normal operation; it should be in the DRAIN position when a manual
drain for service is required. The electronic control board for the humidifier is located in the same
area as the humidifier RUN/DRAIN switch. When the main unit is energized, power is available to
the humidifier circuits.
Figure 48 Run/drain switch
69
Component Operation and Maintenance, Checks and Adjustments
Replacing the Canister
See Step 5 of Operation in 11.6 - Steam Generating Humidifier for indications that a canister
may need to be replaced.
To replace the canister:
1. Turn off the humidifier by lowering the humidity setpoint below the ambient humidity level.
Record the original setpoint.
2. Place the RUN/DRAIN switch in the DRAIN position to drain the water from the canister.
3. Return the RUN/DRAIN switch to the RUN position after the canister has drained.
! WARNING
Risk of humidifier canister meltdown, smoke and fire. Can cause fire suppression system
activation, fire and smoke alarm activation, serious equipment and building damage, injury
and death.
Using a humidifier canister that has reached the end of it’s service life can be extremely
hazardous. If the canister cannot be replaced immediately at the end of life condition, turn Off
the power and water supply to the humidifier and remove the canister until a replacement
canister can be installed.
! WARNING
Risk of electric shock. Can cause injury or death. Disconnect all local and remote electrical
power supplies before working within the unit.
To avoid a shock hazard, all power to the unit must be disconnected before proceeding with
the canister replacement procedure.
! CAUTION
Risk of hot humidifier canister and steam hose. Can cause injury. Allow time for the
humidifier to cool before replacing parts.
4. Turn Off the power at the main unit.
5. Remove the cover from the humidifier cabinet
6. For all models except CW106 and CW114, refer to the replacement instructions that accompany
the replacement kit 153315P1 and P2.
7. For models CW106 and CW114, locate the power wires to the steam canister. Make note of the
wiring configuration before removing any wires. Refer to the schematic on the unit. Slide the
rubber boot back to expose the connections. Remove the three power wires and the canister-full
wires at Terminals 1, 2 and 3. Do not loosen the screws that secure the electrodes.
8. For all models, use a screwdriver to remove the hose clamps that secure the drain and overflow
hoses from the canister ports.
9. Loosen the fill line compression fitting and remove the tube from the input canister port.
10. 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.
11. The canister is now ready to be removed.
On downflow chilled water units: Slide the humidifier cabinet bottom straight out toward you and
drop the canister through the bottom of the cabinet.
On all other units: Pull the canister straight out of the cabinet toward you.
12. Replace the canister with the part indicated in the following table.
Table 5
Humidifier canister part numbers
Capacity
Unit Model
All except below
CW106 CW114
Part Number
Voltage
200-230
153315P2
136799P1
136799P2
380-575*
153315P1
200-480
575
* Note: 575V units have a step-down transformer included with unit.
70
lb/hr
kg/hr
11 or 22
5 or 10
22
22
10
10
Component Operation and Maintenance, Checks and Adjustments
13. Replace the canister by reversing the above procedure. Make special note of the following:
NOTE
When reconnecting the power wiring, follow exactly the instructions included with kit
153315P1 and P2 or the unit electrical schematic with canisters 136799P1 and P2.
When replacing the canister, always check the fill and drain solenoids for proper operation
Table 6
Faults—canister generator humidifier
Priority
Name
LED Indication
Description
1
Over Current
Solid
Humidifier Lockout
2
Fill Valve
2 second flash
Humidifier Lockout
3
End of Life
4 second flash
Humidifier Lockout
4
Fail to Make Capacity
1 second flash
Indicate only
Fault Descriptions
Overcurrent—Operating current exceeds present limit
Fill Valve—Continuously energized valve exceeds preset limit
End of Life—Drain count limit exceeded in a 24-hour period
Fail to Make Capacity—Does not reach operational current within initial 24 hours
Test Points
TP1—Time Cycle Pot
1 VDC = 60 seconds
TP2—Low Drain Pot
3 VDC = 80%
TP3—Capacity Pot
3.5 VDC = 85%
TP5—RT Capacity
1 VDC = 100%
71
Component Operation and Maintenance, Checks and Adjustments
Circuit Board Adjustments
! WARNING
Risk of electric shock. Can cause injury or death. Disconnect all local and remote electrical
power supplies before working within the unit.
Circuit board adjustment should be performed by properly trained and qualified personnel
only. Hazardous voltages are present in the equipment throughout the procedure. Use
extreme caution. If desired, power may be disconnected prior to the procedure.
NOTE
Numbers and percentages within parentheses in the following paragraphs refer to circuit
board settings for downflow models CW106 and CW114.
Humidifier operation is governed by the humidifier control board. This board is located in the lower
right area of the panel in the control section of the unit, or in the humidifier compartment on models
CW106 and CW114. There are two potentiometers mounted on the board. These pots can be used to
adjust for extreme water conductivity conditions and capacity.
The “%” pot controls the amperage at which the drain will energize. The pot is clearly marked in percentages. This adjustment is factory-set, which indicates that the unit will drain when the amperage
falls off of the capacity setpoint. 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 pot marked “SEC” controls the duration of the drain cycle. The pot is clearly marked in seconds.
This adjustment is factory-set at 60 (84) seconds and should not be readjusted without consulting
your Liebert supplier.
Table 7
Steam generating humidifier capacity
60 Hz Models
50 Hz Models
Capacity
lb/hr (kg/hr)
CW026, CW038, CW041
CW026, CW038, CW041
11 (5)
CW051, CW060, CW076,
CW084, CW106, CW114
CW051, CW060, CW076,
CW084, CW106, CW114
22 (10)
! WARNING
Risk of electric shock and slipping hazard from incorrect DIP switch settings. Can cause
injury or death.
The DIP switches must be set exactly as indicated in Table 8. Failure to correctly set the DIP
switches may result in an electrical or water hazard.
The DIP switches are used to set the capacity of the humidifier. These are set at the factory and
should not be changed. Refer to Table 7 for the capacity of your unit. Find your unit voltage and
capacity in Table 8 to determine the correct DIP switch settings for your humidifier. A potentiometer
(R40) is used to regulate the capacity of the humidifier. This adjustment is factory-set fully clockwise
to 100%. It can be used to reduce humidifier capacity, but should never be used to raise the capacity
above the capacity for your model. Turn the adjustment counterclockwise to reduce your capacity. The
minimum setting is approximately 50% of the DIP switch setting.
72
Component Operation and Maintenance, Checks and Adjustments
Figure 49 Steam generating humidifier control board
GT-421 V*.*
Drain Tempering
Shunt
YYDDD
ON OFF
Fault LED
TP6
TP7
DIP Switch
Down (Off), Up (On)
Capacity
Transformer
TP5
TP3
P3
TP2
Low Drain
Microprocessor
P2
TP1
Time Cycle
P1
183116
Rev. 2
Table 8
DIP switch settings for steam generating humidifier
Rated Values
Unit Rated
Voltage
Capacity
SW1
SW2
SW3
SW4
Voltage
AMP Set Pt
200/208
11
Off
On
Off
On
208
12.6
200/208
22
On
Off
On
On
208
23.8
230
11
Off
Off
Off
On
240
10.5
230
22
Off
Off
On
On
240
20.3
380/400/415
11
On
On
Off
Off
400
6.3
380/400/415
22
Off
On
On
On
400
12.6
460
11
On
Off
Off
Off
480
5.5
460
22
Off
Off
Off
On
480
10.5
575*
11
Off
Off
Off
Off
575
4.2
575*
22
Off
On
Off
On
575
9.8
*The values are only suitable in models CW106D and CW114D. All other models use a 575V-to-460V step-down
transformer and therefore use the 460V settings.
73
Component Operation and Maintenance, Checks and Adjustments
11.7
Condensate Drain and Condensate Pump Systems
11.7.1 Condensate Drain
Check and clear obstructions in tubing during routine maintenance.
11.7.2 Condensate Pump
•
•
•
•
•
•
Disconnect power to unit using disconnect switch.
Disconnect power to unit using disconnect switch.
Check and clear obstructions in gravity lines leading to condensate pump.
Remove sump and clean with a stiff nylon brush and flush with water.
Inspect and clear clogs in discharge check valve and float mechanism.
Reassemble and check for leaks.
! WARNING
Risk of electric shock. Can cause injury or death. Disconnect all local and remote electrical
power supplies before working within the unit.
The Liebert iCOM microprocessor does not isolate power from the unit, even in the “Unit Off”
mode. Some internal components require and receive power even during the “unit off” mode of
the Liebert iCOM control.
11.8
Facility Fluid and Piping Maintenance
Facility water and glycol quality remain a requirement throughout the life of the piping system. Fluid
and piping system maintenance schedules must be established and performed. A local fluid maintenance program must be established that will evaluate fluid chemistry and apply necessary treatment.
A periodic leak inspection of facility and unit fluid piping is recommended. Refer to 7.2.1 - Requirements of Systems Using Water or Glycol.
74
Troubleshooting
12.0 TROUBLESHOOTING
! WARNING
Risk of electric shock. Can cause injury or death. Disconnect all local and remote electrical
power supplies before working within the unit.
Only properly trained and qualified personnel should perform service on these units. Lethal
voltage is present in some circuits. Use caution when troubleshooting with power on.
Disconnect and lock out power before replacing components. Use caution and standard
procedures when working with pressurized pipes and tubes.
NOTICE
Risk of improper control circuits. Can cause equipment damage.
When using jumpers for troubleshooting, always remove jumpers when maintenance is
complete. Jumpers left connected could override controls and cause equipment damage.
Table 9
Blower troubleshooting
Symptom
Blower will not start
Possible Cause
Check or Remedy
No main power
Check L1, L2 and L3 for rated voltage.
Blown fuse or tripped circuit
breaker (CB)
Check fuses or CBs to main fan.
Overloads tripped
Push reset button on main fan overload. Check amp. draw.
No output voltage from
transformer
Check for 24 VAC between P24-2 and P24-1. If no voltage,
check primary voltage.
Control fuse blown or circuit
breaker tripped
Check for 24 VAC between P4-4 and E1. If no voltage,
check for short. Replace fuse or reset circuit breaker.
Check for 24 VAC between P36-9 and P36-10. If voltage is
not present, R1 is not receiving power.
Blower runs but controls
will not operate
Check air switch. Jumper P36-4 to P36-7 If R1 closes, air
switch is not closing (check for blower rotation, loose wiring
and pinched tubing.) Remove jumper.
Relay R1 not making contact
(standard controls only)
Check for 24 VAC at R1 coil. If the voltage is present and R1
is not pulling, replace R1.
Table 10
Chilled water troubleshooting
Symptom
Possible Causes
Check or Remedy
Actuator Motors
No 24 VAC power to motor
Check for 24 VAC between P22-3 and P22-5 (open), or
P22-1 and P22-5 (closed).
Chilled water or hot
water/steam valve not
opening
Motor operates but valve won’t
open
Check linkage for adjustment and be sure that it is tight on
the valve.
No 24 VAC power to motor
Check linkage for adjustment and be sure that it is tight on
the valve.
No signal from control
Check DC voltage on printed circuit board in motor. Terminal
No. 1 is grounded and No. 3 is positive. DC voltage should
vary from 0.8 to 2.0 VDC or above as temperature control is
varied below room temperature on cooling valve or above
room temperature on heating valve.
Motor not working
Remove wires on terminal No. 1 and No. 3 from the motor
(do not short). With 24 VAC power from TR to TR jumper
terminal 1 and 2 on motor to drive open. Remove jumper to
drive closed, if motor fails to work, replace it.
Modulating Motors
75
Troubleshooting
Table 11
Humidifier—steam generator troubleshooting
Symptom
False canister full
indication
Main 24 VAC fuse or
circuit breaker trips
Possible Cause
Check or Remedy
Check drain valve to ensure that it drains freely. Check
and replace if defective.
Foaming
Check water supply. If commercially softened,
reconnect to raw water supply. If connected to hot
water reconnect to cold water.
Shorts or loose connections
Check the wiring connections of the 24 VAC circuit.
Faulty circuit board
Replace the circuit board.
Verify that RUN/DRAIN switch is in the RUN position.
Unit ON, humidifier will
not operate
Contactor pulled in, but
no water enters
canister
Water enters canister,
but canister full circuit
activates at a low water
level
Check fuses or CBs and replace or reset if necessary.
Humidifier not receiving power
Make sure molex connector is securely plugged into
circuit board and that no wires art loose.
No water available to unit
Check external shut-off valves.
Clogged fill line strainer
Clean or replace fill line strainer.
Wiring breaks or loose connections
Check for faulty wiring and loose connections.
Faulty circuit board
Replace circuit board.
Foaming
Check drain valve and water supply.
Canister interface connections
incorrect
Check connection on component plate in humidifier
cabinet Terminal #1 on the square block interface
device must be connected to L2 of the power terminal
block. L2 must also be connected to the electrode
closest to the steam outlet port.
Verify that the red wire from terminal #2 on the
interface connects to the red top terminal on the
canister. This is the one farthest from the steam outlet
port and is the high-water sensor probe.
Full isolation has broken down
Remove red canister full wire from canister. If normal
operation resumes, canister must be replaced.
Remove the wire from terminal #3 on the interface. If
normal operation resumes, canister full interface must
be replaced.
Drain assembly not operating freely
Check and replace coil or valve if necessary.
Faulty circuit board
Replace circuit board
Canister full circuit does not activate
Check wiring of canister full interface. Replace circuit
board.
Cylinder full. Interface activated.
See similar symptoms above. Canister expired.
Replace canister.
Problem with fill water system
Water supply is not on. Fill valve problem. Drain valve
stuck open.
Humidifier amps reached 138% of full
load
Canister expired. Replace canister. DIP switch
settings changed with water in canister. Drain canister,
call Emerson Network Power Liebert Services.
Humidifier fill valve stuck open; check valve. Water
conductivity too high; check water conductivity/quality.
Contact Liebert Services.
DIP switches set incorrectly. Refer to Circuit Board
Adjustments on page 72
Mineral deposits obstruct drain valve
Check drain valve for obstructions and clean if
necessary.
Water enters canister,
but canister full circuit
activates at a low water
level
Canister fills but
overflows
Humidifier contactor is
not pulled in (to reset,
de-energize control
unit)
Red LED on humidifier
control board is on.
Humidifier contactor not
pulled in (to reset, deenergize control circuit)
Faulty solenoid
Check for magnetic field at coil.
Faulty circuit board
Replace circuit board.
76
Troubleshooting
Table 11
Humidifier—steam generator troubleshooting (continued)
Symptom
Excessive arcing in the
canister
On cold startup,
canister fills, high-water
alarm activates and
humidifier fails to reach
full amperage after 24
hours
Table 12
Possible Cause
Check or Remedy
Drain valve clogged or defective
Verify that drain valve operates freely when activated.
Clean valve and replace coil or valve if defective.
Flush canister several times and replace if arcing
persists
Improper water supply
If water is commercially softened, reconnect humidifier
to raw water supply, drain canister and restart. If
connected to hot supply, reconnect to cold water.
Insufficient drain rate
Increase drain rate by adjusting % pot on circuit board
above the preset 87% (85%) to roughly 92% (90%).
Excessive iron content in water
Analyze iron cement of water. If it exceeds 0.1 mg/l,
install a filter to remove iron from water supply.
Conductivity of water too low
Turn the % pot to roughly 82% (80%). Restart
humidifier. If canister fails to reach FLA in 24 hours,
have water supply conductivity checked.
Fill solenoid not closing tightly
If humidifier returns to canister full condition, verity that
the fill solenoid closes tightly.
Humidifier—infrared troubleshooting
Symptom
Possible Cause
Check or Remedy
Check water supply.
Check fill valve operation
Humidifier pan not filling
Check drain stand pipe adjustment
Check for clogged waterline
Control not calling for humidity
Check monitor status
No humidification
Check visually. If contact is made, check line voltage
after contactor and fuses or CBs.
Humidity contact not pulling in
Check for open humidifier safety stat. Jumper between
terminals P35-6 and P35-5. If contactor pulls in,
replace safety. Remove jumper.
Replace bulb. Loosen lead on old bulb. Trim excess
lead length on new bulb to avoid shorts.
Humidifier bulb burned out
Table 13
Reheat troubleshooting
Symptom
Reheat will not operate;
contactor not pulling in
Reheat not operating,
contactor pulling in
Possible Cause
Check or Remedy
Control not calling for heat
Check monitor status.
Reheat safety stat open
Jumper between terminals P34-1 and P34-2. If reheat
operates, safety is open. Remove jumper. Replace
safety.
Heater burned out
Turn off power and check heater continuity with Ohm
meter.
77
HVAC Maintenance Checklist
13.0 HVAC MAINTENANCE CHECKLIST
Inspection Date
Job Name
Indoor Unit Model #
Indoor Unit Serial Number #
Room Temperature/Humidity
°
%
Ambient Temperature
Filters
___ 1. Check/replace filters
___ 2. Grille area unrestricted
___ 3. Wipe section clean
___ 4. Coil clean
Blower Section
___ 1. Blower wheels free of debris
___ 2. Check belt tension and condition on centrifugal blower units (replace if needed)
___ 3. Check bearings
___ 4. Check sheave/pulley on centrifugal blower units (replace if worn)
___ 5. Check motor mount
___ 6. Motor amp draw
L1__________________ L2 __________________ L3______________
____ Compare to nameplate amps
Reheat
___ 1. Inspect elements
___ 2. Check wire connections (inside reheat box)
___ 3. Reheat amp draw
___ a. #1
___ a. #2
___ a. #3
Steam Generating Humidifier
___ 1. Check drain valve/drain lines/trap for clogs
___ 2. Check water make-up valve and all hoses for leaks
___ 3. Clean strainer
___ 4. Replace humidifier bottle if necessary
___ 5. Check operation of humidifier
___ 6. Humidifier amp draw
L1 ______________ L2 _______________L3__________________
Infrared Humidifier
___ 1. Check drain lines and trap for clogs
___ 2. Check/clean pan for mineral deposits
___ 3. Clean reflector
___ 4. Check water make-up valve for leaks
___ 5. Check humidifier lamps (replace if burnt out)
___ 6. Check wire connections (inside humidifier box)
___ 7. Humidifier amp draw
L1 ______________ L2 _______________L3__________________
78
°
HVAC Maintenance Checklist
Drain Piping
___ 1. Check for free running drain system
___ 2. Clear out obstructions and material buildup on tubing walls
___ 3. Check for leaks
___ 4. Check for tubing kinks or damage
Condensate Pump
___ 1. Check for debris in sump
___ 2. Check operation of float(s) (free movement)
Electrical Panel
___ 1. Check fuses
___ 2. Check contactors for pitting
___ 3. Check wire connections
Controls
___ 1. Check/Verify Control Operation (Sequence)
___ 2. Check humidifier high-water alarm operation
___ 3. Check operation of the air safety switch
___ 4. Check setting/operation of the filter clog switch
___ 5. Check/test changeover device(s)
___ 6. Check/test water detection device(s)
Notes _______________________________________________________________________________________
____________________________________________________________________________________________
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____________________________________________________________________________________________
____________________________________________________________________________________________
____________________________________________________________________________________________
____________________________________________________________________________________________
____________________________________________________________________________________________
____________________________________________________________________________________________
____________________________________________________________________________________________
____________________________________________________________________________________________
____________________________________________________________________________________________
____________________________________________________________________________________________
____________________________________________________________________________________________
____________________________________________________________________________________________
____________________________________________________________________________________________
Signature ___________________________________________________________________________________
Company ____________________________________________________________________________________
Make photocopies for your records. Compare readings / information to previous maintenance worksheet. To locate your local Emerson representative for Liebert-engineered parts, check the Liebert
Web site: www.liebert.com or call 1-800-LIEBERT.
79
HVAC Maintenance Checklist
NOTES
80
COMPLIANCE WITH EUROPEAN UNION DIRECTIVES
Liebert Corporation
1050 Dearborn Drive
P.O. Box 29186
Columbus, OH 43229
USA
Il Produttore dichiara che, se munito di marchio CE, il prodotto è conforme alle direttive dell'Unione europea:
The Manufacturer hereby declares that this product, when bearing the CE mark, conforms to the European Union directives:
Der Hersteller erklärt hiermit, dass das vorliegende Produkt, sollte es die CE‐Kennzeichnung tragen, den folgenden Richtlinien der Europäischen Union entspricht:
Le fabricant déclare par la présente que ce produit, portant la marque CE, est conforme aux directives de l'Union européenne :
El fabricante declara por la presente que si este producto lleva el marcado CE es conforme con las directivas de la Unión Europea:
O fabricante declara por este meio que este produto, quando ostenta a marca CE, está em conformidade com as directivas da União Europeia:
Tillverkaren tillkännager härmed att den här produkten, när den är CE‐märkt, överensstämmer med EU:s direktiv:
De fabrikant verklaart hierbij dat dit product, indien het van de CE‐markering is voorzien, conform de EU‐richtlijnen is:
Valmistaja vakuuttaa täten, että mikäli tuotteessa on CE‐merkintä, se täyttää seuraavien EU‐direktiivien vaatimukset:
Produsenten erklærer herved at dette produktet, når det er CE‐merket, er i samsvar med EU‐direktiver:
Producenten erklærer hermed, at dette produkt overholder EU's direktiver, når det bærer CE‐mærket:
Ο Κατασκευαστής δηλώνει ότι το προϊόν αυτό, το οποίο φέρει σήμανση CE, είναι σύμμορφο με τις οδηγίες της Ε.Ε.:
2006/42/EC; 2004/108/EC; 2006/95/EC; 97/23/EC
Ensuring The High Availability
Of Mission-Critical Data And Applications.
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continuity, ensures network resiliency and adaptability through
a family of technologies—including Liebert power and cooling
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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.
Technical Support / Service
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