DataMate - Alpine Power Systems

DataMate - Alpine Power Systems
HEAT REMOVAL/PRECISION AIR
DataMate
USER MANUAL FOR REV 3 MODELS
1.5 - 3 Tons
50 & 60 Hz
TABLE OF CONTENTS
1.0
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.1
Product Description and Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1.1
1.1.2
1.1.3
1.1.4
1.2
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Evaporator Components and Air Distribution System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Condensing Components Air Cooled Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Water/Glycol Condensing Units—2 and 3 Ton Only. . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
2
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2.1
1.2.2
1.2.3
1.2.4
1.2.5
1.2.6
Humidifier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Condensate Pump Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pre-Charged Refrigerant Line Sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refrigerant Line Sweat Adapter Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
277-Volt Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Monitoring and Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
2
2
2
2
2
2.0
SITE PREPARATION AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
2.1
Installation Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1.1
2.1.2
2.1.3
DataMate Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Room Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Location Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2
Application Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3
Equipment Inspection (Upon Receipt) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.4
Installing the Evaporator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.4.1
2.4.2
2.4.3
2.4.4
2.5
Outdoor Air Cooled Condensing Unit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.5.1
2.5.2
2.5.3
2.6
Lifting the Units Into Place . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Centrifugal Fan Condensing Unit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.7.1
2.7.2
2.7.3
2.7.4
2.8
Location Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Piping Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Installing Ceiling Condensing Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.6.1
2.7
Changing Air Flow Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Piping Connections and Cooling Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Condensate Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Location Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piping Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ducting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18
18
18
18
Water and Glycol Cooled Condensing Unit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.8.1
2.8.2
2.8.3
Location Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Piping Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Electrical Connections.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
i
2.9
Integral Water/Glycol Condensing Unit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.9.1
2.9.2
2.9.3
Location Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Piping Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.10
Checklist for Completing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.0
MICROPROCESSOR CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.1
Feature Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.2
Main Menu <Menu>. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.3
Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.4
Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.5
Active Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.6
Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.7
Date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.8
Setback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.9
Setup Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.9.1
3.9.2
3.9.3
Restart Time Delay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
C/F Degrees. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Humidity Control Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.10
Change Passwords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.11
Calibrate Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.12
Alarm Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.13
Alarm Time Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.14
Common Alarm Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.15
Custom Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.16
Custom Text . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.17
Run Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.0
SYSTEM PERFORMANCE, MICROPROCESSOR CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.1
Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.1.1
4.1.2
4.1.3
4.2
Humidity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.2.1
4.2.2
4.2.3
4.3
Cooling/Heating Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Cooling Operation (Compressorized Direct Expansion and Chilled Water) . . . . . . . . . . . . . . 42
Heating Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Dehumidification/Humidification Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Dehumidification Operation, Compressorized Direct Expansion (DX) Systems . . . . . . . . . . 42
Humidification Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Load Control Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.3.1
Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
ii
5.0
ALARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.1
Alarms: Definitions and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.1.1
5.1.2
5.1.3
5.1.4
5.1.5
5.1.6
5.2
Custom Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Head Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Humidity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loss of Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Short Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
44
44
45
45
45
45
Optional/Custom Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.2.1
Loss of Water Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.0
SYSTEM TESTING AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
6.1
System Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
6.1.1
6.1.2
6.1.3
6.1.4
6.1.5
6.1.6
6.2
Environmental Control Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Humidification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dehumidification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Shutdown. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
46
46
46
46
46
46
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
6.2.1
6.2.2
6.2.3
6.2.4
6.2.5
Electric Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Direct Drive Blower Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Humidifier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
46
46
47
47
51
7.0
MAINTENANCE INSPECTION CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
8.0
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
iii
FIGURES
Figure 1
Figure 2
Figure 3
Figure 4
Figure 5
Figure 6
Figure 7
Figure 8
Figure 9
Figure 10
Figure 11
Figure 12
Figure 13
Figure 14
Figure 15
Figure 16
Figure 17
Figure 18
Figure 19
Figure 20
Figure 21
Figure 22
DataMate configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Proper room location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Removing the front panel and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Unit, floor cutout dimensional data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Evaporator piping connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Evaporator unit electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Optional condensate pump (field installed). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Outdoor air cooled condensing units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Above the ceiling mounting bracket detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Centrifugal condensing unit dimensions and pipe connections (2 and 3 ton) . . . . . . . . . . . . . . . . 19
Centrifugal condensing unit electrical connections (2 and 3 ton) . . . . . . . . . . . . . . . . . . . . . . . . . 20
General arrangement drawing, chilled water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
General arrangement drawing, water/glycol cooled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
General arrangement drawing, air cooled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Water and glycol cooled condensing units: dimensions and pipe connections (2 and 3 ton). . . . . 25
Water and glycol cooled condensing units: electrical connections (2 and 3 ton) . . . . . . . . . . . . . . 26
Integral water/glycol unit dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Integral water/glycol condensing unit connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Wall box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Control menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Control board (inside evaporator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Wall box board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
TABLES
Table i
Table ii
Table 1
Table 2
Table 3
Table 4
Table 5
Table 6
Table 7
Table 8
Table 9
Table 10
Table 11
Table 12
Table 13
Table 14
Table 15
Table 16
Table 17
Table 18
Table 19
Table 20
Table 21
Table 22
System configurations, 60 Hz. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
System configurations, 50 Hz. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
Application limits, evaporator and chilled-water units* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Application limits, indoor and outdoor air-cooled condensing units . . . . . . . . . . . . . . . . . . . . . . . . 3
Application limits, indoor water/glycol-cooled condensing units . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Evaporator and condensing unit net weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Fan/coil and chilled water module dimensional data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Unit refrigerant charges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Torque values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Typical refrigerant pressures (psig) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Line set refrigerant charges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Unit piping outlet connection sizes — pipe size in. (mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Outdoor air cooled condensing units dimensional data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Air flow – CFM (l/s). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Centrifugal condensing unit dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Default setpoints and allowable ranges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Night and weekend setback plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Setup functions, default values and allowable ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Alarm default time delays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Equipment Switch Settings (Unit Control Board) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Switch settings (wall box board) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Cooling and dehumidification load response of hot gas bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Typical discharge pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
iv
PRODUCT MODEL INFORMATION
DataMate Evaporators—DME027E-PH3
DME
DataMate Evaporator
MC
020E = 1.5-ton Evaporator
P
MiniMate2 Indoor Condensing Unit
0 = No Disconnect
D
027E = 2-ton Evaporator
027E
Indoor Condensing Units—MCD26W2A00
D = Disconnect
037E = 3-ton Evaporator
23A = 2-ton air-cooled condensing unit (50 Hz)
044C = 3-ton Chilled Water Unit
24A = 2-ton air-cooled condensing unit (60 Hz)
- = Place Holder (air cooled)
35A = 3-ton air-cooled condensing unit (50 Hz)
P = 208/230V, 1 ph, 60 Hz
36A = 3-ton air-cooled condensing unit (60 Hz)
26W
Y = 208/230V, 3 ph, 60 Hz
25W = 2-ton water/glycol condensing unit (50 Hz)
W = 200/230V, 1 ph, 50 Hz
26W = 2-ton water/glycol condensing unit (60 Hz)
H = With Humidifier and Reheat
37W = 3-ton water/glycol condensing unit (50 Hz)
H
C = Cooling Only
38W = 3-ton water/glycol condensing unit (60 Hz)
0 = With Reheat
L = Lee-temp Head Pressure Control (Air Cooled)
3
3 = Product Revision Level
2 = 2-way, water/glycol reg valve, 150 psi
L
3 = 3-way, Water/Glycol reg valve, 150 psi
D = 2-way, water/glycol reg valve, 350 psi
Prop Fan Condensing Units
PFC018A-PL0 (example)
PF
C
T = 3-way, water/glycol reg valve, 350 psi
Prop Fan Condensing Unit
P = 208/230V, 1 ph, 60 Hz
C = Standard Condensing Unit
X = 277V, 1 ph, 60 Hz
H = Hot Gas Bypass
S = 220/240V, 1 ph, 50 Hz
020A = 1.5-ton Condensing Unit
18A
-
A = 460V, 3 ph, 60 Hz
027A = 2-ton Condensing Unit
Y = 208/230V, 3 ph, 60 Hz
037A = 3-ton Condensing Unit
M=380/415V, 3 ph, 50 Hz
- = Standard Coil
0=No Hot Gas Bypass
H
C = Coated Coil
P = 208/230V, 1 ph, 60 Hz
P
A
H=Hot Gas Bypass
0
0=Revision Level
S = 220/240V, 1 ph, 60 Hz
Y = 208/230V, 3 ph, 60 Hz*
*Y available only in 3 ton
L = 95°F Ambient, Lee-temp
L
H = High Ambient
0
0 = Revision Level
Table iii
System configurations, 60 Hz
Condensing Unit
Nominal
Capacity
1-1/2 tons
2 tons
3 tons
Table iv
Evaporator
DME020E
DME027E
DME037E
DME044C
Indoor
Centrifugal
N/A
MCD24A
MCD37A
Outdoor
Prop Fan
Remote
Water/Glycol
Integral
Water/Glycol
PFC020A
N/A
PFC027A
MCD26W
PFC037A
MCD38W
Self-Contained Chiller Water
DMC022WG
DMC029WG
DMC040WG
System configurations, 50 Hz
Condensing Unit
Nominal
Capacity
1-1/2 tons
2 tons
3 tons
Evaporator
DME020E
DME027E
DME037E
DME044C
Indoor
Centrifugal
Outdoor
Prop Fan
N/A
MCD23A
MCD36A
Remote
Water/Glycol
PFC019A
N/A
PFC026A
MCD25W
PFC036A
MCD37W
Self-Contained Chiller Water
v
Integral
Water/Glycol
DMC022WG
DMC029WG
DMC040WG
vi
Introduction
1.0
INTRODUCTION
1.1
Product Description and Features
The DataMate is a temperature/humidity control system with a nominal rating of 1.5, 2 and 3 tons.
Actual capacity will depend on selected options. Each DataMate consists of an indoor evaporator module and a condensing module. The evaporator is installed against a wall inside the computer room.
Models are available in air, water, glycol or integral water/glycol cooled condensing units. DataMate
is also available as a self-contained chilled water unit, complete with fan/coil and chilled water valve.
The system may also include an optional humidifier. Models are available for cooling only that do not
include reheat or humidifier.
The DataMate system includes one stage of cooling for temperature control as well as an optional single-stage electric reheat. The optional humidity control uses one stage to dehumidify and an optional
stage to humidify. The system controller automatically switches over to the required function (cool/
heat, dehumidify/humidify) based on programmed setpoints and room conditions.
1.1.1
Controls
The DataMate evaporator module includes a wall-mounted control panel. The control panel includes a
liquid crystal display (LCD) screen and a membrane key pad with 8 selector switches. The display
indicates temperature, humidity, system operating status, setpoints and alarms. Use the selector
switches (pads) to operate the system by adjusting control setpoints for cool/heat, dehumidify/humidify and alarm setpoints.
All control setpoints and alarm setpoints are programmable. The temperature can be displayed in
degrees Fahrenheit or degrees Celsius. The microprocessor can retain a programmed schedule of two
control changes per day for the entire seven-day week. The program is stored in nonvolatile memory,
so it will not be lost during a power failure.
1.1.2
Evaporator Components and Air Distribution System
All DataMate evaporator sections include the evaporator coil, the thermostatic expansion valve, filter
dryer and blower. A reheat assembly and a steam generating humidifier are available as options. The
evaporator unit requires a power source and a power disconnect switch.
The evaporator coil is constructed of copper tubes and aluminum fins and is designed for the high sensible heat ratio required for electronic equipment. Room air circulation is accomplished by doubleinlet, direct-drive centrifugal blowers that have been dynamically balanced. The blower motor has
self-aligning bearings and lifetime lubrication. Two air delivery rates (high and low) are specified for
each unit. The system pulls room air through a return grille at the bottom and delivers conditioned
air from the top grille. Cleanable filter(s) are accessible by unscrewing the quarter-turn fasteners on
the front panel.
1.1.3
Condensing Components Air Cooled Systems
Two different air cooled systems are available: the ceiling-mounted indoor centrifugal fan condensing
unit and the outdoor propeller fan condensing unit.
• The centrifugal fan condensing unit (available in 2 and 3 ton only) is for indoor locations and
includes the scroll compressor with crankcase heater, high-pressure switch, condenser coil and
blower system. Pressure is regulated by the Lee-Temp flood back head pressure control.
• The propeller fan unit is for outdoor locations and includes the scroll compressor with crankcase
heater, high-pressure switch, condenser coil, propeller fan and Lee-Temp flood back head pressure control.
1
Introduction
1.1.4
Remote Water/Glycol Condensing Units—2 and 3 Ton Only
The ceiling-mounted condensing unit for water/glycol-cooled models includes the scroll compressor,
coaxial condenser coil and water regulating valve. The standard design pressure is 150 psig.
Integral Water/Glycol-Cooled Models
This unit consists of the reciprocating compressor, brazed plate condenser and water regulating valve.
The design pressure is 150 psig. The unit is designed solely for indoor use and is attached directly to
the left end of the evaporator. No precharged refrigerant lines are required for this unit.
Chilled Water Model (3 ton only)
The Chilled Water model is designed for use with an existing chilled water loop. It contains a chilled
water coil and an on/off valve to control the flow of chilled water.
1.2
Optional Equipment
1.2.1
Humidifier
The optional steam-generating humidifier is factory-installed and tested. It adds pure water vapor
(up to 3 lb/hr) to the room air to control humidity within levels recommended for computer equipment.
The humidifier components include the steam canister with automatic flushing circuit, strainer, inlet
tube, drain, solenoid valve and copper discharge nozzle. Note that humidity control (humidification
and dehumidification) is available only if a humidifier is provided.
1.2.2
Condensate Pump Kit
A condensate pump is required when the evaporator is installed below the level of the gravity-fed
drain line. Components include the pump, check valve, sump, level sensor and controls. The pump is
automatically controlled by the water level in the sump. The condensate pump kit is field-installed in
the evaporator housing.
1.2.3
Pre-Charged Refrigerant Line Sets
The remote condensing unit requires two refrigerant lines to connect the evaporator to the condensing
unit. Factory precharged line sets, with quick connect fittings, are available in 15 and 30 foot lengths.
Each set includes an insulated copper suction line and a copper liquid line, both charged with R-22
refrigerant and sealed.
1.2.4
Refrigerant Line Sweat Adapter Kit
This kit includes the compatible fittings required (two for the insulated suction line and two for the
liquid line) when using field-supplied interconnecting refrigerant lines, instead of the pre-charged
line sets.
1.2.5
277-Volt Transformer
When the evaporator requires 277 volts, one transformer is required for the evaporator. A transformer may also be required if the condensing unit is not rated for 277 volts. See unit serial tag to
determine voltage required. The integral water/glycol-cooled units require only one transformer to
power the entire system. 1-1/2 and 2 ton systems use the 37.5 amp transformer; 3 ton systems use a
50 amp transformer.
1.2.6
Remote Monitoring and Control
Liebert can provide a variety of remote monitoring and control devices to enhance your DataMate system. These include water detection, remote monitoring of a single unit, remote control of multiple
units and remote monitoring and control of a complete building system, including security access control.
2
Site Preparation and Installation
2.0
SITE PREPARATION AND INSTALLATION
2.1
Installation Considerations
NOTE
Before installing unit, determine whether any building alterations are required to run piping,
wiring and duct work. Carefully follow all unit dimensional drawings and refer to the
submittal engineering dimensional drawings of individual units for proper clearances.
The system can be installed in any of several ways. However, the evaporator should always be
mounted on a wall in the equipment room. The condensing unit can be mounted above the ceiling,
underneath a raised floor, in another room or outside. The condensing unit for the integral water/glycol units is attached directly to the evaporator.
2.1.1
DataMate Configurations
Air-cooled models may utilize an indoor centrifugal fan condensing unit if an outdoor location is
impractical. The indoor condensing unit may be located near the evaporator to minimize refrigerant
piping or near the outside wall to minimize air duct work.
Air-cooled models may also use an outdoor condensing unit, which can be mounted on either the roof
or the ground.
Water and glycol-cooled models utilize condensing units that can be located above the ceiling or under
a raised floor.
The integral water/glycol model condensing unit attaches directly to the left end of the evaporator and
requires no pre-charged refrigerant lines. It must be connected to an electric source and a water or
glycol loop.
Table 1
Application limits, evaporator and chilled-water units*
Input Voltage
Range of Return Air Conditions to Unit
Min
Max
Dry Bulb Temp.
Relative Humidity
-5%
+10%
65°F to 85°F
(18°C to 29°C)
20% to 80%
*Unit will operate at these conditions but will not control to these extremes.
Table 2
Application limits, indoor and outdoor air-cooled condensing units
Input
Voltage
Entering Dry Bulb
Air Temperature
Min
Max
-5%
+10%
Table 3
Condensing Units
Min
Max
Outdoor Prop Fan Condensing Unit
-30°F (-34°C)
120°F (49°C)
Indoor Air-Cooled Centrifugal Condensing Unit
-20°F (-29°C)
115°F (46°C)
Application limits, indoor water/glycol-cooled condensing units
Input Voltage
Entering Fluid Temperature
Min
Max
Min
Max
-5%
+10%
65°F (18.3°C) *
115°F (46°C)
*Operation below 65°F (18°C) may result in reduced valve life and fluid noise.
3
Site Preparation and Installation
Figure 1
DataMate configurations
¨
Liebert
¨
Liebert
¨
Liebert
¨
Liebert
¨
Liebert
2.1.2
Room Preparation
The room should be well insulated and must have a sealed vapor barrier. The vapor barrier in the
ceiling and walls can be a polyethylene type film. Paint on concrete walls or floors should be vapor
resistant.
NOTE
The single most important requirement for maintaining environmental control in the
conditioned room is the vapor barrier.
Outside or fresh air should be kept to a minimum. Outside air adds to the heating, cooling, humidifying and dehumidifying loads of the site. It is recommended that outside air be kept below 5% of the
total air circulated in the computer room. Doors should be properly sealed to minimize leaks and
should not contain grilles.
2.1.3
Location Considerations
!
CAUTION
Units contain water. Water leaks can cause damage to sensitive equipment below. DO NOT
MOUNT UNITS OVER SENSITIVE EQUIPMENT. A field-supplied pan with drain must be
installed beneath cooling units and water/glycol-cooled condensing unit.
NOTE
Do not mount units in areas where normal unit operating sound may disturb the working
environment.
Try to locate the evaporator in an unobstructed floor space to facilitate service. Avoid locations in confined areas that affect the air flow pattern and result in short cooling cycles, downdrafts and air noise.
Avoid locating the unit in an alcove or at the extreme end of a long, narrow room. Avoid installing
multiple units close to each other. This can result in crossing air patterns, uneven loads and competing operating modes. Do not attach additional devices (such as smoke detectors, etc.) to the cabinet
that will interfere with routine maintenance or service.
4
Site Preparation and Installation
Figure 2
Proper room location
Recommended
Location
NOT
Recommended
2.2
Application Weights
WARNING
!
Follow all unit dimensional drawings carefully. determine whether any building alterations
are required to run piping, wiring and duct work. Also refer to the submittal engineering
dimensional drawings of individual units for clearances.
Table 4
Evaporator and condensing unit net weights
Model Number
lb
kg
DME020E
230
104
DME027E
330
150
DME037E
365
166
DME044E
365
166
Evaporator Section
Outdoor, Propeller Fan Condensing Unit
PFC020A
200
91
PFC027A
200
91
PFC037A
241
109
Indoor, Centrifugal Fan Condensing Unit
MCD24A
230
104
MCD36A
240
109
Water/Glycol Cooled Condensing Unit
MCD26W
175
79
MCD38W
190
86
Piggyback Water/Glycol Condensing Unit
DMC022WG
170
77
DMC029WG
170
77
DMC040WG
175
78
5
Site Preparation and Installation
2.3
Equipment Inspection (Upon Receipt)
When the DataMate arrives, inspect all items for any visible damage. Do not accept a damaged unit
from the shipper!
If possible, do not uncrate equipment until it is close to its final location. All required assemblies are
banded and shipped in corrugated containers. If you discover any damage when you uncrate the unit,
report it to the shipper and to your Liebert supplier immediately.
2.4
Installing the Evaporator
Unlatch the front cabinet door and remove the screws that secure the cabinet to the chassis. Lift off
the cabinet. Eight keyholes (.50 in. head, .22 in. slot) are provided on the back of the unit for mounting
on the wall. The unit must be level.
NOTE
Make sure the wall can support the full weight of the unit.
2.4.1
Changing Air Flow Direction
The air discharge grille on the evaporator can be placed in one of three different positions: vertical,
horizontal or 45°.
To change the air flow direction:
1.
2.
3.
4.
5.
6.
Figure 3
Remove the front panel using quarter turn fasteners.
Remove the cabinet by removing the four retaining screws. Lift off the cabinet.
Remove the left end panel.
Remove the grille by sliding it to the left end of the unit.
The grille can be inverted or rotated to select the desired air discharge direction.
After the desired air flow direction has been set, reverse Steps 1 through 4 above.
Removing the front panel and cover
Two Grille
Retaining Screws
Quarter-Turn
Fastener
Quarter-Turn
Fastener
Four Cabinet
Retaining Screws
6
Site Preparation and Installation
Figure 4
Unit, floor cutout dimensional data
GRILLES ARE REVERSIBLE
TO ALLOW AIR DIRECTION CHANGES
AS SHOWN BY THE ARROWS.
Air Outlet
A
Removable Access
Panel
SHADED AREAS INDICATE A
RECOMMENDED CLEARANCE OF 34"
(864mm) IN THE FRONT OF THE UNIT.
Air Inlet
32 "
(813mm)
Standard Refrigeration
and Chilled Water
Piping Opening
5/8"
(16mm)
3 1/2"
(89mm)
A
FLOOR CUTOUT DIMENSIONS
CABINET
OUTLINE
10 7/8"
(276mm)
1/2" (13mm) Dia. Hole for
Wallbox Temperature &
Humidity Control Wiring
1"
(25mm)
Knockouts for customer low and
high voltage connections
3.62
92mm
5.88
149mm
31.88
810mm
5.88
149mm
5.88
149mm
31.23
793mm
6.00
152mm
B
.62
16mm
Table 5
.62
16mm
C
3.50
89mm
LAYOUT FOR KEYHOLE SLOTS
7.25
184mm
Fan/coil and chilled water module dimensional data
Dimensional Data, In. (mm)
MODEL
A
B
C
Shipping weight
lbs. (kg)
DME020E
DME027E
DME037E
DME044C
46-1/2 (1181)
64-1/8 (1628)
64-1/8 (1628)
64-1/8 (1628)
33-3/4 (857)
51-1/2 (1308)
51-1/2 (1308)
51-1/2 (1308)
34-7/16 (874)
52-3/16 (1325)
52-3/16 (1325)
52-3/16 (1325)
230 (104)
330 (150)
365 (165)
365 (165)
7
4.75
121mm
Drain and Humidifier
piping and alternate
electrical knockouts
Site Preparation and Installation
2.4.2
Piping Connections and Cooling Requirements
The following pipe connections are required (refer to Figure 5):
• A drain line from the evaporator coil drain pan
• A drain line from the optional humidifier (if applicable)
• A drain line from the optional condensate pump (if required for this installation) (Refer to
Figure 7)
• A water supply line to the optional humidifier (if applicable)
• Connections between the evaporator unit and the appropriate loop (water, glycol or refrigerant to
condensing unit
NOTE
During start-up, inspect for leaks at all piping connections
Evaporator Coil Drain Line
A 3/4 in. (19mm) O.D. connection is provided for the evaporator coil condensate drain. The drain line
must be located so it will not be exposed to freezing temperatures. The drain line should be the full
size of the drain connection. Pitch the drain line per local and national codes.
NOTE
The drain line must be trapped outside the unit.
Humidifier Drain Line
Units supplied with the optional humidifier have a 1/2 in. (13mm) hose barb connection to drain the
steam generating humidifier canister. The drain line should be the full size of the drain connection.
Pitch the drain line per local and national codes.
NOTE
The drain line must be trapped outside the unit. This line may contain boiling water. Use
copper or other suitable material for the drain line.
Humidifier Water Supply Line
Units supplied with the optional humidifier package have a 1/4 in. (6.4mm) tube fitting connection for
water inlet. Supply pressure range is 10 psig to 150 psig. Required flow rate is 1 gpm. A shut-off valve
should be installed in this line to isolate the humidifier for maintenance.
Loop Connections
Chilled Water Piping—Install manual service shut-off valves at the supply and return lines of each
unit. This will provide for routine service or emergency isolation of the unit.
The ambient conditions and the minimum water temperature to be supplied from the chiller will
determine whether supply and return lines should be insulated. Insulating them will prevent condensation of the water supply and return lines to the unit.
The minimum recommended water temperature is 42°F. Design pressure is 125 psig. Connections
size is 3/4 in. FPT for supply and return lines.
Water/Glycol Piping—Manual service shut-off valves should be installed at the supply and return
line to each unit to enable routine service and/or emergency isolation of the unit. When the condensing fluid quality is poor, it is recommended that filters (that can be easily replaced or cleaned) be
placed in the supply line. These filters extend the service life of the condenser.
The maximum fluid pressure is 150 psig. For applications above this pressure, consult the factory.
The water/glycol-cooled systems will operate in conjunction with a cooling tower, city water or drycooler.
8
Site Preparation and Installation
Refrigerant (R-22) Piping—Two refrigerant lines, an insulated copper suction line and a copper
liquid line, are required between the evaporator and the condensing unit.
All refrigeration piping should be installed with high temperature brazed joints. Prevailing good
refrigeration practices should be employed for piping supports, leak testing, dehydration and charging of the refrigeration circuits. The refrigeration piping should be isolated from the building by the
use of vibration isolating supports. To prevent tube damage when sealing openings in walls and to
reduce vibration transmission, use a soft flexible material to pack around the tubes.
When installing remote condensing units above the evaporator, the suction gas line should be trapped
at the evaporator. This trap will retain refrigerant oil in the off cycle. When the unit starts, oil in the
trap is carried UP the vertical riser and returns to the compressor.
NOTE
When installing remote condensing units below the evaporator, the suction gas line should be
trapped with an inverted trap the height of the evaporator. This prevents refrigerant migration
to the compressor during off cycles.
If it is necessary to charge units after piping is complete, refer to 2.10 - Checklist for
Completing Installation for refrigerant charge (R-22) requirements.
Pre-Charged Lines—Pre-charged refrigerant line sets (insulated copper suction line and copper liquid line) are available from the factory in lengths of 15 and 30 feet. The maximum distance between
the evaporator and condensing unit is 45 feet (connecting one 30 foot and one 15 foot line set
together). For longer piping runs, contact your sales representative. A sweat adapter kit is also available to permit field supplied piping. It is recommended that lines be sized so they do not exceed 2°F
saturated temperature loss for the total equivalent length.
It is important to handle the pre-charged lines with care so that they will not get kinked or damaged.
Use tube benders and make all bends before making connections to either end. Coil any excess tubing
in a horizontal plane with the slope of the tubing towards the condensing unit.
Refrigerant Charge Requirements
Total refrigerant charge (R-22) will be required only if units are evacuated during installation or
maintenance. During operation, refer to pressures in 2.4.2 - Piping Connections and Cooling
Requirements.
Total Refrigerant = Units and Lines
Table 6
Unit refrigerant charges
Charge
Model No.
lb-oz
kg
DME020E
0-4
0.11
DME027E
0-5
0.14
DME037E
0-7
0.20
MCD24A
8-6
3.8
MCD36A
13-5
6.0
MCD26W
2-9
1.2
MCD38W
3-6
1.5
PFC020A
5-10
2.5
PFC027A
8-12
3.9
PFC037A
15-12
7.1
DMC022WG
2-15
1.3
DMC029WG
3-11
1.6
DMC04OWG
3-13
1.7
9
Site Preparation and Installation
Table 7
Line set refrigerant charges
Line Set, in.
1/4 liquid, 5/8 suction
3/8 liquid, 7/8 suction
Charge
Length
ft. (m)
lb-oz.
kg
15 (4.6)
0-4
0.11
30 (9.1)
0-8
0.23
15 (4.6)
0-10
0.28
30 (9.1)
1-4
0.57
Quick Connect Fittings
NOTE
When hard piping is used, complete all piping and evacuate lines before connecting quick
connects.
Be especially careful when connecting the quick connect fittings. Read through the following steps
before making the connections.
1.
2.
3.
4.
5.
Remove protector caps and plugs.
Carefully wipe coupling seats and threaded surfaces with a clean cloth.
Lubricate the male diaphragm and synthetic rubber seal with refrigerant oil.
Thread the coupling halves together by hand to insure that the threads mate properly.
Tighten the coupling body hex nut and union nut with the proper size wrench until the coupling
bodies “bottom out” or until a definite resistance is felt.
6. Using a marker or pen, make a line lengthwise from the coupling union nut to the bulkhead.
7. Tighten the nuts an additional quarter turn; the misalignment of the lines shows how much the
coupling has been tightened. This final quarter turn is necessary to insure that the joint does not
leak.
If a torque wrench is used, the following torque values are recommended:
Table 8
Torque values
Coupling Size
lb-ft
– #6
10-12
– #10
35-45
– #11
35-45
Table 9
Typical refrigerant pressures (psig)
Suction
60 to 90
Discharge
Air Cooled
260
Water Cooled
65°F to 75°F water
210
85°F water
225
Glycol Cooled
295
Maximum
330
High-pressure cut-out
360
10
Site Preparation and Installation
Figure 5
Evaporator piping connections
OPTIONAL
STEAM HUMIDIFICATION
DISCHARGE GRILLE
OPTIONAL STEAM
GENERATING
HUMIDIFIER
A -- Liquid Refrigerant Line
Quick Connect Female Coupling
with Access Valve
(Chilled Water-In)
B -- Suction Refrigerant Line
Quick Connect Female Coupling
with Access Valve
(Chilled Water-Out)
1/4" (6mm) O.D.
Plastic Compression Fitting.
Use Copper Lines for
Humidifier supply line
CONDENSATE PUMP
LOCATION IN THE UNIT
1/2" (13mm) hose barb.
Humidifier drain. Field pitch a
min. of 1/8" (13mm per meter)
per ft. The pipe material must be
rated for 212° F as humidifier will
discharge hot water periodically.
3/4" (19.05mm) Hose Barb
Drain Line.
Field pitch a min of 1/8"
(13mm per meter) per ft.
Table 10
Unit piping outlet connection sizes — pipe size in. (mm)
Model #
Liquid Line
A
Suction Line
B
DME020E
3/8 – #6 (9.5)
5/8 – #10 (15.9)
DME027E
3/8 – #6 (9.5)
7/8 – #11 (22.2)
DME037E
3/8 – #6 (9.5)
7/8 – #11 (22.2)
Water Inlet
Water Outlet
3/4 FPT
3/4 FPT
DME044C
11
Site Preparation and Installation
2.4.3
Electrical Connections
!
WARNING
Unit contains hazardous electrical voltage. Disconnect power supply before working within.
Line side of factory disconnect remains energized when disconnect is off.
Each unit is shipped from the factory with all internal wiring completed. Refer to electrical schematic
when making connections. Electrical connections to be made at the installation site are:
•
•
•
•
•
Power supply to the evaporator unit
Power supply to the condensing unit
Control wiring between the evaporator unit and the condensing unit
Power and control wiring (factory supplied) to the condensate pump (if applicable)
Control wiring between wall box remote controls and the evaporator unit
Power Connections
All power and control wiring and ground connections must be in accordance with the National Electrical Code and local codes. Refer to unit serial tag for wire size and circuit protection requirements.
!
CAUTION
Use copper wiring only. Make sure that all connections are tight.
Make sure that voltage supplied matches the voltage specified on the unit name plate. A power disconnect switch is required to isolate the unit for maintenance. Route the supply power to the disconnect switch and then to the unit. Route the conduit through the hole provided in the cabinet. Connect
earth ground to lug provided near terminal board.
NOTE
When an Integral Water/Glycol Cooled condensing unit is being used, the line voltage supply
is connected to the condensing unit. The evaporator is powered from the condensing unit using
a factory-supplied interconnecting cable.
Transformer Taps
The power terminal connections are labeled L1 and L2. For 208VAC applications, you must
change the input transformer connection. Refer to the electrical schematic.
Control Connections
A field-supplied 3 or 4 wire control connection (24VAC) is required between the evaporator and the
condensing unit. Control wiring must be installed in accordance with the National Electrical Code
(NEC) Class 1 circuit. Glycol-cooled units also require a two-wire control connection to the drycooler
and pump. A Class 1 circuit is required for water/glycol units.
Control wiring between the evaporator and the condensing unit must not allow a voltage drop in the
line of more than 1 volt (16 gauge minimum for 75 feet). Do not connect additional electrical
devices to the control circuit. The circuit breaker contained in the transformer housing is sized
only for the factory-supplied control system.
Additional control wiring will be required if your system includes other optional monitoring and control devices.
Four wire (thermostat-type) must be connected between the evaporator control board and the wall
box. See Figure 6.
12
Site Preparation and Installation
Figure 6
Evaporator unit electrical connections
Optional Remote
Sensor Connection
P16-1,2,3,4
Liebert
I/O
MENU
HI/LO
?
ESC
ENTER
Field supplied 24V (NEC Class 1)
to condensing module. (if
applicable)
Field supplied, field wired
thermostat wire to remote wall box.
Recommended disconnect switch
located within sight of unit.
Not by Liebert.
Single Phase Electric Service
Not by Liebert.
Customer Remote Alarm Connection.
Field supplied 24V Class 1 wiring to
connection TB6-1, 2, 3.
1
2
3
4
5
Optional Condensate Pump
Auxiliary Float Switch Connection
to terminal TB6-4 and TB6-5.
Transformer connection
Unit wired for 230 Volts. For
208V connection, replace the
yellow wire with orange wire.
Refer to Schematic
1
2
3
4
5
6
7
8
9
10
37
38
77
78
High Volt Power
Connections Electric
service connection terminals
Earth Ground Connection
Connections terminal for field
supplied earth grounding wire.
Heat Rejection Connection. Field supplied
24V (NEC Class 1 wiring) for remote air cooled
units from terminals TB5-1 through TB5-4 in Fan/Coil
module to wires 1 through 4 in the condensing module.
1. 24V GND
2. 24V Supply
3. High Pressure Alarm (OPT)
4. Hot Gas Bypass Connection
(only on units with Hot Gas Bypass)
Remote Contol Panel Connections to TB5-5, 6, 7, 8
connected with field supplied Thermostat wire
(22ga. shielded/jacketed: available from Liebert
and others).
Common Alarm Connection. Field
supplied 24V Class 1 wiring to common
alarm connection TB5-9 and TB5-10.
Remote Unit Shutdown. Replaces existing
jumper between terminals TB5-37 and TB5-38
with normally closed switch having a minimum
75 VA rating. Use field supply 24V Class 1 wire.
Site Monitoring Connection. Terminals
TB5-77 (-) TB5-78 (+) are for connection of
a 2 wire, twisted pair, communication cable
(available from Liebert or others) to optional
sitescan.
Entrance for high voltage single
phase electric.
Entrances for low voltage
connections.
NOTE: Refer to specification sheet for full load am
p. and wire size amp. ratings.
13
Site Preparation and Installation
2.4.4
Condensate Pump Installation
A condensate pump is required when the evaporator is installed below the level of the gravity-fed
drain line. Components include the pump, check valve, sump, level sensor and controls. The pump is
automatically controlled by the water level in the sump.
Install the condensate pump inside the evaporator housing on the right side. The pump kit includes
all necessary fittings and complete instructions.
Disconnect power and remove the evaporator housing.
The following piping connections are required:
• Unit drain pan
• Unit humidifier drain (if present)
• Pump output to customer drain line
A wiring harness is provided for the condensate pump. The following electrical connections are
required:
• Line voltage (yellow wires)
• Control voltage (red wires)
• Ground connection (green wire)
Tighten all connections. Apply power and check pump operation before replacing the evaporator housing. Inspect for leaks. Replace evaporator housing.
Schedule periodic inspections of the piping connections. The pump sump should be cleaned as often as
the evaporator air filter. Monthly cleaning is recommended.
Figure 7
Optional condensate pump (field installed)
1/2" Hose Barb Provided
with the Kit. Humidifier
Connection Rated 212° F
3/8" Hose Barb. Connect to
customer drain tube (rated for
212°F, if humidifier is used).
Note that a trap may be required
for local codes.
FRONT
3/4" Hose Barb Provided
with the Kit. Evaporator
Drain Pan Connection.
Rated 140° F
2.5
Outdoor Air Cooled Condensing Unit Installation
2.5.1
Location Considerations
To insure a satisfactory air supply, locate air cooled propeller fan condensing units in a clean area,
away from loose dirt and foreign matter that may clog the coil. Condensing units must not be located
in the vicinity of steam, hot air or fume exhausts or closer than 18 inches from a wall, obstruction or
adjacent unit. Avoid areas where heavy snow will accumulate at air inlet and discharge locations.
The condensing unit should be located for maximum security and maintenance accessibility. Avoid
ground-level sites with public access. Note that recommended maximum refrigerant line length is 45
feet.
Install a solid base capable of supporting the weight of the condensing unit. The base should be at
least two inches higher than the surrounding grade and two inches larger than the dimensions of the
condensing unit base.
14
Site Preparation and Installation
Figure 8
Outdoor air cooled condensing units
REMOVABLE (RIGHT) PANEL
FOR ACCESS TO
REFRIGERATION COMPONENT.
Fan Rotation
CCW
(left side)
A
RIGHT
AIR
DISCHARGE
LEFT
AIR
INTAKE
B
SHADED AREA
INDICATES A MINIMUM
CLEARANCE OF 18" (457mm)
FOR PROPER AIR FLOW
C
SHADED AREA
INDICATES A MINIMUM
CLEARANCE OF 18" (457mm)
FOR PROPER AIR FLOW.
Table 11
Outdoor air cooled condensing units dimensional data
Model Numbers
2.5.2
REMOVABLE (FRONT) PANEL FOR
ACCESS TO HIGH VOLTAGE &
LOW VOLTAGE CONNECTIONS,
AND REFRIGERATION COMPONENTS
SHADED AREA
INDICATES A RECOMMENDED
CLEARANCE OF 24" (610mm)
FOR COMPONENT
ACCESS AND REMOVAL.
60 HZ
50HZ
PFH014A-L
PFH013A-L
PFH020A-L
PFH019A-L
PFH027A-L
PFH026A-L
PFH027A-H
PFH026A-H
PFHZ27A-L
PFHZ26A-L
PFH037A-L
PFH036A-L
PFH042A-L
PFH041A-L
PFH037A-H
PFH036A-H
PFHZ37A-L
PFHZ36A-L
Dimensional Data, In., (mm)
A
B
C
Module Weight
lbs. (kg) net.
40 (1016)
23 1/2 (597)
18 (457)
200 (91)
48 (1219)
31 (787)
18 (457)
241 (109)
53 (1343)
36 1/4 (918)
18 (457)
351 (159)
Piping Connections
Two refrigerant lines are required to connect the outdoor condensing unit to the ceiling unit. The bottom connection is for the insulated copper suction line. The top connection is for the copper liquid line.
Details are given in 2.4.2 - Piping Connections and Cooling Requirements.
15
Site Preparation and Installation
2.5.3
Electrical Connections
!
WARNING
Unit contains hazardous electrical voltage. Disconnect power supply before working within.
Line side of factory disconnect remains energized when disconnect is off.
Power Connections
The outdoor condensing unit requires its own power source and earth ground, with a disconnect
switch (field supplied) to isolate the unit for maintenance. Voltage supplied must agree with the voltage specified on the unit nameplate. An optional transformer is available for 277VAC, single-phase
applications.
Control Connections
A field-supplied 3 or 4-wire (24VAC) control connection is required between the condensing unit and
the evaporator. Refer to Figure 8 and the electrical schematic.
2.6
Installing Ceiling Condensing Units
The unit is mounted above the ceiling and must be securely mounted to the roof structure. Use
threaded suspension rods (SAE Grade 1 minimum) and four locknuts (3/8 in. – 16).
Recommended clearance between ceiling grids and structural members is unit height plus
three inches.
Install the four field-supplied rods by suspending them from a suitable ceiling support. Locate the
rods so that they mate with the four outside comer rigging holes.
Attach hanging brackets to the threaded rods with the supplied nuts and grommets. The rubber
grommets provide vibration isolation. The ceiling and ceiling supports of existing buildings may
require reinforcements. Be sure to follow all applicable codes.
!
WARNING
Be sure the supporting roof structure is capable of supporting the weight of the unit(s) and the
accessories.
Be sure to securely anchor the top ends of the suspension rods. make sure all nuts are tight.
Do not install units directly above computer equipment.
Install a safety pan, with drainline, under water/glycol-cooled condensing units.
2.6.1
Lifting the Units Into Place
NOTE
Be sure to read the directions for installing each type of unit before proceeding.
Using a suitable lift device, raise each unit up to meet the bottom of the two hanging brackets suspended from the ceiling via the threaded rods. Center the unit so that the bolts can be easily inserted
into the factory-supplied captive nuts.
Use bolts, washers and locknuts to attach hanging brackets to the bottom of the cabinet.
Tighten locknuts sufficiently so that the weight of the unit is supported evenly by the four rods. Make
sure the unit is level within the space by adjusting the locknuts.
NOTE
The unit must be level in order to operate properly.
16
Site Preparation and Installation
Figure 9
Above the ceiling mounting bracket detail
3/8" Threaded Rod
(field-supplied)
3/8" Hex Nut
3/8" Washer
Sleeve
Isolator
3/8" Fender Washer
3/8" Hex Nut
3/8" Hex Nut Nylock
Unit Base Pan (ref)
17
Site Preparation and Installation
2.7
Centrifugal Fan Condensing Unit Installation
2.7.1
Location Considerations
The centrifugal fan air cooled condensing unit may be located above the dropped ceiling or any remote
indoor area using the hangers and hardware provided.
To mount the unit in the ceiling, refer to 2.6 - Installing Ceiling Condensing Units.
2.7.2
Piping Connections
Details for refrigerant (R-22) loop piping are in 2.4.2 - Piping Connections and Cooling Requirements.
2.7.3
Electrical Connections
!
WARNING
Unit contains hazardous electrical voltage. Disconnect power supply before working within.
Line side of factory disconnect remains energized when disconnect is off.
Power Connections
The centrifugal condensing unit requires its own power source and earth ground, with a disconnect
switch (field supplied) to isolate the unit for maintenance. Voltage supplied must agree with the voltage specified on the unit nameplate.
Control Connections
A field-supplied three- or four-wire control connection is required from the evaporator unit to the condensing unit. Refer to Figure 11 and the electrical schematic.
2.7.4
Ducting
The total external static pressure for the inlet and outlet ducts, including grille, must not exceed 0.5
inches of water. Hood intake dimensions should be the same as the condensing unit duct dimensions.
If the condensing unit draws air from the outside of the building, rain hoods must be installed. In
addition, install a triple layer bird screen over rain hood openings to eliminate the possibility of
insects, birds, water and debris from entering the unit.
Use flexible ductwork or nonflammable cloth collars to attach ductwork to the unit and to control
vibration transmission to the building. Attach the ductwork to the unit using the flanges provided.
Locate the unit and ductwork so that the discharge air does not short circuit to the return air inlet.
Avoid directing the hot exhaust air toward adjacent doors or windows.
Normal operating sound may be objectionable if the condensing unit is placed directly over quiet work
areas. Ductwork that runs through a conditioned space or is exposed to areas where condensation
may occur must be insulated. Whenever possible, ductwork should be suspended using flexible hangers. Ductwork should not be fastened directly to the building structure. In applications where the ceiling plenum is used as the heat rejection domain, the discharge air must be directed away from the
condensing unit air inlet and a screen must be added to the end of the discharge duct to protect service personnel.
For multiple unit installations, space the units so that the hot condensing unit exhaust air is not
directed toward the air inlet of an adjacent unit.
Table 12
Air flow – CFM (l/s)
2 Ton
3 Ton
1,000 (472)
1,650 (779)
18
Site Preparation and Installation
Figure 10 Centrifugal condensing unit dimensions and pipe connections (2 and 3 ton)
22 3/4" (578mm)
Overall Dimension
21 1/2" (546mm)
Cabinet Dimension
19 1/2" (495mm)
Threaded Rod
Centers
50 1/4" (1276mm)
Overall Dimension
46 1/2" (1181mm)
Cabinet Dimension
48 1/4" (1225mm)
Threaded Rod Centers
Customer Supplied Threaded
Rods for Module Support
from Ceiling (typ. 4)
C
1/2" (13mm)
D
20 3/4"
(527mm)
22 1/2"
(572mm)
Cabinet
Dimension
20 7/16"
(519mm)
Coil Inlet
Duct Conn.
B
30 1/8"
(765mm)
Coil Inlet
Duct Connection
Holes for Module
Rigging (typ. 2 each end)
Duct Flange
1"
(25.4mm)
Integral
Hanging Bracket
Minimum Clearance 33" (838mm)
This End for Component Access
and Removal
2 1/4"
(57mm)
DIMENSIONAL DATA
Note: Unit is evenly spaced in
reference to threaded rod centers.
7/8" (22.2mm) Dia.
Electrical Entrance
for Line Voltage
Connection.
7/8" (22.2mm) Dia.
Electrical Entrance
for Low Voltage
Connection.
Suction Line
Male Quick
Connect
Liquid Line Male
Quick Connect
Table 13
Centrifugal condensing unit dimensions
Dimensions, in. (mm)
Model
A
B
C
D
MC*23A
MC*24A
MC*35A
MC*36A
1-7/16 (37)
11-7/16 (290)
1/2 (13)
20-7/16 (519)
MC*39A
1-5/8 (41)
11-3/4 (298)
5-3/8 (137)
11-3/4 (298)
19
Air Outlet
Duct Connection
Air Outlet
Duct Dimension
A
Blower Motor Service Access
Panel on Bottom of Unit
Minimum Clearance 33" (838mm)
for Component Access and Removal.
Site Preparation and Installation
Figure 11 Centrifugal condensing unit electrical connections (2 and 3 ton)
Field supplied unit disconnect switch
when optional disconnect is not
provided in unit.
Single or three phase
electric service not
by Liebert.
Field supplied 24V NEC
class 2 wiring to Fan/Coil
unit.
Optional factory installed
disconnect switch
Line voltage electric power
supply conduit entrance.
Factory wired
to components on
electric panel
Single or three phase electric service
not by Liebert.
Connection terminal for field supplied
earth grounding wire.
Low voltage electric power
supply entrance.
Heat rejection connection. Field
supplied 24V NEC class 2 wiring. See note 2.
Wire connections from evaporator mod:
1. 24V GRD
2. 24V Supply
3. High Pressure Alarm (OPT)
4. Hot Gas Bypass Connection
(only on units with hot gas bypass)
NOTES:
1. Refer to specification sheet for full load amp. and wire size amp. ratings.
2. Control voltage wiring must be a minimum of 16 GA (1.6mm) for up to 75’ (23m) or not
to exceed 1 volt drop in control line.
20
Site Preparation and Installation
Figure 12 General arrangement drawing, chilled water
Bleed Valve
Chilled
Chilled Water
Water Supply
Return
Chilled Water
Control
Valve
Chilled Water
Coil
Shutoff *
Valves
Hose*
Bibs
Female
Adapters
FIELD PIPING
FACTORY PIPING
* Components are not supplied by Liebert
but are recommended for proper
circuit operation and maintenance
21
Site Preparation and Installation
Figure 13 General arrangement drawing, water/glycol cooled
Tube in Tube
Condenser
High
Pressure
Switch
Scroll
Compressor
Liquid Injection
Valve Bulb
Hot Gas
Bypass
Solenoid
Valve
Suction Line Male Quick
Connect Coupling
Suction Line Female Quick
Connect Coupling
External
Equalizer
Sensing
Bulb
Hot Gas Bypass Water/Glycol
Control
Return Line
Water/Glycol
Valve
Supply Line
Fluid Return
From Unit
Liquid
Injection
Valve
Fluid
Supply
To Unit
Service Access
Ports
Filter
Drier
Expansion
Valve
Liquid Line
Female Quick
Connect
Coupling
Liquid Line
Male Quick
Connect
Coupling
Shut - off *
Valves
2 - Way Water
Regulating Valve
Hose Bibs *
Liquid Line
Solenoid Valve
Tube in Tube
Condenser
Evaporator
Coil
FIELD PIPING
FACTORY PIPING
* Components are not supplied by Liebert
but are recommended for proper
circuit operation and maintenance.
Fluid Return
From Unit
Fluid Supply
To Unit
22
3 - Way Water
Regulating Valve
(Optional)
Site Preparation and Installation
Figure 14 General arrangement drawing, air cooled
Condenser Coil
High Pressure
Switch
Scroll
Compressor
Liquid Injection
Valve Bulb
Hot Gas Bypass
Solenoid Valve
Suction Line Male Quick
Connect Coupling
3 - Way Head
Pressure
Relief Valve
Suction Line Female Quick
Connect Coupling
Hot Gas Bypass
Control Valve
Sensing Bulb
External Equalizer
1/2" (12.7mm) NPT
Pressure Relief Valve
Check
Valve
Sight
Glass
Liquid Injection
Valve
Lee - Temp
Receiver
Service Access
Ports
Filter
Drier
Expansion Valve
Liquid Line Male Quick
Connect Coupling
Liquid Line Female Quick
Connect Coupling
FIELD PIPING
Liquid Line
Solenoid Valve
FACTORY PIPING
* Field piping refers to the use of hard
piping using sweat adapter kit
or precharged line set.
Evaporator Coil
23
Site Preparation and Installation
2.8
Water and Glycol Cooled Condensing Unit Installation
2.8.1
Location Considerations
The Water and Glycol Cooled condensing units may be located above the dropped ceiling or any
remote indoor area using the hangers and hardware provided.
To mount the unit in the ceiling, refer to 2.6 - Installing Ceiling Condensing Units.
2.8.2
Piping Connections
Piping Considerations
Do not use galvanized pipe in glycol systems. Manual service shut-off valves should be installed at the
supply and return line to each unit. This enables routine service and/or emergency isolation of the
unit. When the condensing unit fluid quality is poor, filters (that can be easily replaced or cleaned,
with 16-20 mesh screen) should be placed in the supply line. These filters extend the service life of the
condensing units.
Condensing fluid connections (FPI) are 3/4 in. Details for refrigerant (R-22) loop piping are in 2.4.2 Piping Connections and Cooling Requirements.
Condensing Unit Fluid Requirements
The maximum fluid pressure is 150 psig. For applications above this pressure, consult the factory.
The water cooled system will operate in conjunction with either a cooling tower or city water. Glycol
cooled systems will operate in conjunction with a cooling tower, city water or drycooler. Automotive
anti-freeze must not be used in glycol systems. Prepare glycol solution using customary practices.
Regulating Valve
Water/Glycol cooled units include a coolant flow regulating valve which may require adjustment.
Attach refrigeration gauges to the compressor discharge and suction lines. Raise the head pressure by
turning the adjusting screw clockwise. Allow enough time between adjustments for the system to stabilize. Refer to recommended operating pressures in 2.4.2 - Piping Connections and Cooling
Requirements.
When the refrigeration system has been off for approximately 10 to 15 minutes, the coolant flow
should stop. If the coolant continues to flow, the valve is improperly adjusted (head pressure too low).
Flush the valve by inserting a screwdriver or similar tool under the two sides of the main spring and
lifting. This will open the valve seat and flush out any dirt particles,
2.8.3
Electrical Connections.
!
WARNING
!
CAUTION
Unit contains hazardous electrical voltage. Disconnect power supply before working within.
Line side of factory disconnect remains energized when disconnect is off.
Use copper, copper-clad aluminum or aluminum wiring only. Make sure that all connections
are tight.
Power Connections
The condensing unit requires its own power source and earth ground, with a disconnect switch (field
supplied) to isolate the unit for maintenance. Voltage supplied must agree with the voltage specified
on the unit nameplate.
Control Connections
A field-supplied 3- or 4-wire (24VAC) control connection is required from the evaporator unit to the
condensing unit. Refer to Figure 16 and the electrical schematic.
24
Site Preparation and Installation
Figure 15 Water and glycol cooled condensing units: dimensions and pipe connections (2 and 3 ton)
3 7/8" (98mm)
8 7/8" (225mm)
50 1/4" (1276mm)
Overall Dimension
14" (356mm)
Overall Cabinet
Dimension
48 1/4" (1225mm)
Threaded Rod Centers
8 7/16" (214mm)
12" (305mm)
Threaded Rod
Centers
46 1/2" (1181mm)
Cabinet Dimension
Customer Supplied
Threaded Rods for Module
Support from Ceiling (typ. 4).
20 3/4"
(527mm)
22 1/2"
(572mm)
Outlet
Cabinet
Dimension
Inlet
Minimum Clearance
33" (838mm) This Side
for Component Access
and Removal.
Holes for Module
Rigging (typ. 2 each end).
Note: Unit is Spaced Evenly in
Reference to Threaded Rod Centers.
Integral Hanging Bracket
DIMENSIONAL DATA
3/4" (19mm) N.P.T. Female
Water/Glycol Inlet Connection.
3/4" (19mm) N.P.T. Female
Water/Glycol Outlet Connection.
7/8" (22mm) Dia.
Electrical Entrance
for High Voltage
Connection.
Suction Line
Male Quick
Connect
Liquid Line
Male Quick
Connect
7/8" (22mm) Dia.
Electrical Entrance
for Low Voltage
Connection.
PIPING CONNECTIONS
25
Site Preparation and Installation
Figure 16 Water and glycol cooled condensing units: electrical connections (2 and 3 ton)
Field supplied unit disconnect switch
when optional disconnect is not
provided in unit.
Single or three phase
electric service not
by Liebert
Field supplied 24V
NEC Class 1 wiring to Fan/Coil unit
Field supplied 24V
NEC class 1 wiring to Drycooler
(Glycol cooled units only)
Earth ground connection.
Connection terminal for field supplied
earth grounding wire.
Line voltage electric power
supply entrance.
Factory wired to components on
electric panel.
Optional factory installed
disconnect switch.
Low voltage electric power
supply entrance.
Remote Drycooler connection.
Terminals 70 & 71 supplied for
connection to remote Drycooler,
use field supplied 24V NEC class 1
wiring (Glycol cooled units only).
Heat Rejection Connection.
Field supplied 24V NEC class 2 wiring.
See note 2.
Wire connections from evaporator mod:
1. 24V GND
2. 24V Supply
3. High Pressure Alarm (OPT)
4. Hot Gas Bypass Connection
(only on units with hot gas bypass)
NOTES:
1. Refer to specification sheet for full load amp. and wire size amp. ratings.
2. Control voltage wiring must be a minimum of 16 GA (1.6mm) for up to 75’ (23m) or not
to exceed 1 volt drop in control line.
26
Site Preparation and Installation
2.9
Integral Water/Glycol Condensing Unit Installation
2.9.1
Location Considerations
The integral water/glycol condensing unit is suitable for indoor installation only. The unit is designed
to be attached to the left side of the evaporator chassis.
Figure 17 Integral water/glycol unit dimensions
FLOOR
DATAMATE
EVAPORATOR
UNIT
7/8"
(22mm)
CONDENSING
UNIT
5"
(127mm)
OVERLAP FOR CONNECTION OF
CONDENSING UNIT & EVAPORATOR UNIT
3 7/8"
(100mm)
REF.
11 3/8"
(289mm)
CABINET
OUTLINE
5 7/8"
(150mm)
ACCESS PANEL
(REMOVABLE)
5 7/8"
(150mm)
14"
(356mm)
5 7/8"
(150mm)
9 3/4" (248mm)
32"
(813mm)
Unit
Height
31 1/4"
(794mm)
Wall
Mount
Layout
3/8"
(9.5mm)
32"
(813mm)
ACCESS PANEL
(REMOVABLE)
14"
(356mm)
18 1/4"
(464mm)
19"
(483mm)
OVERALL
DIMENSION
FLOOR
3/4"
(19mm)
REF.
ACCESS PANEL
(REMOVABLE)
WALL MOUNT LAYOUT
KEYHOLE SLOTS
MODEL
DMC022WG
DMC029WG
DMC040WG
SHIPPING WEIGHT
Ibs. (kg)
12"
(305mm)
UNIT
DIMENSIONAL DATA
169 (77)
169 (77)
172 (78)
14"
(356mm)
SHADED AREA INDICATES A RECOMMENDED
CLEARANCE OF 34" (864mm) ON THE FRONT
OF THE UNIT AND 12" (305mm) ON THE
LEFT SIDE FOR COMPONENT ACCESS AND
REMOVAL. MINIMUM CLEARANCE IS 1" (25mm)
ON LEFT SIDE AND 18" (457mm) IN FRONT.
Unlatch the front cabinet door and remove the two screws that secure the cabinet to the chassis. Lift
off the cabinet. Eight keyhole slots are provided for mounting the unit on the wall (refer to
Figure 17).
27
Site Preparation and Installation
2.9.2
Piping Connections
Manual service shut-off valves should be installed at the supply and return line to each unit. This
enables routine service and/or emergency isolation of the unit. When the condensing unit fluid quality
is poor, it is recommended that filters (that can be easily replaced or cleaned, with 16-20 mesh screen)
be placed in the supply line. These filters extend the service life of the condensing unit.
Remove back plate. Reinstall after connections. Remove piping access plate on evaporator end panel
but do not remove the end panel.
Connection Sizes O.D. Copper
DME020E
5/8
DME027E/DME037E
7/8
Condensing Unit Fluid Requirements
The maximum fluid pressure is 150 psig. For applications above this pressure, consult the factory.
The system will operate in conjunction with either a cooling tower, city water or drycooler.
Regulating Valve
Refer to 2.8.2 - Piping Connections for a description of the regulating valve and instructions for
adjustment.
2.9.3
Electrical Connections
!
WARNING
Unit contains hazardous electrical voltage. Disconnect power supply before working within.
Line side of factory disconnect remains energized when disconnect is off.
When an integral condensing unit is used with the evaporator, the evaporator is powered from the
condensing unit. Route the factory-supplied interconnecting power/control cable to the evaporator and
wire it to the power terminal block in the electric box. This unit is shipped with a wire harness. Refer
to Figure 18 and the electrical schematic.
Heat Rejection Connections
If the integral condensing unit is used in a glycol loop, it must be connected to the drycooler. Terminals are provided on the condensing unit electric box for Class 2 wiring to the heat rejection equipment.
28
Site Preparation and Installation
Figure 18 Integral water/glycol condensing unit connections
Interconnecting power
& control cable.
Heat Rejection interlock
connection. Factory supplied
wiring from condensing unit to
terminals 1, 2 & 3 in the
Fan/Coil unit.
1. 24V GND
2. 24V Supply
3. High Pressure Alarm (OPT)
4. Hot Gas Bypass Connection
(Not available with water/glycol
condensing units)
Datamate
Evaporator
1
2
3
4
5
6
7
8
9
10
37
38
77
78
Line voltage connection block.
CONDENSING
UNIT
Factory supplied wiring from
condensing unit to fan coil
unit, connected by field.
Refer to Evaporator section
for other terminal block
descriptions.
Line voltage single phase
electric conduit connection
location.
Heat rejection interlock
conduit connection location.
Earth ground connection.
Connection terminal for field
supplied earth grounding wire.
Remote unit shutdown
conduit connection location.
DATAMATE FAN/COIL UNIT
ELECTRIC BOX
Heat rejection connection. Field
supplied 24V class 1 wire to interlock
heat rejection from terminals 70 & 71.
(for drycooler & pump)
Earth ground connection
connection terminal.
Factory supplied interconnecting power
and control cable routed from condensing
unit electric box to fan/coil unit electric
box. Terminals 1, 2 & 3.
L1
L2
Single phase electric service
with ground not by Liebert.
Single phase connection
electrical service connection
terminals L1 & L2.
WATER/GLYCOL CONDENSING UNIT
ELECTRIC BOX
NOTE: Refer to specification sheet for full load amp. and wire size amp. ratings.
29
Site Preparation and Installation
2.10
Checklist for Completing Installation
___ 1. Proper clearances for service access have been maintained around the equipment.
___ 2. Equipment is level and mounting fasteners are tight.
___ 3. Piping completed to refrigerant or coolant loop (if required). Refrigerant charge added (if
required).
___ 4. Condensate pump installed (if required).
___ 5. Drain line connected.
___ 6. Water supply line connected to humidifier (if required).
___ 7. All piping connections are tight.
___ 8. Safety pan installed under water/glycol cooled condensing units.
___ 9. Ducting completed if required.
___ 10. Line voltage to power wiring matches equipment nameplate.
___ 11. Power wiring connections completed to disconnect switch, evaporator and condensing unit,
including earth ground.
___ 12. Control panel DIP switches set based on customer requirements.
___ 13. Power line circuit breakers or fuses have proper ratings for equipment installed.
___ 14. Control wiring connections completed to evaporator and condensing unit (if required),
including wiring to optional controls.
___ 15. All wiring connections are tight.
___ 16. Foreign materials have been removed from in and around all equipment installed (shipping
materials, construction materials, tools, etc.).
___ 17. Fans and blowers rotate freely without unusual noise.
___ 18. Inspect all piping connections for leaks during initial operation.
30
Microprocessor Control
3.0
MICROPROCESSOR CONTROL
The Microprocessor Control features an easy to use menu-driven LCD display. The menus, control
features and circuit board details are described in this section. Detailed information concerning controls (4.0 - System Performance, Microprocessor Controls) and alarms (5.0 - Alarms) are provided.
3.1
Feature Overview
To turn the unit ON, press the ON/OFF (I/O) key after power is applied. To turn the unit OFF, press
the ON/OFF (I/O) key before power is disconnected.
The following control keys may be used to move through the menus, as prompted on the LCD display:
• I/O—turns unit on or off (top far left).
• MENU – Enables user to access the program menu to change control parameters, alarms, setback
schedule, etc. (top near left).
• UP ARROW—Increases the value of displayed parameter while in a set mode (setpoints, time,
etc.) (top near right).
• ESC—Escape; allows user to move back to a previous menu (top far right).
• FAN HI/LO—Changes the fan speed between high and low (bottom far left)
• Alarm Silence/? (Help)—If an alarm is present, pressing this key will silence the alarm. If this
key is pressed when no alarm is present, help text will appear (bottom near left).
• DOWN ARROW—Decreases the value of displayed parameter while in a set mode (bottom near
right).
• ENTER—After setting a control point, press ENTER to store the information in the microprocessor (bottom far right).
Figure 19 Wall box
Active alarms are displayed on the LCD screen and sound an audible beep. To silence an alarm, press
the Alarm Silence/Help key as prompted on the display.
Setpoints, DIP switch settings and other selections were made during factory testing of your unit and
are based upon typical operating experience. (Other default selections were made according to options
included with your unit). MAKE ADJUSTMENTS TO THE FACTORY DEFAULT SELECTIONS
ONLY IF THEY DO NOT MEET YOUR SPECIFICATIONS.
Allowable ranges are displayed by pressing the help key. A password will be required (if enabled) to
change setpoints, time delays, etc.
The display normally shown includes the present room temperature, humidity, active status functions (cooling, heating, dehumidifying, humidifying), normal fan speed/low fan speed and active
alarms. The status display my also be selected from the main menu. More detailed status and alarm
information is available from the menu.
31
Microprocessor Control
3.2
Main Menu <Menu>
Press the MENU key to display the Main Menu. Menu selections (in the following order) include:
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
SETPOINTS
STATUS
ACTIVE ALARMS
TIME
DATE
SETBACK
SETUP OPERATION
SETPT PASSWORD
SETUP PASSWORD
CALIBRATE SENSORS
ALARM ENABLE
ALARM TIME DELAY
COMMON ALARM ENABLE
CUSTOM ALARMS
CUSTOM TEXT
DIAGNOSTICS
END OF MENU
Use the UP or DOWN arrow to scroll through the selections, then when ready to select a particular
function press “Enter” key.
3.3
Setpoints
Setpoints and system setup parameters are kept in nonvolatile memory. Selecting SETPOINTS from
the Main Menu will display the following selections:
•
•
•
•
•
•
•
•
TEMPERATURE SETPOINT
TEMPERATURE SENSITIVITY
HUMIDITY SETPOINT
HUMIDITY SENSITIVITY
HIGH TEMPERATURE ALARM
LOW TEMPERATURE ALARM
HIGH HUMIDITY ALARM
LOW HUMIDITY ALARM
Scroll through this submenu by using the UP or DOWN arrow, then press ENTER to select a particular function. To change a value, press ENTER and use the UP or DOWN arrows. When the value has
been changed press ENTER to store the value. For example to change the temperature setpoint from
the main status display.
1.
2.
3.
4.
Press MENU key to display main menu.
Scroll to “SETPOINTS” using the UP or DOWN arrow key. Press ENTER key.
Scroll to “TEMP SETPOINT” using the UP or DOWN arrow key. Press ENTER key.
Use the UP or DOWN arrow to change the value. Press ENTER key.
32
Microprocessor Control
Table 14
Default setpoints and allowable ranges
Setpoint
3.4
Default
Range
Temperature Setpoint
72°F
40-90°F (5-32°C)
Temperature Sensitivity
2.0°F
1-9.9°F (0.6-5.6°C)
Humidity Setpoint
50%
20-80% RH
Humidity Sensitivity
5%
1-30% RH
High Temperature Alarm
80°F
35-95°F (2-35°C)
Low Temperature Alarm
65°F
35-95°F (2-35°C)
High Humidity Alarm
60%
15-85% RH
Low Humidity Alarm
40%
15-85% RH
Status
The operator can monitor the percentage heating, cooling, dehumidifying and humidifying status of
the unit by selecting the STATUS submenu.
3.5
Active Alarms
The operator can monitor the alarms status by selecting ALARMS, which will display a “No Alarm
Present” or “Alarm XX of YY” alert and description. If more than one alarm is activated, use the UP or
DOWN arrow to scroll through the alarms list. (“XX” reference is the number of the alarm shown,
while the “YY” reference is the total number of alarms activated).
3.6
Time
The controller time clock must be set to allow for the setback control. The clock uses the 24 hour system (i.e., 12 midnight is entered 24:00). To change the time press ENTER to select the function, then
use the UP or DOWN arrow to change the first character, press enter to store, then press the UP or
DOWN arrow to change the section character, press ENTER to store, etc. There is a battery backup
for the date and time feature.
3.7
Date
The controller date must be set to allow for setback control. To change the date press ENTER, then
use the UP or DOWN arrow to change the first character, press ENTER to store, press the UP or
DOWN arrow to change the second character, etc.
3.8
Setback
The microprocessor can be programmed for night and weekend setback. Two (2) events can be programmed for a five-day workweek and two (2) events can be programmed for a two-day weekend. The
following table can be used to devise a setback plan.
Table 15
Night and weekend setback plan
Event
Weekend
Weekday
Time 1
Temperature1
Sensitivity 1
Humidity 1
Humidity Sensitivity 1
Time 2
Temperature 2
Sensitivity 2
Humidity 2
Humidity Sensitivity 2
33
Microprocessor Control
3.9
Setup Operation
Selecting SETPOINT/SETUP from the Main Menu will display the following selections:
• RESTART TIME DELAY
• C/F DEGREES
• HUMIDITY CONTROL METHOD
Use the UP and DOWN arrows to scroll through the submenu. Press ENTER to select a particular
function.
3.9.1
Restart Time Delay
This function delays unit restart after main power is restored to the unit. If several systems are operating, the time delays should be set to different values to cause a sequential start. Delay can be set
from 0.1 minutes (6 seconds to 9.9 minutes. Setting the value to zero (0) will prevent unit restart
when power is restored. In this case, the unit must be restarted manually by pressing the I/O button
on the keypad.
3.9.2
C/F Degrees
The control may be selected to show readings and setpoints in either degrees Fahrenheit (°F) or Celsius (°C). To change the value use ENTER to select this function, then use the UP or DOWN arrow to
change the value. Press ENTER to store the value.
3.9.3
Humidity Control Method
The operator may select either relative (direct) or absolute (predictive) humidity control. If relative is
selected, the RH control is taken directly from the RH sensor. If absolute is selected, the RH control is
automatically adjusted whenever return air temperature deviates from the desired temperature setpoint (i.e., predictive humidity control). The LCD display will indicate percentage relative humidity
for both methods of control. If the absolute feature is selected, the adjusted humidity reading will also
be shown. When utilizing the predictive humidity control feature, the humidity level is automatically
adjusted ~2% RH for each degree difference between the return air temperature and the temperature
setpoint.
In terms of relative humidity control, unnecessary dehumidification can result when overcooling
occurs during a dehumidification cycle. This is due to a higher than normal RH reading caused by
overcooling the room (about 2% RH for each degree of overcooling). This drop in temperature extends
the dehumidification cycle. Later, when the dehumidification ends and the temperature rises to the
setpoint, the RH reading falls. The final RH reading will then be lower than actually desired. If the
temperature drop was significant enough, the percentage RH could be low enough to activate the
humidifier.
If the absolute humidity control is selected, over-dehumidification may be avoided. When overcooling
occurs (i.e., causing an increase in the RH reading) the humidity control program estimates what the
RH will be when the dehumidification cycle ends and temperature returns to the setpoint. This allows
the dehumidification cycle to end at the proper time. The predictive humidity control can greatly
reduce energy consumption by minimizing both compressor/reheat operation. Use the UP or DOWN
arrow to select the desired humidity control method.
Table 16
Setup functions, default values and allowable ranges
Function
Restart Time
Delay
Default
Range
0.1
0 to 9.9 min
(0 = manual restart)
C/F Degrees
°F
°C or °F
Humidity Control
Rel
Relative or Absolute
34
Microprocessor Control
3.10
Change Passwords
The display will prompt the operator to enter a three-digit password when attempting to make
changes. The system includes two (2) passwords, one for setpoints and one for setup. The system
allows the password to be changed by first entering the default password set at the factory (1-2-3) for
setpoints and (3-2-1) for setup. The password function provides system security, so that only authorized personnel are allowed to make changes to the system. (If unauthorized changes are being made,
the passwords may be compromised and new ones should be selected). The password function can be
disabled by setting DIP switch 8 in the wallbox to OFF.
3.11
Calibrate Sensors
The temperature and humidity sensors can be calibrated by selecting the CALIBRATE SENSORS
menu item. The temperature sensor can be calibrated ±5°F, while the humidity sensor can be calibrated ±10% RH. When calibrating the humidity sensor, the value shown will always be% RH, even
though absolute humidity control may be selected. If absolute humidity control is selected, the Normal Status Display will display the adjusted reading. This reading may not agree with the relative
humidity reading displayed while in calibration.
If the sensors are subject to frequent wide temperature and humidity swings, it may be necessary to
shorten the cycling by increasing the sensor response time delay. If the sensors are located too close to
the air discharge, they will likely experience rapid swings in measurement. The factory default is 30
seconds. Another method in reducing compressor cycling is to increase the temperature and/or humidity sensitivity.
3.12
Alarm Enable
Each alarm can be disabled or enabled. Use the UP or DOWN arrow to select a particular alarm,
press ENTER to select either ENABLE or Disable. Then press ENTER again to store the change.
When the alarm is disabled it will NOT report to either the wallbox beeper or the common alarm
relay.
NOTE
The high water alarm will automatically shut the unit off. Similarly, optional factory-installed
smoke detectors are wired to shut the evaporator unit off, regardless of the enable/disable
status.
3.13
Alarm Time Delay
Each individual alarm can be programmed with a time delay (Table 17), causing the unit to delay a
specified amount of time (0-255 seconds) before recognizing the alarm. The alarm condition must be
present for the full amount of the time delay before the alarm will sound. If the alarm condition is
diverted prematurely, the alarm will not be recognized and the time delay will automatically reset.
NOTE
For software alarms such as “loss of power” and “short cycle,” the time delay should be left at
the factory default of 0.
Table 17
Alarm default time delays
Alarm
Custom Alarm #1
Default Time Delay
(seconds)
0
Custom Alarm #2
6
High Temperature
30
Low Temperature
30
High Humidity
30
Low Humidity
30
Short Cycle
0
Loss of Power
0
Humidifier Problem
2
High Head Pressure
2
35
Microprocessor Control
3.14
Common Alarm Enable
Each individual alarm can be selected to activate/deactivate the common alarm relay. If the energize
common alarm function is set to YES, the relay is energized immediately as the alarm is annunciated
and de-energized when the alarm condition is diverted after the alarm has been recognized. If the
alarm is completely DISABLED, the alarm has no effect on the common alarm relay. Use the UP or
DOWN arrow to scroll to a particular alarm, press the ENTER button to select it, then press the
ENTER key again to select YES or NO.
3.15
Custom Alarms
The custom alarm messages can be selected from a list of standard alarm messages or the operator
can write his/her own message. A MAXIMUM OF TWO (2) ALARM MESSAGES CAN BE CUSTOMIZED. The two custom alarm messages will initially display the previously programmed message but
can be changed.
The text for custom alarms can be changed at any time by selecting CUSTOM ALARMS. To change
the text for a custom alarm, select the alarm you would like to change, 1 or 2. Using the UP or DOWN
arrow, step through the list of seven standard alarm messages (listed below) and two custom alarms.
Select the alarm message desired and store it by pressing ENTER.
•
•
•
•
•
•
3.16
SMOKE DETECTED
WATER FLOW LOSS
SMOKE DETECTED
LOSS OF AIR FLOW
HUMIDIFIER PROBLEM
FILTER CLOG
Custom Text
To modify the two custom alarm messages select CUSTOM TXT. Then select CUS TXT #1 or
CST TXT #2. Text can be up to 20 characters in length and can be either a blank space or any of the
following alphanumeric characters and symbols:
• A,B,C,D,E,F,G,H,I,J,K,L,M,N,O,P,Q,R,S,T,U,V,W,X,Y,Z
• #,%,*,• 0,1,2,3,4,5,6,7,8 or 9
Use the UP or DOWN arrow to select a character, then press ENTER. The cursor will move to the
next space where you may once use the UP or DOWN arrow to select another character, etc.
LCD Display Contrast
The level of contrast due to the viewing angle of the LCD display can be adjusted using a potentiometer screw, inside the wallbox next to the display.
Nonvolatile Memory
All critical information is stored in nonvolatile memory. Setpoints, setup parameters and component
run hours are kept inside the microcontroller in EEPROM.
Equipment Options Switches
Equipment options are selected and enabled using DIP switches 1 through 7. These are located on the
control board near TB1. These switches are factory set and should not require any user changes. The
setting and function of the switches can be individually read on the LCD display.
NOTE
In order to update the dip switch settings, power must be cycled off, then
on, from the unit disconnect switch.
36
Microprocessor Control
Table 18
Switch
Equipment Switch Settings (Unit Control Board)
OFF Position
ON Position
1
Compressor
2
Staged Reheat
n/a
3
Not Used
Not Used
4
Not Used
Not Used
5
Enable Reheat
Disable Reheat
6
Enable Humidifier
Disable Humidifier
7
Enable Dehumidifier
Disable Dehumidifier
8
Electric Reheat
n/a
Table 19
Switch
Chill Water
Switch settings (wall box board)
OFF Position
ON Position
1
Beeper Disable
Beeper Enable
2
Not Used
Not Used
3
Not Used
Not Used
4
Not Used
Not Used
5
Not Used
Not Used
6
Not Used
Not Used
7
Disable Setback
Enable Setback
8
Enable Password
Disable Password
37
Microprocessor Control
3.17
Run Diagnostics
By selecting RUN DIAGNOSTICS, maintenance personnel can check system inputs, outputs and conduct a test of the microcontroller circuit board from the wall box control. A review of the system
inputs and the microcontroller test can be done without interrupting normal operation.
Test Outputs
When this feature is selected, the unit is effectively turned off. When stepping from one load to the
next, the previous load is automatically turned off. The loads can also be toggled on/off by selecting
ENTER. Once turned on, the output will remain on for five minutes unless toggled off or the test outputs function is exited by selecting MENU/ESC (compressor is limited to 15 seconds on to prevent
damage).
!
CAUTION
!
CAUTION
Testing compressor output for more than a few seconds could damage the compressor. To
eliminate damaging the compressor during testing, DO NOT test compressor output for more
than a few seconds.
Extended unit operation in the test outputs mode for troubleshooting may cause damage to
unit. DO NOT operate unit in the test outputs mode any longer than is necessary for
troubleshooting.
NOTE
Fan turned on with all loads.
The outputs are as follows:
• Main Fan
• Comp1
• C1 & HGBP
• Comp2
• C2 & HGBP
• C1 & C2
• Chill Water/Gly (if present)
• Reheat 1
• Reheat 2
• Humidifier
• Common Alarm
Test Inputs
With the unit on and the fan running, the input states may be displayed for the following devices:
• Input Power.
• High Water in Pan
• High Head Comp1
• High Head Comp2
• Air sail switch (requires additional factory-installed components).
• Filter Clog
• Humidifier Prob.
• Custom Alarm #1
• Custom Alarm #2
• Custom Alarm #3)
Test Control Board
By selecting this function, the microcontroller will perform a self test lasting approximately 10 seconds. When the test is complete, the display will show the ROM checksum, ROM part number and
firmware revision number.
38
Microprocessor Control
Figure 20 Control menu
Setpoints
Temp Setpt
Temp Sens
Hum Setpt
Hum Sens
Hi Temp Alm
Lo Temp Alrm
Hi Hum Alm
Lo Hum Alm
Status Display
72 F 50 %RH
NO ALARMS
Menu
Setpoints
Status
Active Alarms
Alarm History
Time
Date
Setback
Setup Operation
Setpoint
Password
Setup Password
Calibrate Sensor
Alarm Enable
Alarm Time Delay
Com Alarm
Enable
Custom Alarms
Custom Text
Diagnostics
End of Menu
Status
Dx Cool %
0
CW Valve% 0
Econo Cool % 0
Heat %
0
Dehumidify% 0
Humidify%
0
Active Alarms
No Alarms
or
Alarm 01 of 01
High Head
Time
Date
Setback
Wknd Time 1
On/Off:
Wknd Temp 1
Wknd Tsens 1
Wknd Humd 1
Wknd Hsens 1
Wknd Time 2
On/Off:
Wknd Temp 2
Wknd Tsens 2
Wknd Humd 2
Wknd Hsens 2
Wkdy Time 1
On/Off:
Wkdy Temp 1
Wkdy Humd 1
Wkdy Hsens 1
Wkdy Time 2
On/Off:
Wkdy Temp 2
Wkdy Tsens 2
Wkdy Humd 2
Wkdy Hsens 2
39
Setup Operation
Restart TD
C/F Degrees
Humidity Control
Lead Compr
Dipswch 00000000
Pos 12345678
Valve Time
CW Flush
Setpoint Password
Enter New PSW
Setpt PSW = 000
Setup Password
Enter New PSW
Setup PSW = 000
Calibrate sensor
Temp Cal
Hum Cal
Temp Delay
Hum Delay
Alarm Enable
Hum Prob
Chng Fltr
Loss Air
Custom #1
Custom #2
Custom #3
High Temp
Low Temp
High Hum
Low Hum
Short Cyc1
Short Cyc2
Fan Ovrld
Loss Pwr
Alarm Time Delay
Hum Prob
Chng Filt
Loss Air
Custom #1
Custom #2
Custom #3
High Temp
Low Temp
High Hum
Low Hum
Short Cyc1
Short Cyc2
Fan Ovrld
Loss Pwr
Com Alarm Enable
Hum Prob
Hi Head 1
Hi Head 2
Chng Fltr
Loss Air
Custom #1
Custom #2
Custom #3
Hi Water
High Temp
Low Temp
High Hum
Low Hum
Short Cyc1
Short Cyc2
Fan Ovrld
Loss Pwr
Custom Alarms
Custom Alarm #1
Custom Alarm #2
Custom Alarm #3
Custom Text
Custom Text #1
Custom Text #2
Custom Text #3
Diagnostics
Test Outputs
Test Inputs
Test Microcontroller
Microprocessor Control
Figure 21 Control board (inside evaporator)
DIP Switches
TB2-4
Hot Gas Bypass
TB2-3
High Head Alarm Connection
TB2-2
Heat Rejection
TB2-1
Heat Rejection
TB1-9
Condensate Pump Aux Alarm
TB1-8
Condensate Pump Aux Alarm
TB1-7
Common Alarm Connection
TB1-6
Common Alarm Connection
TB1-5
Remote Shutdown
TB1-4
Remote Shutdown
TB1-3
Customer Alarm Connection #2
TB1-2
Customer Alarm Connection #1
TB1-1
Customer Alarm Connection (Common)
TB3-4
Connection to TB3 pin 4 of wall box
TB3-3
Connection to TB3 pin 3 of wall box
TB3-2
Connection to TB3 pin 2 of wall box
TB3-1
Connection to TB3 pin 1 of wall box
TB4-2
Site Monitoring Connection (-)
TB4-1
Site Monitoring Connection (+)
P16
Remote Sensor Connection
40
Microprocessor Control
Figure 22 Wall box board
TB3-1
TB3-2
TB3-3
TB3-4
DIP Switches
(1-8)
41
System Performance, Microprocessor Controls
4.0
SYSTEM PERFORMANCE, MICROPROCESSOR CONTROLS
This section provides a detailed description of how the DataMate responds to operator inputs and
room conditions.
4.1
Temperature Control
4.1.1
Cooling/Heating Required
The temperature control program for the microprocessor is based on a calculated percentage requirement for cooling/heating.
4.1.2
Cooling Operation (Compressorized Direct Expansion and Chilled Water)
Cooling is ACTIVATED when the temperature control calculates a requirement for cooling of 100%. It
is DEACTIVATED when the cooling requirement drops below 50%. The optional hot gas bypass is
energized when a call for cooling occurs, unless there is also a call for dehumidification.
Table 20
Cooling and dehumidification load response of hot gas bypass
Situation
4.1.3
Hot Gas Bypass
Cooling only
ON
Dehumidification only
OFF
Cooling with Dehumidification
OFF
Heating Operation
Electric Heat
The reheat stage is ACTIVATED when the temperature control calculates a requirement of 100%.
Conversely, the reheat is DEACTIVATED when the heat requirement is 50% less than the activation
point.
4.2
Humidity Control
4.2.1
Dehumidification/Humidification Required
The humidity control is based on a calculated percentage requirement for dehumidification or humidification (i.e., the difference between the return air humidity and the humidity setpoint). As the
return air humidity rises above the humidity setpoint, the percent dehumidification required
increases proportionally from 0 to 100% over a humidity band equal to the humidity sensitivity setting. The converse is true for percent humidification requirement.
4.2.2
Dehumidification Operation, Compressorized Direct Expansion (DX) Systems
Dehumidification with the standard configuration is accomplished by operating the compressor without the hot gas bypass active. The fan will operate at low speed unless the cooling requirement
reaches 100%. At that time, the low speed fan is disabled (unless manually overridden by the user)
until the cooling requirement decreases to 0%. Dehumidification will also be disabled if the heating
requirement exceeds 125%. It is re-enabled when the heating requirement reaches 50%.
4.2.3
Humidification Operation
The canister humidifier is activated when the humidity control calculates a requirement of 100%
humidification and is deactivated when the humidification requirement falls below 50%.
4.3
Load Control Features
The control system monitors the compressor and prevents it from turning on within a 3 minute period
of being off. If this on-off-on cycle occurs too often (e.g., 10 times in one hour) a Short Cycle Alarm will
occur.
42
System Performance, Microprocessor Controls
4.3.1
Communications
The control system uses a two-wire, RS-422 channel to communicate with Liebert Site Products via a
proprietary protocol. A converter board (ECA2) is available to allow communications with a “dumb”
terminal or a computer using RS-232 channel. More details are provided in the Site Products and
ECA2 User Manual.
The communications channel provides both monitoring and control options, including:
•
•
•
•
TEMPERATURE/HUMIDITY: Current temperature and humidity readings.
STATUS (%), Cooling/heating and humidify/dehumidify operating status.
PRESENT ALARMS: Alarms currently activated.
SETPOINTS:
• Temperature Setpoint
• Temperature Sensitivity
• Humidity Setpoint
• Humidity Sensitivity
• High Temperature Alarm
• Low Temperature Alarm
• High Humidity Alarm
• Low Humidity Alarm
• ON/OFF STATUS and CONTROL
• SILENCE ALARM
43
Alarms
5.0
ALARMS
The microprocessor control system will audibly and visually signal all enabled alarms (including two
custom alarms). These special alarms can be chosen from the optional alarm list and/or can have their
own fully custom text. The custom alarm inputs are contact closures wired from terminal TB1-1
through a normally open contact to either TB1-2 (alarm 1) or TB1-3 (alarm 2). The alarms can be
enabled/disabled (refer to 3.0 - Microprocessor Control) and a time delay of 0-255 seconds can be
set. The alarms can also be programmed to either sound the alarm & activate the common alarm
relay OR to sound the alarm only.
When a new alarm occurs, it is displayed on the screen and the audible alarm is activated. (If communicating with a Liebert Site Product, the alarm is also transmitted). The message PRESS ALARM
SILENCE will prompt the operator to silence the alarm. After the alarm is silenced, the display will
return to the Normal Status Display. Alarms can be reviewed by selecting the ACTIVE ALARMS feature. The alarms also can be silenced through communications with a Liebert Site Products Unit.
Many alarms will reset automatically when the alarm condition is no longer present and only after it
has been acknowledged by being silenced. The exceptions are: 1) software alarms, i.e., Loss of Power
and Short Cycle alarms will reset automatically 30 seconds after being silenced or acknowledged; and
2) specific alarms monitoring overload or high-pressure switches may require a manual reset depending upon the model.
5.1
Alarms: Definitions and Troubleshooting
The following list provides a definition and troubleshooting suggestions for each type of alarm. Refer
to 8.0 - Troubleshooting for additional details. If you need further assistance, contact your Liebert
supplier. ALARMS MUST BE SPECIFIED AT THE TIME OF ORDER. OTHER DEVICES AND
WIRING MAY BE REQUIRED AT THE FACTORY FOR SOME OF THE ALARMS.
5.1.1
Custom Alarms
Custom alarm(s) messages are programmed at the LCD display. The message displayed may be
included in a list of provided alarms or it may be customized text (for up to 3 alarms). IF CUSTOMIZED TEXT IS USED, MAINTENANCE PERSONNEL SHOULD BE INFORMED OF THE ALARM
FUNCTION AND THE REQUIRED ACTION.
5.1.2
High Head Pressure
Compressor head pressure is monitored with a pressure sensor switch. (One SPDT pressure switch is
used.) If head pressure exceeds 360 psig, the switch turns off the compressor contactor and sends an
input signal to the control. The condition is acknowledged by pressing the alarm silence button on the
wall box, which will clear if high head pressure is alleviated. If the head pressure alarm has activated
three times, the alarm will lock until the unit is serviced. After the head-pressure problem is fixed,
reset the control by disconnecting power to the evaporator unit.
Air Cooled Systems
Check for power shut off to the condenser, condenser fans not working, defective head pressure control valves, dirty condenser coils or crimped lines.
Water/Glycol/ Systems
Check water regulating valves. Verify water/glycol flow (i.e., pumps operating and service valves
open). Is water tower or drycooler operating? Is the coolant temperature entering the condenser at or
below design conditions? Is AUX relay (terminals 70 & 71) operating during cooling to turn on the
drycooler?
44
Alarms
5.1.3
Humidity
The humidity alarm may be activated under the following conditions:
• High: The room return air humidity exceeds the pre-set high humidity alarm setpoint. Is the unit
set up for dehumidification? Check DIP switch.
• Low: The room return air humidity decreases to the low humidity alarm setpoint. Is the unit
setup for humidification? Check DIP switch.
• High and Low Humidity (simultaneously): The simultaneous display of two alarms results in
loss of the humidity input signal. DASHES WILL BE DISPLAYED IN THE HUMIDITY READING DISPLAY. Under these conditions, the control system deactivates both humidification and
dehumidification. Check for a disconnected cable or failed sensor.
NOTE
Check for proper setpoints. Does the room have a vapor barrier to seal it from outdoor
humidity? Are doors or windows open to outside air?
5.1.4
Temperature
The temperature level alarm may be activated under the following conditions:
• High: The room return air temperature increases to the high temperature alarm setpoint. Check
for proper setpoint value. Is the room load more than the unit can handle (i.e., capacity too small)?
Make sure cooling components are operating (compressor or valves).
• Low: The room return air temperature decreases to the low temperature alarm setpoint. Check
for proper setpoint value. Make sure all heating components are operating (e.g., contactors,
reheats, etc.). Are reheats drawing the proper current (refer to amp rating on nameplate).
• High and Low (simultaneously): The simultaneous display of these two alarms results in loss
of the temperature input signal (or the humidity is out of sensor range-15 to 85% RH). Dashes will
be displayed for the temperature reading. The control system will initiate 100% cooling. Check for
a disconnected cable or a failed sensor.
5.1.5
Loss of Power
The Loss of Power alarm will activate (after power is restored to the unit) if the unit has lost power or
the disconnect switch was incorrectly turned off before the unit ON/OFF switch was pressed. A Liebert remote monitoring unit (optional) will immediately indicate loss of power.
5.1.6
Short Cycle
A Short Cycle alarm will occur if a compressor system has exceeded 10 cooling start attempts in a onehour period. This can be caused by low refrigerant level or if the room cooling load is small compared
to unit capacity. Check for leaks, crimped lines and defective components. If the room load is low,
increase the temperature sensitivity to reduce cycle.
5.2
Optional/Custom Alarms
5.2.1
Loss of Water Flow
The Loss of Water Flow alarm will occur if no water flow is detected in the chilled water or condenser
water supply line. And external flow switch is required for this alarm. Check of service valves closed,
pumps not working, etc.
45
System Testing and Maintenance
6.0
SYSTEM TESTING AND MAINTENANCE
This section describes system testing, maintenance and replacement procedures. Use copies of the
Maintenance Inspection Checklist to record preventive maintenance inspections.
!
WARNING
Unit contains hazardous electrical voltage. Disconnect power supply before working within.
Line side of factory disconnect remains energized when disconnect is off.
6.1
System Testing
6.1.1
Environmental Control Functions
The performance of all control circuits can be tested by changing the setpoints, which activates each
of the main functions.
6.1.2
Cooling
To test the cooling function, set the setpoint to a temperature of 10°F (5°C) below room temperature.
A call for cooling should register and prompt the equipment to begin cooling cycle. (Disregard any
temperature alarms.) Upon completion of testing, return setpoint to the desired temperature.
6.1.3
Heating
Reheat may be tested by setting the setpoint 10°F (5°C) above room temperature. A call for heating
should register and prompt the equipment to begin heating cycle. (Disregard any temperature
alarms). Upon completion of testing, return setpoint to the desired temperature.
6.1.4
Humidification
To check humidification, set the humidity setpoint at RH 10% above the room humidity reading. After
a short delay, the canister will fill with water and steam will be produced. Upon completion of testing,
return the humidity setpoint to the desired humidity.
6.1.5
Dehumidification
The dehumidification performance can be tested by setting the humidity setpoint at RH 10% below
room relative humidity. The compressor should turn on. Upon completion of testing, return humidity
setpoint to the desired humidity.
6.1.6
Remote Shutdown
A connection point is provided for remote shutdown devices supplied by the customer. This terminal
strip is located in the electric panel. (Terminals 37 and 38 are fitted with a jumper when no remote
shutdown device is installed).
6.2
Maintenance
6.2.1
Electric Panel
The electric panel should be inspected on a semiannual basis for any loose electrical connections.
6.2.2
Filters
Filters are usually the most neglected item in an environmental control system. In order to maintain
efficient operation, they should be checked monthly and changed as required. ALWAYS TURN
POWER OFF BEFORE REPLACING FILTERS.
The washable filter is located behind the access door on the lower front of the fan coil unit.
46
System Testing and Maintenance
6.2.3
Direct Drive Blower Package
Monthly inspection of the blower package includes: motors, motor mounts and impellers.
Fan Impellers and Motor Bearings
Fan impellers should be thoroughly inspected and any debris removed. Check to see if they are tightly
mounted on the fan shaft and do not rub against the fan housing during rotation. Although the motor
bearings are permanently sealed and self-lubricating and do NOT need lubricated, they should be
inspected monthly for signs of wear.
Air Distribution
Since all unit models are designed for constant volume air delivery, any unusual restrictions within
the air circuit must be avoided.
6.2.4
Refrigeration System
Each month the components of the refrigeration system should be inspected for proper function and
signs of wear. Since in most cases evidence of malfunction is present prior to component failure, periodic inspections can be a major factor in the prevention of most system failures. Refrigerant lines
must be properly supported and not allowed to vibrate against ceilings, floors or the unit frame.
Inspect all refrigerant lines every six months for signs of wear and proper support. Inspect the capillary and equalizer lines from the expansion valve.
Suction Pressure
Suction pressure will vary with load conditions. Suction pressure normally ranges from 58 psi to 75
psi (405 kPa to 517 kPa).
Discharge Pressure
The discharge pressure will vary greatly with load and ambient conditions (Table 21). The high-pressure switch will shutdown the compressor at its cut-out setting.
Table 21
Typical discharge pressures
System Design
psig
(kPa)
Air Cooled
180-275
(1242-1895)
Water Cooled
65 to 85ºF water
(18 to 29.4ºC)
200-225
(1380-1550)
Glycol Cooled
210-275
(1445-1895)
Maximum
330
(2275)
High-Pressure Cut-Out
360
(2480)
Thermostatic Expansion Valve
The thermostatic expansion valve keeps the evaporator supplied with enough refrigerant to satisfy
load conditions. Proper valve operation can be determined by measuring superheat level. If too little
refrigerant is being fed to the evaporator, then the superheat will be high. Conversely, if too much
refrigerant is being supplied, then the superheat will be low. The correct superheat setting is between
10 and 15°F (5.6 and 8.3°C).
Air Cooled Condensing Units
Restricted airflow through the condenser coil will reduce the operating efficiency of the unit. Additionally, it can result in high compressor head pressure and loss of cooling. Using compressed air or
commercial coil cleaner, clean the condenser coil of all debris that will inhibit airflow. In winter, do
not permit snow to accumulate around the side or underneath the condenser. At the same time check
for bent or damaged coil fins and repair as necessary. Check all refrigerant lines and capillaries for
vibration and support as necessary. Carefully inspect all refrigerant lines for signs of oil leaks.
47
System Testing and Maintenance
Coaxial Condensers (Water/Glycol Cooled Condensing Units)
Each water or glycol-cooled module has a coaxial condenser consisting of an exterior steel tube and an
interior copper tube. If the water supply is clean, coaxial condensers do not normally require maintenance or replacement. Should your system begin to operate at high head pressure with reduced capacity and all other causes have been eliminated, the condenser may be obstructed or fouled and should
be replaced.
Regulating Valves
The water regulating valve automatically regulate the amount of fluid necessary to remove the heat
from the refrigeration system, permitting more fluid to flow when load conditions are high and less
fluid to flow when load conditions are low. The valve consists of a brass body, balance spring, valve
seat, valve disc holders, capillary tube to discharge pressure and adjusting screw.
The water regulating valve is designed to begin opening at 180 psi (1240 kPa) and be fully opened at
240 psi (1655 kPa). The valve is factory set and should not need adjustment. There is a significant difference in the way standard pressure and high-pressure valves are adjusted. Consult Liebert Service.
Glycol Solution Maintenance
It is difficult to establish a specific schedule of inhibitor maintenance since the rate of inhibitor depletion depends upon local water conditions. Analysis of water samples at time of installation and every
six (6) months should help to establish a pattern of depletion. A visual inspection of the solution and
filter residue is often helpful in judging whether or not active corrosion is occurring. The complexity of
problems caused by water requires expert advice from a water treatment specialist plus a regular
maintenance program schedule. It is important to note that improper use of water treatment chemicals can cause severe problems.
Proper inhibitor maintenance must be performed in order to prevent corrosion of the glycol system.
Consult your glycol manufacturer for proper testing and maintenance procedures. Do not mix products from different manufacturers.
Hot Gas Bypass (Optional)
Operation
When applying hot gas bypass with split system condensing units, bypassing discharge gas to the
compressor suction line offers more flexibility than conventional hot gas bypass to the evaporator
unit.
The hot gas bypass valve is installed between the compressor discharge piping and suction piping,
bypassing the condenser and evaporator coils. The discharge gas mixes with the suction gas, raising
the suction temperature and pressure and decreasing the mass flow through the evaporator. The
higher suction temperatures could cause compressor overheating, therefore a separate liquid quenching valve is provided to mix refrigerant from the system liquid line with the discharge gas before mixing with the suction gas entering the compressor.
During normal operation, when the evaporator is under full load the hot gas bypass equalizer pressure will remain high enough to keep the valve port closed. If the evaporator load decreases, the evaporator temperature and pressure will drop. When the suction pressure reduces below the hot gas
bypass valve setting the hot gas bypass valve opens diverting some of the refrigerant flow back to the
compressor suction. The liquid quenching valve bulb senses this increased superheat and opens,
allowing liquid refrigerant to mix with the discharge gas, desuperheating it.
Proper mixing of the three refrigerant paths ensures stable operation and system performance. The
liquid quenching valve bulb must be located downstream of all these connections to control superheat
at the compressor inlet. Superheat settings for the liquid quenching valve are chosen to maintain consistency with the system expansion valve. During hot gas bypass operation higher superheats,
25-40°F (14-22°C), may be observed at the compressor. The liquid quenching valve is internally equalized and superheat is not adjustable.
48
System Testing and Maintenance
Adjustment
1. Install the suction and discharge pressure gauge.
2. Adjust temperature setpoint to call for cooling so that the refrigeration compressor will run
continuously.
3. Remove the TOP adjusting nut from the valve.
4. Insert an Allen wrench in the brass hole at top of valve in adjusting port and turn CLOCKWISE if
a higher evaporator temperature is required. Adjust no more than 1/4 turn at a time. Let the
system stabilize for 15 minutes before determining if additional adjustment is necessary.
5. After obtaining the suction pressure required, reinstall cap tightly making sure there are no
leaks.
6. Let the evaporator operate for approximately 10 to 15 minutes to make sure the suction pressure
is within the range desired.
7. There may be a fluctuation of approximately 3 to 6 psig (21 to 41 kPa) on the evaporator due to
the differential on the hot gas bypass.
8. Return temperature setpoint to the desired setting.
49
System Testing and Maintenance
Replacement Procedures
Compressor Replacement—Infrequently, a fault in the motor insulation may result in a motor
burnout (if system is properly installed, motor burnout rarely occurs). Primarily this type of failure is
due to mechanical or lubrication problems, where the burnout is a secondary consequence.
Early detection can prevent a large percentage of the problems that can cause compressor failures.
Periodic maintenance inspections by alert service personnel (i.e., identification of abnormal operation) can be a major factor in reducing maintenance costs. It is easier and more cost-effective to implement the necessary preventative steps that ensure proper system operation; rather than ignore a
problem until it results in compressor failure and costly replacement. When troubleshooting a compressor problem, check all electrical components for proper operation:
!
CAUTION
Avoid touching or contacting the gas and oils with exposed skin. Severe
burns will result. Use long rubber gloves in handling contaminated parts.
• Check all fuses and circuit breakers.
• Check pressure switch operation.
• If a compressor failure has occurred, determine whether its cause is an electrical or mechanical
problem.
!
CAUTION
System contains refrigerant. Recover refrigerant before maintenance
Mechanical Failure—If you have determined that a mechanical failure has occurred, the compressor must be replaced. If a burnout occurs, correct the problem and clean the system. It is important to
note that successive burnouts OF THE SAME SYSTEM are usually caused by improper cleaning. If a
severe burnout has occurred, the oil will be black and acidic.
Electrical Failure—In the event of an electrical failure and subsequent burnout of the refrigeration
compressor motor, proper procedures must be followed to thoroughly remove any acids that would
cause a future failure. There are two kits that can be used with a complete compressor burnout Sporlan System Cleaner and Alco Dri-Kleener. Follow the manufacturer's procedure. DAMAGE TO A
REPLACEMENT COMPRESSOR DUE TO IMPROPER SYSTEM CLEANING CONSTITUTES
ABUSE UNDER THE TERMS OF THE WARRANTY, THEREBY VOIDING THE WARRANTY.
Replacement compressors are available from your Liebert supplier and will be shipped to the job site
in a reusable crate (as required by the service contractor). If the compressor is under warranty, it
must be returned to Liebert in order to receive proper warranty credit. It should be returned in the
same container the replacement was shipped in. The possible cause(s) or condition(s) of the damage
should be legibly recorded on the provided return tag.
Proper procedures to remove and replace the failed compressor are:
1. Disconnect power
2. Attach suction and discharge gauges to access fittings.
3. Recover refrigerant using standard recovery procedures and equipment.
NOTE
Release of refrigerant to the atmosphere is harmful to the environment and unlawful.
Refrigerant must be recycled or discarded in accordance with federal, state and local
regulations.
4. Remove failed compressor.
5. Install replacement compressor and make all connections. Pressurize and leak test the system at
approximately 150 psig (1034 kPa) pressure.
6. Follow manufacturer's instructions for clean out kits.
7. Evacuate the system twice to 1500 microns and the third time to 500 microns. Break the vacuum
each time with clean, dry refrigerant to 2 psig (13.8 kPa).
8. Charge the system with refrigerant (R-22) based on requirements of the evaporator, condensing
unit and lines. Refer to the installation manual or the unit nameplate.
9. Apply power and operate the system. Check for proper operation. Refer to Table 21 for discharge
pressure.
50
System Testing and Maintenance
6.2.5
Humidifier
The optional humidifier system consists of a water canister with an internal set of electrodes that
generate the steam used for humidification. The steam is introduced into the air through a copper discharge tube in the coil bypass section.
The humidifier Run/Drain switch is located near the humidifier canister. This switch should be in the
Run position when the humidifier is in normal operation and in the Drain position when a manual
drain sequence is required.
The humidifier is designed to operate with water systems having 10 to 150 psig water pressure.
Steam generating capacity is 3 lb/hr.
Humidifier Operation
1. During start-up, when the controller calls for humidification, the fill valve opens and water enters
the canister. When the water level reaches the electrodes, current flows and heats the water. The
canister fills until the amperage reaches the setpoint and the fill valve closes. As the water
warms, its conductivity increases and the current rises. If the amperage reaches 115% of the
setpoint, the drain valve opens momentarily. This reduces electrode contact with the water and
lowers the current to 100%. Boiling soon commences and the canister operates normally.
2. Normal operation is controlled by a time cycle which is factory set at 60 seconds. At the end of
each cycle, the fill valve opens to replenish the water boiled off so a “steady state” is maintained.
3. If the conductivity of the water is low, the fill valve will remain open. Before the amperage
reaches setpoint, the water level may reach the overflow tube and drain. Boiling should
commence in time. As water is boiled off, the mineral concentration in the canister increases. The
humidifier eventually reaches full output and goes into normal operation. Refer to Circuit Board
Adjustments on page 52 for the “%” pot.
4. During canister operation, the mineral concentration increases and water boils off rapidly. The
current decreases quickly because water contacts less electrode surface. When the current
decreases to the low threshold point before the end of the time cycle, the drain valve opens. The
mineral laden water drains out and is replaced 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. The electrode surface will eventually become coated with a layer of insulating material, which
causes a drop in current flow. 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 overflow tube and continuously drain water out of the canister. Steam capacity will
decline. At this point, all of the electrode surface has been used up and the canister should be
replaced.
NOTE
When the unit stays in humidification mode and no longer produces steam, the humidifier
canister needs to be replaced.
6. 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.
See Page 52 for instructions for replacing the canister.
51
System Testing and Maintenance
Circuit Board Adjustments
!
WARNING
Circuit board adjustment should be performed by qualified personnel only. Hazardous
voltages are present in the equipment. Use extreme caution. Power may be disconnected
while making adjustments.
Humidifier operation is governed by the humidifier control board. This board is located on the left
side of the evaporator unit. Three potentiometers are 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. This adjustment is factory set at
70%, which indicates that the unit will drain when the amperage decreases to 70% of the setpoint.
The% value should be increased for highly conductive water and decreased for less conductive water.
If a change of three to four percent in either direction does not resume normal operation, consult Customer Service and Support.
The pot marked “cap adj” controls humidifier capacity. It is factory set at 65%. Adjustment may be
required if more humidification is needed.
NOTE
If condensation occurs on the discharge grille, reduce humidifier capacity.
The pot marked “sec” controls the duration of the drain cycle. This adjustment is factory set at 60 seconds. Consult Customer Service and Support before adjusting either of these two pots.
Replacing the Humidifier Canister
The proper procedure to replace the humidifier canister is:
1. Turn off the humidifier by lowering the humidity setpoint below the ambient humidity level.
Record the original setpoint.
2. Turn unit off at wallbox.
3. Place the RUN/DRAIN switch in the DRAIN position to drain the water from the canister.
4. Return the RUN/DRAIN switch to the RUN position after the canister has drained.
5. Turn OFF the power at the main unit.
6. Remove the cover from the humidifier cabinet.
7. Locate the power wires to the steam canister. They are connected to the canister with 1/4" quick
connects. Make note of the wiring configuration before removing any wires. Refer to schematic on
unit. Slide the rubber boot back to expose the connections. Remove the three (3) power wires and
the canister full wire. Do not loosen the screws that secure the electrodes.
!
WARNING
Canister and steam hose may be hot! Allow time for the humidifier to cool before replacing
parts.
8. Loosen the steam outlet hose clamps and slide the steam hose away from the canister fitting.
9. Remove the canister.
10. Reverse previous steps to reassemble humidifier, paying special attention to the following:
• sealing the O-ring on the canister
• making sure the steam outlet hose is connected without leaks
• connecting the power wire correctly
• returning the run/drain switch to the “run” position
• checking to make sure no leaks are present
52
Maintenance Inspection Checklist
7.0
MAINTENANCE INSPECTION CHECKLIST
Date:
Prepared By:
Model #:
Serial Number:
NOTE
Regular inspections are necessary to assure proper cleanliness. Should inspection reveal
corrosion particles on the reheating element or adjoining surfaces (including ducts and
plenums), appropriate cleaning should be performed. Periodic reheating element replacement
may be required to meet specific application requirements.
MONTHLY
Humidifier
Filters
___ 1. Check for restricted airflow.
___ 2. Check for filter.
___ 3. Wipe section clean.
___ 1.
___ 2.
___ 3.
___ 4.
Fan Section
___ 1. Impellers free of debris and move freely
___ 2. Bearings in good condition
Compressor Section
Check canister for mineral deposits.
Check condition of electrodes.
All hoses and fittings tight.
Check water make-up valve for leaks.
System, Including Condensate Pump
___ 1. Check and clean out unit drain lines,
humidifier and drain, condensate pump and
building drain lines
SEMIANNUALLY
Flood Back Head Pressure Control
___ 1. Signs of oil leaks
___ 2. Vibration isolation
___ 1. Check refrigerant level
Refrigeration Cycle
___ 1. Water valve adjustment
___ 2. Water flow
___ 3. Water leaks
___ 1.
___ 2.
___ 3.
___ 4.
___ 5.
Water or Glycol Cooled Condensing Unit
Suction pressure
Head pressure
Superheat
Evaporator coil clean
Insulation intact
Glycol Pump (if applicable)
___ 1.
___ 2.
___ 3.
___ 4.
Air Cooled Condensing Unit (if applicable)
___ 1.
___ 2.
___ 3.
___ 4.
Condenser coil clean
Motor mount tight
Bearings in good condition
Refrigerant lines properly supported
Glycol leaks
Pump operation
Glycol solution
pH level
Electric Panel
___ 1. Check electrical connections
___ 2. Operational sequence
Electric Reheat
___ 1. Check element for signs of corrosion.
Notes:
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
Signature: ______________________________________________________________________
Make photocopies of this form for your records
53
Troubleshooting
8.0
TROUBLESHOOTING
Table 22
Troubleshooting
Symptom
Unit will not start
No cooling
Compressor high
head pressure
Humidifier does not
operate
Reheat will not
operate
Possible Cause
Check Or Remedy
No power to unit
Check voltage at input terminal block.
Control voltage circuit
breaker (at transformer)
open
Locate short and reset circuit breaker.
Float switch relay has closed
due to high water in the
condensate pump sump.
Check drain and line as well as for failed pump. Access through left
panel. Power must be cycled at the disconnect to reset.
Jumper not in place
Check terminal 37 and 38 for jumper or N/C contact. Check pins
P39-1 and P39-2 for jumper or N/C firestat contact.
“Cooling” is not displayed at
the control panel.
Adjust TEMP control setpoint and sensitivity to require cooling.
Short cycle prevention
control
Control software delays compressor 3 minutes cooling, from stop to
start
Compressor contactor not
pulling in.
Check for 24VAC ± 2VAC at terminals TB5-1 and TB5-2. If voltage,
check contactor.
Compressor high head
pressure
See below for cause.
Plugged filter/dryer.
Replace filter/dryer.
Low refrigerant charge.
Check pressure gauges. At low ambient temperatures, proper
refrigerant charge is very important on units with Lee-Temp receivers.
Insufficient air flow across
condenser coil
Remove debris from coil and air inlets.
Water/Glycol Cooled only:
No fluid flowing through
condenser.
Check fluid supply to regulating valve. Adjust valve if necessary.
Condenser fan not operating
Check fan operation.
DIP switch not set to enable
humidifier option
See DIP switch settings.
“HUMIDIFY” not displayed
at control panel
Increase humidity control setpoint and sensitivity to require
humidification.
Defective board
Check voltage at P3-1 and P3-2 on interface board for 24VAC
± 2VAC. If no voltage, check wiring and/or replace board. Check
wiring from control panel to humidifier circuit board.
Failed humidity sensor
Humidity display will indicate dashes. Check wiring from temperature/
humidity board to the control board and from the wall box to the
control board. Replace wallbox or temperature/humidity circuit board
(if remote).
No water flow
Make sure switch is in Run position. Check humidifier water supply
(including filter screen) and check nylon overflow line if canister is full.
Canister fill rate is not
keeping up with the steam
output
Check fill valve screen opening and capillary tube for obstructions.
Check water supply pressure (minimum 10 psig).
DIP switch not set to enable
reheat option
See DIP switch settings.
“HEAT” not displayed at the
control panel
Increase temperature setpoint to require heating.
Reheat safety open,
defective reheat contact or
defective board
Check voltage at P2-1 or P2-2 to P34-10 on control board for 24VAC
± 2VAC. If voltage, check reheat contactor and reheat safety. If no
voltage, check wiring and/or replace board.
Element is burned out
Turn off power. Check element continuity with Ohm meter.
54
Troubleshooting
Table 22
Troubleshooting (continued)
Symptom
Cooling cycle too
short
Possible Cause
Check Or Remedy
Sensor response delay too
short
Increase sensor response delay. See 3.11 - Calibrate Sensors.
Display freezes
and control pads
do not respond
Static discharge
During period of low humidity, static electricity can cause the control
program to freeze or display incorrect information. Although this is
unlikely, the control can be reset by cycling power from the disconnect
switch.
Condensate pump
does not operate
Open or short circuit in
wiring
Find open or short circuit and repair power to pump.
Continuous cooling
Failed temperature sensor
Temperature display will indicate dashes. Check wiring from
temperature/humidity board (remote sensors) to the control board or
from control board to wallbox. Replace temperature/humidity circuit
board (remote sensors) or wallbox.
Continuous
Heating
Dehumidification
Humidification
Shorted wiring or failed
control board
Check wiring and/or replace control board.
No fan operation at
low speed when
selected at control
panel
Open wiring or failed
interface board
Verify “LOW FAN” is displayed at the control panel. Check for 24VAC
± 2VAC at terminals P1-6 and P1-7. If no voltage, check wiring and/or
replace interface board.
No fan operation at
low speed during
dehumidification
Temperature is more than
2°F above the HIGH TEMP
setpoint
Verify with display. COOL requirement overrides DEHUMIDIFY.
Incorrect wiring
Review section 2.4.3 - Electrical Connections. Verify VDC between
5 and 6 volts at TB-3 Pin 1 (ground) and TB-3 Pin 2 of the control
board and wall box. If the transmit lines (TB-3 Pin 3 & 4) are not
connected, only the power LED will be lit. It will flash once every
10-12 seconds. If T- is connected but not T+, TX1 will flash about
every 2-3 seconds, and the power LED will flash once every 1012 seconds. If T+ and T- are reversed, the power LED and RX1 Will
be lit and flash every 10-12 seconds. NOTE: Erratic operation of the
unit could occur. If no LED is lit, there is no power or the +5VDC
polarity is reversed. If any of these conditions occur, remove power
from the evaporator using the disconnect switch, and correct the
wiring from the control board to the wall box. NOTE: It may take up
to 20 seconds for the display to appear on the wall box LCD after
power is applied.
Display
55
Troubleshooting
NOTES
56
HEAT REMOVAL/PRECISION AIR
DataMate
USER MANUAL FOR REV 3
The Company Behind the Products
With over a million installations around the globe,
Liebert is the world leader in computer protection
systems. Since its founding in 1965, Liebert has
developed a complete range of support and
protection systems for sensitive electronics:
•
•
•
•
•
Environmental systems—close-control air
conditioning from 1 to 60 tons
Power conditioning and UPS with power
ranges from 300 VA to more than 1000 kVA
Integrated systems that provide both
environmental and power protection in a
single, flexible package
Monitoring and control—from systems of any
size or location, on-site or remote
Service and support through more than 100
service centers around the world and a 24/7
Customer Response Center
While every precaution has been taken to ensure
the accuracy and completeness of this literature,
Liebert Corporation assumes no responsibility and
disclaims all liability for damages resulting from
use of this information or for any errors or
omissions.
© 2004 Liebert Corporation
All rights reserved throughout the world.
Specifications subject to change without notice.
® Liebert and the Liebert logo are registered
trademarks of Liebert Corporation. All names
referred to are trademarks or registered
trademarks of their respective owners.
SL-11040 (6/04)
Technical Support/Service
Web Site
www.liebert.com
Monitoring
800-222-5877
[email protected]
Outside the US: 614-841-6755
Single-Phase UPS
800-222-5877
[email protected]
Outside the US: 614-841-6755
Three-Phase UPS
800-543-2378
[email protected]
Environmental Systems
800-543-2778
Outside the United States
614-888-0246
Locations
United States
1050 Dearborn Drive
P.O. Box 29186
Columbus, OH 43229
Italy
Via Leonardo Da Vinci 8
Zona Industriale Tognana
35028 Piove Di Sacco (PD)
+39 049 9719 111
Fax: +39 049 5841 257
Asia
23F, Allied Kajima Bldg.
138 Gloucester Road
Wanchai
Hong Kong
+852 2 572 2201
Fax: +852 2 831 0114
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