Mini-Mate2 Installation and Maintenance Manual

Mini-Mate2 Installation and Maintenance Manual
®
ENVIRONMENTAL CONTROL
MINI-MATE2
INSTALLATION, OPERATION & MAINTENANCE MANUAL
MANUAL
5 Tons
50 & 60 Hz
TABLE OF CONTENTS
PRODUCT MODEL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.0
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.1
Product Description and Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1.1
1.1.2
1.1.3
1.2
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2.1
1.2.2
1.2.3
1.2.4
1.2.5
1.2.6
1.2.7
1.2.8
1.2.9
1.3
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Evaporator System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Condensing Unit Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Canister Humidifier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electric Reheat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SCR Electric Reheat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hot Water Reheat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hot Gas Bypass (Condensing Units). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Free-Cooling Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Smoke Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Firestat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filter Clog. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
6
6
6
6
6
6
6
6
Ancillary (Ship Loose Accessories) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.3.1
1.3.2
1.3.3
1.3.4
1.3.5
1.3.6
Single Point Power Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refrigerant Line Sweat Adapter Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Return Air Filter Box with Duct Collar Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Condensate Pump Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Monitoring and Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
7
7
7
7
7
2.0
SITE PREPARATION AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
2.1
Installation Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1.1
2.1.2
Room Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Location Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2
System Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.3
Equipment Inspection Upon Receipt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.4
Installing the Ceiling Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.4.1
2.4.2
2.4.3
2.4.4
2.5
Close Coupled Installations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Evaporator Air Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piping Connections and Coolant Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
12
12
17
Indoor Air Cooled Centrifugal Fan Condensing Unit Installation . . . . . . . . . . . . . . . . . 20
2.5.1
2.5.2
2.5.3
2.5.4
Location Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piping Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ducting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20
20
20
20
i
2.6
Outdoor Air Cooled Condensing Unit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.6.1
2.6.2
2.6.3
2.7
Indoor Water and Glycol Cooled Condensing Unit Installation . . . . . . . . . . . . . . . . . . . 25
2.7.1
2.7.2
2.7.3
2.8
Location Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Piping Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Location Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Piping Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Optional Equipment Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.8.1
2.8.2
Free-Cooling Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Hot Water Reheat Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.9
Checklist for Completed Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.0
MICROPROCESSOR CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.1
Feature Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.2
Main Menu <Menu>. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.3
Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.4
Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.5
Active Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.6
Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.7
Date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.8
Setback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.9
Setup Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.9.1
3.9.2
3.9.3
3.9.4
3.9.5
3.9.6
Restart Time Delay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C/F Degrees. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Humidity Control Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Show DIP switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Time (for Systems With a Modulating Chilled Water Valve) . . . . . . . . . . . . . . . . .
CW Flush (for systems with a modulating chilled water valve) . . . . . . . . . . . . . . . . . . . .
35
35
35
35
35
36
3.10
Change Passwords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.11
Calibrate Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.12
Alarm Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.13
Alarm Time Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.14
Common Alarm Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.15
Custom Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.16
Custom Text . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.17
Run Diagnostics (Available On Rev 1.001.0 and higher) . . . . . . . . . . . . . . . . . . . . . . . . . 39
ii
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Load Control Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.3.1
Communications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
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
5.1.7
5.1.8
5.2
Custom Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Head Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Humidity Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Humidifier Problem Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Water Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loss of Power:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Short Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
44
44
45
45
45
45
45
45
Optional/Custom Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.2.1
5.2.2
5.2.3
Change Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Firestat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Smoke Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
6.0
SYSTEM OPERATION, TESTING AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.1
System Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
47
47
47
47
47
47
Maintenance and Component Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6.2.1
6.2.2
6.2.3
6.2.4
6.2.5
6.2.6
6.2.7
Electric Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blower Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steam Generating Humidifier-Operation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Board Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
48
48
48
48
49
52
53
7.0
MAINTENANCE INSPECTION CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
8.0
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
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
Air Cooled Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Water/Glycol Cooled Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Chilled Water Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Evaporator Unit Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Threaded Rod and Hardware Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Evaporator Unit Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Close Coupled Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Indoor Air Cooled Centrifugal Condensing Unit Dimensions and Pipe Connections . . . . . . . 21
Indoor Air Cooled Centrifugal Condenser Electrical Connections . . . . . . . . . . . . . . . . . . . . . . 22
System Piping with Indoor or Outdoor Air Cooled Condensing Unit . . . . . . . . . . . . . . . . . . . 23
Indoor Water/Glycol Condensing Unit Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Indoor Water/Glycol Condensing Unit Electrical Field Connections. . . . . . . . . . . . . . . . . . . . 27
System Piping with Indoor Water/Glycol Cooled Condensing Unit . . . . . . . . . . . . . . . . . . . . . 28
Optional Free Cooling Coil (3-Way Valve) on Water/Glycol Units. . . . . . . . . . . . . . . . . . . . . . 29
Optional Hot Water Reheat (2-Way Valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Wallbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Control Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Control Board (Inside Evaporator). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Wallbox Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
TABLES
Table 1
Table 2
Table 3
Table 4
Table 5
Table 6
Table 7
Table 8
Table 9
Table 10
Table 11
Table 12
Table 13
Table 14
Table 15
Table 16
Table 17
Table 18
Table 19
Table 20
Table 21
Table 22
iv
System Configurations—60 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
System Configurations—50 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Application Limits, Evaporator and Chilled Water Units* . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Application Limits, Indoor and Outdoor Air Cooled Condensing Units . . . . . . . . . . . . . . . . . . 8
Application Limits, Indoor Water/Glycol Cooled Condensing Units . . . . . . . . . . . . . . . . . . . . . 8
Unit Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Evaporator External Static Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Recommended Line Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5 Ton Unit Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Line Charges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Refrigerant Quick Connect Sizes and Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Prop Fan Condensing Unit Dimensions – in. (mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Default Setpoints and Allowable Ranges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Night and Weekend Setback Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Set-Up Functions, Default Values and Allowable Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Alarm Default Time Delays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Equipment Switch Settings (Unit Control Board) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Switch Settings (Wallbox Board) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Cooling and Dehumidification Load Response of Hot Gas Bypass . . . . . . . . . . . . . . . . . . . . . 42
Typical Discharge Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Humidifier Control Board DIP Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
PRODUCT MODEL INFORMATION
Figure i
Evaporators and Chilled Water Units Model Number Designation Condensing Unit Model
Number Designation
5 Ton Evaporators
M = Mini-Mate2
M = Microprocessor Control
D = Disconnect Switch
0 = No Disconnect Switch
Nominal BTUHs (1000)
E = Split Evaporator
K = Evaporator w/Free Cooling (3-way)
M M D 60 E -
C H E L A
- = DX Evaporator
A = 460V-3ph-60hz
B = 575V-3ph-60hz
C = 208V-3ph-60hz
D=230V-3ph-60hz
M=380/415V-3ph-50hz
H = Canister Humidifier
0 = No Humidifier
0 = No Reheat
E = Electric Reheat
S = SCR Reheat
H = Hot Water Reheat
L = Low Speed Drive (1.5 hp)
H = High Speed Drive (2.0 hp)
0 = None
A = Filter Clog
B = Smoke Detector
C = Firestat
D = Filter Clog & Smoke Detector
E = Filter Clog & Firestat
F = Smoke Detector & Firestat
G = Filter Clog, Smoke Detector, & Firestat
1
5 Ton Chilled Water Units
M = Mini-Mate2
M = Microprocessor Control
D = Disconnect Switch
0 = No Disconnect Switch
Nominal BTUHs (1000)
C = Chilled Water
M M D 92 C 2 C H E L A
2 = 2-Way Chilled Water Slow-Close Valve
3= 3-Way Chilled Water Slow-Close Valve
D = 2-Way Mod Chilled Water Valve
T = 3-Way Mod Chilled Water Valve
A = 460V-3ph-60hz
B = 575V-3ph-60hz
C = 208V-3ph-60hz
D=230V-3ph-60hz
M=380/415V-3ph-50hz
H = Canister Humidifier
0 = No Humidifier
0 = No Reheat
E = Electric Reheat
S = SCR Reheat
H = Hot Water Reheat
L = Low Speed Drive (1.5 hp)
H = High Speed Drive (2.0 hp)
0 = None
A = Filter Clog
B = Smoke Detector
C = Firestat
D = Filter Clog & Smoke Detector
E = Filter Clog & Firestat
F = Smoke Detector & Firestat
G = Filter Clog, Smoke Detector, & Firestat
2
5 Ton Air Cooled Centrifugal
Condensing Units
M = Mini-Mate2
C = Condensing Unit
D = Disconnect Switch
0 = No Disconnect Switch
Nominal BTUHs (1000)
M C D 65 A L A H 0
A = Air Cooled Unit
L = 95°F Ambient Lee-Temp (Air)
A = 460V-3ph-60hz
B = 575V-3ph-60hz
Y = 208/230V-3ph-60hz
M = 308/415V-3ph-50hz
H = Hot Gas Bypass
0 = No Hot Gas Bypass
0 = Revision Level
3
5 Ton Water/Glycol
Condensing Units
M = Mini-Mate2
C = Condensing Unit
D = Disconnect Switch
0 = No Disconnect Switch
Nominal BTUHs (1000)
M C D 69 W 2 A H 0
A = Air Cooled Unit
2 = 2-Way Chilled Water Slow-Close Valve
3= 3-Way Chilled Water Slow-Close Valve
D = 2-Way Mod Chilled Water Valve
T = 3-Way Mod Chilled Water Valve
A = 460V-3ph-60hz
B = 575V-3ph-60hz
Y = 208/230V-3ph-60hz
M = 308/415V-3ph-50hz
H = Hot Gas Bypass
0 = No Hot Gas Bypass
0 = Revision Level
Table 1
System Configurations—60 Hz
Condensing Unit
Nominal
Capacity
Cooling Unit
Indoor Air Cooled
Centrifugal Fan
Outdoor Air Cooled
Propeller Fan
Indoor Water/
Glycol
5 Tons
MMD60E
MCD65A
PFC067A
MCD69W
5 Tons
MMD92C
Table 2
Self Contained – Chilled Water
System Configurations—50 Hz
Condensing Unit
Nominal
Capacity
5 Tons
4
Cooling Unit
Indoor Air Cooled
Centrifugal Fan
Outdoor Air Cooled
Propeller Fan
Indoor Remote
Water/Glycol
Cooled
MMD59E
MCD64A
PFC066A
MCD68W
MMD91C
Self-Contained – Chilled Water
1.0
INTRODUCTION
1.1
Product Description and Features
The Mini-Mate2 is a temperature/humidity control system designed to be installed above a ceiling
grid system. The unit is available as a split system evaporator to be matched with an Indoor Centrifugal Condensing Unit, Outdoor Prop Fan Condensing Unit or Indoor Water/Glycol Condensing
Unit. A self-contained Chilled Water Fan Coil is also available.
1.1.1
Controls
The Mini-Mate2 system includes a wall-mounted display panel that includes a liquid crystal display (LCD) screen and a 7 membrane keypad. The control is menu-driven for ease of use.
Figure 17 depicts the complete menu tree for the control. All control setpoints and alarm setpoints are programmable.
1.1.2
Evaporator System Components
DX Evaporator Section
The evaporator section includes the evaporator coil, thermostatic expansion valve, filter dryer and
blower. 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 a double inlet, belt driven centrifugal blower that has been dynamically balanced. The
blower motor has self-aligning bearings and lifetime lubrication.
Chilled Water Model
The Chilled Water model is self-contained and is designed for use with an existing chilled water
loop. It contains a chilled water coil and a slow open/close valve or optional modulating valve to
control the flow of chilled water.
1.1.3
Condensing Unit Components
The condensing unit is connected to the evaporator unit by two refrigerant lines and a low voltage
control wire. The condensing unit requires a power source and a power disconnect switch. A single
point power kit is available for close-coupled units.
Air Cooled Condensing Unit (Indoor Centrifugal)
The Air Cooled Condensing units (MC models) include: scroll compressor with crankcase heater,
high pressure switch, condenser coil and Lee-Temp head pressure control with receiver.
Air Cooled Condensing Unit (Outdoor Prop Fan)
Outdoor Air Cooled Condensing Units (PFC models) include: scroll compressor with crankcase
heater, high pressure switch, condenser coil, filter dryer, propeller fan and Lee-Temp head pressure control with receiver.
Water/Glycol Condensing Unit (Indoor)
The Water/Glycol Cooled Condensing units include: scroll compressor with crankcase heater, high
pressure switch, coaxial condenser and regulating valve. Drycooler and pumps are selected separately for glycol systems.
Introduction
5
1.2
Optional Equipment
1.2.1
Canister Humidifier
The optional, factory-installed steam generating humidifier adds pure water vapor to the room air
to control humidity. Room humidity setpoints are established by the user. The humidifier components include a steam canister (replaceable), control board, inlet strainer, fill and drain valves.
1.2.2
Electric Reheat
The reheat feature is energized when required to heat room air or to control room temperature
during dehumidification. A safety switch prevents the reheat from exceeding temperature limits.
1.2.3
SCR Electric Reheat
The optional electric reheat is pulsed rapidly to provide precise temperature control, while cooling
is locked on. A safety switch prevents the reheat from exceeding temperature limits.
1.2.4
Hot Water Reheat
The optional hot water reheat circulates building hot water through a cleanable Y-strainer, solenoid valve and finned-tubed heating coil to provide reheat.
1.2.5
Hot Gas Bypass (Condensing Units)
This optional system bypasses hot gas around the compressor directly to suction to provide capacity control and reduce compressor cycling. System includes liquid injection valve to maintain
proper suction superheat.
1.2.6
Free-Cooling Coil
A separate source of chilled water can be used to provide cooling. Upon loss of the chilled water
source, cooling is switched to DX cooling.
1.2.7
Smoke Detector
If smoke is detected in the return air, the unit display sounds an audible signal and the unit shuts
down.
1.2.8
Firestat
When the return air temperature limit of approximately 125°F (51.7°C) is exceeded, the unit
shuts down.
1.2.9
Filter Clog
If high pressure differential is detected in the return air, an adjustable pressure differential
switch sounds an audible signal.
6
Introduction
1.3
Ancillary (Ship Loose Accessories)
1.3.1
Single Point Power Kit
A Single Point Power Kit allows the connection of a system (evaporator and condensing unit) to a
single power source when the units are close coupled. The kit includes a junction box with power
distribution, sub-fusing and evaporator and condenser wiring.
1.3.2
Refrigerant Line Sweat Adapter Kit
This kit includes the compatible fittings required (two suction and two liquid line connections)
when using field supplied interconnecting refrigerant lines.
1.3.3
Return Air Filter Box with Duct Collar Kit
A return air filter box with duct flange, 4" (102mm) filter and a supply air duct flange are provided for ducting the evaporator air.
1.3.4
Condensate Pump Kit
A condensate pump is required when the evaporator is installed below the level of the gravity-fed
drain line. Components include: the pump; check valve; sump; level sensor; float switch; and controls. Refer to detailed instructions and drawings supplied with the pump.
1.3.5
Remote Monitoring and Control
Liebert can provide a variety of remote monitoring and control devices to enhance your
Mini-Mate2 system. These include water detection, remote monitoring of a single unit and remote
control/monitoring of multiple units.
1.3.6
Remote Sensors
Remote temperature/humidity sensors can be mounted in the controlled space or in ductwork and
includes 30 feet of control cable.
Introduction
7
2.0
SITE PREPARATION AND INSTALLATION
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.
2.1
Installation Considerations
The evaporator unit is usually mounted above the suspended ceiling in the space to be conditioned. Ducted systems may be located in a different room. Refer to Figure 1 and Figure 2 for
possible configurations. The condensing unit may be:
• Indoor Air Cooled Centrifugal Fan Condensing Unit mounted remotely or close coupled to the
evaporator in the ceiling space.
• Outdoor Air Cooled Propeller Fan Condensing Unit.
• Water/Glycol Cooled Condensing Unit, mounted remotely or close coupled to the evaporator.
Table 3
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 4
Application Limits, Indoor and Outdoor Air Cooled Condensing Units
Input
Voltage
Min
-5%
Table 5
Condensing
Units
Max
+10%
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
Min
-5%
Entering Dry Bulb Air
Temperature
Entering Fluid Temperature
Max
+10%
Min
Max
65°F (18.3°C) *
115°F (46°C)
*Operation below 65°F (18°C) may result in reduced valve life and fluid noise.
2.1.1
Room Preparation
The room should be well insulated and must have a sealed vapor barrier. The vapor barrier in the
ceiling and walls can be a polyethylene film. Paint on concrete walls and floors should contain
either rubber or plastic.
NOTE
The single most important requirement for maintaining environmental
control in the conditioned room is the vapor barrier.
Outside or fresh air should be kept to a minimum when tight temperature and humidity control is
required. Outside air adds to the cooling, heating, dehumidifying and humidifying loads of the
site. Doors should be properly sealed to minimize leaks and should not contain ventilation grilles.
8
Site Preparation and Installation
2.1.2
Location Considerations
CAUTION
Units contain water. Water leaks can cause damage to sensitive
equipment below. DO NOT MOUNT UNITS OVER SENSITIVE
EQUIPMENT. A field supplied pan with drain must be installed
beneath cooling units and water/glycol cooled condensing unit.
!
NOTE
Do NOT mount units in areas where normal unit operating sound may
disturb the working environment.
Locate the evaporator unit over an unobstructed floor space if possible. This will allow easy access
for routine maintenance or service. Do not attach additional devices (such as smoke detectors,
etc.) to the housing, as they could interfere with the maintenance or service.
NOTE
Temperature and humidity sensors are located in the wall box. Carefully
select a position for the box where discharge air DOES NOT directly blow
on the sensors.
Figure 1
Air Cooled Systems
Evaporator
Evaporator
Prop Fan
Condensing Unit
Split System Evaporator
Supply & Return Air Ducted
Outdoor Prop Fan Condensing Unit
Centrifugal Fan
Condensing Unit
Split System Evaporator
Supply & Return Air Ducted
Indoor Air Cooled Condensing Unit
Site Preparation and Installation
9
Figure 2
Water/Glycol Cooled Systems
Figure 3
Chilled Water Systems
2.2
System Weights
Table 6
Unit Weights
Cooling Units*
lbs
kg.
MMD60E
498
226
MMD59E
498
226
Condensing Units
lbs.
kg.
MCD65A
449
204
MCD64A
449
204
MCD69W
282
128
MCD68W
282
128
*Add 40 lbs. (20 kg.) to units with free cooling or hot water reheat coils.
2.3
Equipment Inspection Upon Receipt
When the unit arrives, do not uncrate equipment until it is close to its final location. All required
assemblies are banded and shipped in corrugated containers. If you discover any damage when
you uncrate the unit, report it to the shipper immediately. If you later find any concealed damage,
report it to the shipper and to your Liebert supplier.
10
Site Preparation and Installation
2.4
Installing the Ceiling Units
!
WARNING
BE SURE THE SUPPORTING ROOF STRUCTURE IS CAPABLE OF
SUPPORTING THE WEIGHT OF THE UNIT(S) AND THE ACCESSORIES
DURING INSTALLATION AND SERVICE. (SEE 2.2 - SYSTEM WEIGHTS.)
BE SURE TO SECURELY ANCHOR THE TOP ENDS OF THE SUSPENSION
RODS. MAKE SURE ALL NUTS ARE TIGHT.
The evaporator unit and indoor condensing unit are usually mounted above the ceiling and must
be securely mounted to the roof structure. The ceiling and ceiling supports of existing buildings
may require reinforcements. Be sure to follow all applicable codes. Use field-supplied threaded
suspension rods and 3/8"–16 factory hardware kit.
Recommended clearance between ceiling grids and building structural members is unit height
plus three inches.
Install the four field-supplied rods by suspending them from suitable building structural members. Locate the rods so that they will align with the four mounting holes in the flanges that are
part of the unit base.
Using a suitable lifting device, raise the unit up and pass the threaded rods through the four
mounting holes in the flanges that are part of the unit base.
Attach the threaded rods to the unit flanges using the supplied nuts and grommets (see
Figure 5). The rubber grommets provide vibration isolation.
1. Use the plain nuts to hold unit in place. Adjust these nuts so that the weight of the unit is
supported evenly by the four rods, does not rest on the ceiling grid and is level.
NOTE
The units must be level in order to drain condensate properly.
2. Use the Nylock nuts to “jam” the plain nuts.
2.4.1
Close Coupled Installations
If the evaporator and condensing units are to be mounted side-to-side (close coupled), hang each
unit before connecting them together (see Figure 7). Align bolt holes in the condensing unit and
in the evaporator. Insert rubber spacers and secure four (4) sets of hardware provided. Align the
refrigerant connections and tighten them as described in 2.4.3 - Piping Connections and Coolant Requirements.
Site Preparation and Installation
11
2.4.2
Evaporator Air Distribution
Filter Box
The optional filter box mounts directly to the return air opening of the evaporator. The filter box
is supplied with two (2) 20% (Liebert part # 1A19647P1) or 30% (Liebert part # 128161P3)
20 in. x 20 in. x 4 in filters.
NOTE
Do not operate the unit without filters installed in return air system.
Connections for Ducted Systems
Use flexible duct work or non-flammable cloth collars to attach duct work to the unit and to help
control the transmission of vibrations to building structures. Insulation of duct work is vital to
prevent condensation during the cooling cycle. The use of a vapor barrier is required to prevent
absorption of moisture from the surrounding air into the insulation.
If the return air duct is short or if noise is likely to be a problem, sound-absorbing insulation
should be used inside the duct. Duct work should be fabricated and installed in accordance with
local and national codes.
Table 7
Evaporator External Static Pressure
1.5 hp Motor (60hz)
Turns
Open
Blower
rpm
External
Static, in.
2.0 hp Motor (60hz)
Blower
rpm
External
Static, in.
1
n/a
n/a
1329
n/a
1.5
n/a
n/a
1296
n/a
2
1037
0.9
1264
n/a
2.5
1005
0.7
1231
1.5
3
972
0.6
1199
1.4
3.5
940
0.5
1164
1.3
4
907
0.4
1134
1.2
4.5
875
0.3
1102
1.1
5
843
0.2
1069
1.0
5.5
810
0.1
1037
0.9
6
778
0.0
1005
0.7
Additional components such as a free-cooling coil, hot water reheat coil or high efficiency filters
will reduce available static pressure.
2.4.3
Piping Connections and Coolant Requirements
Drain Line
!
CAUTION
The drain line must not be trapped outside the unit or water may
back up in drain pan. Drain is internally trapped.
This line may contain boiling water. Use copper or other suitable
material for the drain line.
A 3/4 in. (19.1 mm) female pipe thread (FPT) connection is provided for the evaporator coil condensate drain. This line also drains the humidifier, if applicable. The drain line must be located so it will
not be exposed to freezing temperatures. The drain should be the full size of the drain connection.
The evaporator drain pan includes a float switch to prevent unit operation if drain becomes blocked.
The optional condensate pump kit is required when the evaporator is installed below the level of
the gravity-fed drain line.
12
Site Preparation and Installation
Humidifier Water Supply Line
Units supplied with the optional humidifier package have a 1/4 in. (6.4 mm) FPT 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.
NOTE
Do NOT route humidifier supply line in front of filter box access panel.
Chilled Water Piping—On chilled water units install manual service shut-off valves at the supply and return lines of each unit. These shut-off valves are used for routine service or emergency
isolation of the unit.
Chilled water supply and return lines must 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. Connection sizes are 1 in. (25.4 mm)
FPT.
Water/Glycol Piping—Water and Glycol cooled systems require coolant loop connections as
specified in the condensing unit installation instructions.
Refrigerant (R-22) Piping—All split systems require two refrigerant lines (an insulated copper
suction line and a copper liquid line) between the evaporator and the condensing unit.
Two possible methods exist for installing the copper suction and liquid lines.
• Close coupling the units together using the quick connects. (See Figure 7).
• Using an optional Sweat Adapter Kit and hard piping between the two units.
All refrigeration piping should be installed with high temperature brazed joints. Prevailing good
refrigeration practices should be employed for piping supports, leak testing, evacuation, 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.
Table 8
Recommended Line Sizes
Equivalent
Feet
Liquid
O.D. Cu
Suction
O.D. Cu
up to 45
1/2”
1-1/8”
NOTE
If field supplied refrigerant piping is installed, refrigerant (R-22) must be added to the
system.
Refrigerant Charge Requirements—Total refrigerant charge (R-22) will be required only if
units are evacuated during installation or maintenance. For safe and effective operation, refer to
2.4.3 - Piping Connections and Coolant Requirements.
Site Preparation and Installation
13
Total refrigerant = Units and Lines
Table 9
5 Ton Unit Refrigerant Charge
Evaporator
Model No.
Charge (ounces)
MMD60E
4
MMD59E
4
Condensing Units
Model No
Charge (pounds)
MCD65A
27.0
MCD64A
27.0
MCD69A
5.9
MCD68A
5.9
Units are charged at the factory with R-22
Refrigerant per Table 9. If field-supplied
piping is installed, refrigerant must be
added to the system per Table 10.
*
Table 10
Line Charges
O.D.
Liquid Line
Suction Line
1/2”
7.3 (1.1)
0.2 (0.1)
5/8”
11.7 (1.7)
0.3 (0.1)
7/8”
24.4 (3.6)
0.7 (0.1)
1-1/8”
41.6 (6.2)
1.2 (0.2)
* weight of R-22 in type “L” copper tube: lb per
100 ft (kg per 10m
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
will not leak. Refer to Table 11 for torque requirements.
Table 11
14
Refrigerant Quick Connect Sizes and Torque
Size O.D.
Cu
Coupling
Size
Torque
lb-ft
1/2”
#10
35-45
1-1/8”
#12
50-65
Site Preparation and Installation
Figure 4
Evaporator Unit Dimensional Data
Shaded area indicates a
recommended clearance of
30" (762mm) for access and
filter removal. For recommended minimum clearance refer to installation
manual.
Site Preparation and Installation
15
Figure 5
16
Threaded Rod and Hardware Kit Installation
Site Preparation and Installation
2.4.4
Electrical Connections
Each unit is shipped from the factory with internal wiring completed. Refer to electrical schematic when making connections. Electrical connections to be made at the installation site are:
• Power supply to each ceiling unit.
!
!
WARNING
UNIT CONTAINS HAZARDOUS ELECTRICAL VOLTAGE.
DISCONNECT POWER SUPPLY BEFORE WORKING WITHIN.
LINE SIDE OF FACTORY DISCONNECT REMAINS ENERGIZED
WHEN DISCONNECT IS OFF.
WARNING
UNIT CONTAINS HAZARDOUS ELECTRICAL VOLTAGE. MORE
THAN ONE DISCONNECT MAY BE REQUIRED TO REMOVE
POWER. EVAPORATOR AND CONDENSING UNITS MAY HAVE
SEPARATE DISCONNECTS. OPEN ALL DISCONNECTS BEFORE
WORKING WITHIN.
• Control wiring between the evaporator unit and the condensing unit, if applicable.
• Control wiring between the control panel (wallbox) and the evaporator unit control board.
Power Connections
All power and control wiring and ground connections must be in accordance with the National
Electrical Code (NEC) and local codes. Refer to Unit serial tag data for electrical requirements.
!
CAUTION
Use copper wiring only. Make sure that all connections are tight.
Voltage supplied must agree with the voltage specified on the unit serial tag. If a field supplied
disconnect switch is required, it may be bolted to the ceiling unit, but not to any of the removable
panels. This would interfere with access to the unit. Make sure that no refrigerant lines are punctured when mounting the disconnect switch.
Route the electrical service conduit through the hole provided in the cabinet and terminate it at
the electric box. Make connections at the factory terminal block or disconnect switch, L1, L2, L3.
Connect earth ground to lug provided. See transformer label for primary tap connections.
Installer will need to change transformer primary taps if applied unit voltage is other than prewired tap voltage.
An optional single point power kit is available for units that are close coupled (See 2.4.3 - Piping
Connections and Coolant Requirements). This kit should be mounted inside the condensing
unit before installing the unit in the ceiling. Specific installation instructions are included with
the single point power kit.
Control Connections
A field-supplied, 3- or 4-wire control connection (24 VAC) is required between the evaporator and
the condensing unit. Control wiring must be installed in accordance with the National Electrical
Code (NEC) Class 2 circuit. Glycol cooled units also require a two-wire control connection to the
drycooler and pump. A Class 1 circuit is required for Water/Glycol units.
Control wiring between the evaporator and the condensing unit must not allow a voltage drop in
the line of more than 1 volt (16 gauge minimum for 75 feet). Do not connect additional 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 (4) wire (thermostat type) must be connected between the evaporator control board and the
wall box. See Figure 6.
Site Preparation and Installation
17
Figure 6
18
Evaporator Unit Electrical Connections
Site Preparation and Installation
Figure 7
Close Coupled Installation
Evaporator Unit (Left)
Condensing Unit (Right)
Evaporator Unit
Condensing Unit
Spacer Between Close-Coupled Evaporator
and Condensing Unit (4 places)
Refrigerant Quick Connect Fittings
(Inside Units)
Site Preparation and Installation
19
2.5
Indoor Air Cooled Centrifugal Fan Condensing Unit Installation
2.5.1
Location Considerations
The centrifugal fan air cooled condensing unit may be located above the dropped ceiling or any
remote indoor area. If noise is of concern, the condensing unit should be located away from personnel. Normal operating sound may be objectionable if the condensing unit is placed near quiet
work areas.
To mount the unit in the ceiling, refer to 2.4 - Installing the Ceiling Units.
2.5.2
Electrical Connections
Refer to 2.4.4 - Electrical Connections for general wiring requirements and cautions. Refer to
electrical schematic when making connections. Refer to unit serial tag for full load amp and wire
size amp ratings.
Power Connections
The condensing unit requires its own power source and earth ground, with a disconnect switch to
isolate the unit for maintenance.
NOTE
Refer to serial tag for full load amp and wire size amp ratings
Control Connections
Field-supplied control wires must be connected between the evaporator and the condensing unit
(See Figure 6 and Figure 9) and the electrical schematic on the units for more details.) Three (3)
wires are required between the evaporator and condensing unit. A fourth wire is required on systems with hot gas bypass.
2.5.3
Piping Connections
Details for Refrigerant (R-22) Loop piping are in 2.4.3 - Piping Connections and Coolant
Requirements.
2.5.4
Ducting
Fan operation is designed for 3300 CFM (560 CMH) at 0.5" external static pressure.
General Considerations
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.
Ductwork that runs through a conditioned space or is exposed to areas where condensation may
occur must be insulated. Ductwork should be suspended using flexible hangers. Ductwork should
not be fastened directly to the building structure.
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.
Considerations for Specific Applications
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. Locate the air discharge a minimum of
4 feet from an adjacent wall. Failure to do so may result in reduced air flow and poor system performance.
If the condensing unit draws air from the outside of the building, rain hoods must be
installed. Hood intake dimensions should be the same as the condensing unit duct dimensions. In
addition, install a triple layer bird screen over rain hood openings to eliminate the possibility of
insects, birds, water or debris entering the unit. Avoid directing the hot exhaust air toward adjacent doors or windows.
20
Site Preparation and Installation
Figure 8
Indoor Air Cooled Centrifugal Condensing Unit Dimensions and Pipe Connections
Note: Unit is spaced
evenly in reference to
threaded rod centers.
Site Preparation and Installation
21
Figure 9
22
Indoor Air Cooled Centrifugal Condenser Electrical Connections
Site Preparation and Installation
Figure 10 System Piping with Indoor or Outdoor Air Cooled Condensing Unit
Site Preparation and Installation
23
2.6
Outdoor Air Cooled Condensing Unit Installation
2.6.1
Location Considerations
To insure a satisfactory air supply, locate air cooled propeller fan condensing units in an environment providing clean air, 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.
Install a solid base, capable of supporting the weight of the condensing unit. The base should be at
least 2 inches higher than the surrounding grade and 2 inches larger than the dimensions of the
condensing unit base. For snowy areas, a base of sufficient height to clear snow accumulation
must be installed.
Table 12
Prop Fan Condensing Unit Dimensions – in. (mm)
Model
Weight
60 HZ
50 HZ
Width (A)
Height (B)
Depth (C)
lbs. (kg) net
PFC067A-_L
PFH067A-_L
PFC066A-_L
53 (1343)
36 1/4 (918)
18 (457)
351 (159)
53 (1343)
36 1/4 (918)
38 1/2 (978)
488 (222)
PFC067A-_H
PFH067A-_H
PFCZ67A-_L
2.6.2
Dimensional Data in. (mm)
PFC066A-_H
PFCZ66A-_L
Piping Connections
Details for Refrigerant (R-22) Loop piping are in 2.4.3 - Piping Connections and Coolant
Requirements.
2.6.3
Electrical Connections
Refer 2.4.4 - Electrical Connections for general wiring requirements and cautions. Refer to
electrical schematic when making connections.
Power Connections
The outdoor condensing unit requires its own power source and earth ground, with a disconnect
switch (field supplied) to isolate the unit for maintenance.
Control Connections
Field-supplied control wires must be connected between the evaporator and the condensing unit.
(See Figure 6 and the electrical schematic on the units for more details.) Three (3) wires are
required between the evaporator and condensing unit. A fourth wire is required on systems with
hot gas bypass.
24
Site Preparation and Installation
2.7
Indoor Water and Glycol Cooled Condensing Unit Installation
2.7.1
Location Considerations
The condensing unit may be located above the dropped ceiling or any remote indoor area. If noise
is of concern, the condensing unit should be located away from personnel. Normal operating
sound may be objectionable if the condensing unit is placed near quiet work areas.
To mount the unit in the ceiling, refer to 2.4 - Installing the Ceiling Units.
2.7.2
Electrical Connections
Refer to 2.4.4 - Electrical Connections for general wiring requirements and cautions. Refer to
electrical schematic when making connections. Refer to serial tag for full load amp and wire size
amp ratings.
Control Connections
A 3 or 4-wire control connection is required from the evaporator unit to the condensing unit. Glycol cooled units also require a two-wire control connection to the drycooler and pump
package.
2.7.3
Piping Connections
Details for Refrigerant (R-22) Loop piping are in 2.4.3 - Piping Connections and Coolant
Requirements.
Water/Glycol Piping Considerations
Manual service shut-off valves must 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 serviced should be placed in the supply line. These filters
extend the service life of the condensing unit.
Condensing Unit Fluid Requirements
The maximum fluid pressure is 150 PSI standard pressure and 350 PSI for high pressure units
(Refer to unit serial tag and model number description page at beginning of this manual).
Automotive antifreeze 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 that is factory-adjusted and
should not need field adjustment.
Standard pressure and high pressure valves are adjusted differently. Contact Liebert Global Services before making any adjustments.
Site Preparation and Installation
25
Figure 11 Indoor Water/Glycol Condensing Unit Dimensional Data
26
Site Preparation and Installation
Figure 12 Indoor Water/Glycol Condensing Unit Electrical Field Connections
WATER/GLYCOL
Site Preparation and Installation
27
Figure 13 System Piping with Indoor Water/Glycol Cooled Condensing Unit
* Components are not supplied by
Liebert but are recommended for proper
circuit operation and maintenance.
28
Site Preparation and Installation
2.8
Optional Equipment Piping
2.8.1
Free-Cooling Coil
The free-cooling coil is a secondary coil located downstream of the DX coil. The free-coiling coil
does not operate at the same time as the DX coil. A temperature sensor is factory-mounted to the
free-cooling piping. If the water temperature is less than the set temperature (usually 45°F
[7.2°C]), the 3-way valve opens to allow chilled water flow to the free-cooling coil and the compressor is locked off. If the water temperature is above the set temperature, the 3-way valve closes
(bypasses) and enables the compressor. To keep deposits from building up in the free-cooling coil,
an adjustable timer is factory-set to flush every 400 minutes.
NOTE
If the free-cooling coil is piped to an open water tower, a CU/NI (cupro-nickel) type coil
must be ordered to prevent corrosion of the copper tubes; or a heat exchanger must separate the tower water from the free-cooling loop.
On water-cooled systems, the free-cooling coil outlet can be field piped to the condensing unit
inlet, provided a 3-way regulating valve has been installed within the water/glycol condensing
unit (see figure).
Figure 14 Optional Free Cooling Coil (3-Way Valve) on Water/Glycol Units
* Components are not supplied by
Liebert but are recommended for proper
circuit operation and maintenance.
Site Preparation and Installation
29
2.8.2
Hot Water Reheat Coil
Building hot water can be piped to a factory-installed hot water reheat coil, located downstream of
the cooling coil. A factory-installed solenoid valve opens upon a call for reheat.
Figure 15 Optional Hot Water Reheat (2-Way Valve)
* Components are not supplied by
Liebert but are recommended for proper
circuit operation and maintenance.
30
Site Preparation and Installation
2.9
Checklist for Completed Installation
___ 1. Proper clearance for service access has 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). Route to allow air filter removal.
___ 7. Field provided pan with drain installed under all cooling units and water/glycol
condensing units.
___ 8. Filter box installed.
___ 9. Ducting completed.
___ 10. Filter(s) installed in return air duct.
___ 11. Line voltage to power wiring matches equipment serial tag.
___ 12. Power wiring connections completed between disconnect switch, evaporator and
condensing unit, including earth ground.
___ 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 wall-mounted control panel and optional controls).
___ 15. Control panel DIP switches set based on customer requirements.
___ 16. All wiring connections are tight.
___ 17. Foreign materials have been removed from in and around all equipment installed
(shipping materials, construction materials, tools, etc.)
___ 18. Fans and blowers rotate freely without unusual noise.
___ 19. Inspect all piping connections for leaks during initial operations. Correct as needed.
Site Preparation and Installation
31
3.0
MICROPROCESSOR CONTROL
The Microprocessor Control for the Liebert Mini-Mate2 unit features an easy to use menu-driven
LCD display. The menus, control features and circuit board details are described in this section.
Detailed information concerning controls (4.0 - System Performance Microprocessor 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).
• Alarm Silence/? (Help)—If an alarm is present, pressing this key will silence the alarm. If this
key is pressed when no alarms are 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 16 Wallbox
Active alarms are displayed on the LCD screen and sound an audible beeper. 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 on 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) and active alarms. The Status Display may
also be selected from the Main Menu.
32
Microprocessor Control
3.2
Main Menu <Menu>
Press the MENU key to display the Main Menu. The menu selections (in the following order) include:
• SETPOINTS
• STATUS
• ACTIVE ALARMS
• TIME
• DATE
• SETBACK
• SETUP OPERATION
• SET PASSWORD
• SETUP PASSWORD
• CALIBRATE SENSOR
• ALARM ENABLE
• ALARM TIME DELAY
• COM ALARM ENABLE
• CUSTOM ALARMS
• CUSTOM TEXT
• DIAGNOSTICS
• END OF MENU
Use the UP and DOWN arrows to scroll through the selections; when ready to select a particular
function press Enter.
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 sub-menu by using the Up and Down arrows, then press Enter to select a particular function. To change a particular value, press Enter and use the Up and Down arrows to
change the value. When the value has been changed press Enter to store the value. For example
to change the temperature setpoint from the main status display.
1. Press Menu key to display main menu.
2. Scroll to “SETPOINTS” using the Up and Down arrows. Press Enter.
3. Scroll to “TEMP SETPOINT” using the Up and Down arrows. Press Enter.
4. Use the Up and Down arrows to change the value. Press Enter.
Table 13 Default Setpoints and Allowable Ranges
Setpoint
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
Microprocessor Control
33
3.4
Status
The operator can monitor the percentage heating, cooling, dehumidifying and humidifying status
of the unit by selecting the “STATUS” sub-menu.
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., midnight is entered as 24:00). To change the time press Enter to select the function,
then use the Up and Down arrows to change the first character, press Enter to store, then press
the Up or Down arrows to change the character, press Enter to store, etc. THERE IS A BATTERY
BACKUP FOR THE DATE AND TIME FEATURES.
3.7
Date
The controller date must be set to allow for setback control. To change the date press Enter, then
use the Up and Down arrows to change the first character, press enter to store, press the Up and
Down arrows 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 work week and two (2) events can be programmed for a two-day weekend. The following table can be used to devise a setback plan.
Table 14
Night and Weekend Setback Plan
Event
Time 1
Temperature1
Sensitivity 1
Humidity 1
Humidity Sensitivity 1
Time 2
Temperature 2
Sensitivity 2
Humidity 2
Humidity Sensitivity 2
34
Microprocessor Control
Weekend
Weekday
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
SHOW DIPSWITCH
CW FLUSH
VALVE TIME
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 to 9.9 minutes (6 seconds to 9.54 seconds). Setting the value to zero (0)
will prevent the unit from restarting when power is restored. In this case, the unit must be
restarted manually by pressing the “ON/OFF” 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 and Down
arrows 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.
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. Predictive humidity
control can greatly reduce energy consumption by minimizing both compressor/reheat operation.
Use the UP or DOWN arrow key to select the desired humidity control method.
3.9.4
Show DIP switch
This function shows the position of the DIP switches, which are located on the control board in the
unit; 1 = Switch is “ON” and 0 = Switch is “OFF.” For more information on the DIP switches and
their functions, see Table 17.
3.9.5
Valve Time (for Systems With a Modulating Chilled Water Valve)
This function shows the full valve travel time of the modulating valve on a chilled water system.
This is the time it takes for the valve to travel from full closed to full open. It is programmable
from 50 to 250 seconds; factory default time is 165 seconds and should not be changed. The full
valve travel time is used by the control to determine the appropriate valve position. For example,
if the valve travel time is 165 seconds and 50% cooling is being called for, the valve will open for
83 seconds to achieve 50% open.
Microprocessor Control
35
3.9.6
CW Flush (for systems with a modulating chilled water valve)
This function shows the interval time at which the system will perform a modulating chilled
water valve system flush cycle. The factory default is 24 (hours) and is programmable from 0
(hours) which signifies to never flush, to 99 (hours) which signifies to flush after every 99 hours of
valve non-use. If the valve is called on by the control to open within the programmed interval
time, the timer will be reset to 0. The flush cycle is active even when the fan is turned off, but
power is applied to the unit. When the interval timer reaches the programmed time, the valve will
be opened for 3 minutes to flush any contaminants that may have collected in the system.
Table 15
Set-Up Functions, Default Values and Allowable Ranges
Function
3.10
Default
Range
Restart Time
Delay
0.1
0 to 9.9 min
(0 = manual restart)
C/F Degrees
°F
°C or °F
Humidity Control
Rel
Relative or Absolute
Valve Time
165
50 to 250 sec(s)
CW Flush
24
0 to 99 hours
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, then resetting power to
the unit.
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 time delay. If the sensors are located too close to
the air discharge, they will likely experience rapid swings in measurement. Another method in
reducing compressor cycling is to increase the temperature and/or humidity sensitivity.
3.12
Alarm Enable
Each alarm can be disabled or enabled. Use the Up and Down arrows to select a particular alarm,
press Enter to select either Enable or Disable. Press Enter again to store the change. When the
alarm is disabled it will NOT report to either the wallbox beeper or to the common alarm relay.
NOTE
The high water alarm will automatically shut the unit off, even if the alarm is disabled.
Similarly, optional factory-installed smoke detectors are wired to shut the evaporator unit
off, regardless of the enable/disable status.
36
Microprocessor Control
3.13
Alarm Time Delay
Each individual alarm can be programmed with a time delay, causing the unit to delay a specified
amount of time (0-255 seconds) before recognizing the alarm. See Table 16 for the default times.
The alarm condition must be present for the full amount of the time 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 16
3.14
Alarm Default Time Delays
Alarm
Default Time Delay
(seconds)
Custom Alarm #1
0
Custom Alarm #2
6
High Temperature
30
Low Temperature
30
High Humidity
30
Low Humidity
30
Short Cycle
0
Loss of Power
0
Common Alarm Enable
Each individual alarm can be selected to activate or 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 has been recognized. If the alarm is completely Disabled, the alarm has no effect on the common alarm relay. Use the Up and Down
arrows to scroll to a particular alarm, press the Enter button to select it, then press the Enter button again to select Yes or No.
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 Alarm. To change the
text for a custom alarm, select the alarm you would like to change, 1 or 2. Using the Up and Down
arrows, step through the list of five standard alarm messages (listed below) and two custom
alarms. Select the alarm message desired and store it by pressing Enter.
•
•
•
•
•
•
STANDARD CUSTOM ALARM MESSAGES
WATER FLOW LOSS
SMOKE DETECTED
LOSS OF AIR FLOW
HUMIDIFIER PROBLEM
FILTER CLOG
Microprocessor Control
37
3.16
Custom Text
To modify the two custom alarm messages select “CUSTOM TXT”. Then select “CUS TXT #1” or
“CUS TXT #2”. Text can be up to 20 characters in length and can be either a blank space or any of
the following alphanumeric characters and symbols:
• A,B,C,D,E,F,G,H,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 and Down arrows to select a character, then press Enter. The cursor will move to the
next space where you may once use the Up and Down arrows 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 wall box next to the display.
Nonvolatile Memory
All critical information is stored in nonvolatile memory. Setpoints and setup parameters 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.
Table 17
Switch
OFF Position
ON Position
1
Compressor
Chilled Water
2
Standard Reheat
SCR Reheat
3
No Modulating Valve
Modulating CW Valve
4
Not Used
Not Used
5
Enable Reheat
Disable Reheat
6
Enable Humidifier
Disable Humidifier
7
Enable Dehumidifier
Disable Dehumidifier
8
Electric Reheat
Gas Reheat
Table 18
Switch
38
Equipment Switch Settings (Unit Control Board)
Switch Settings (Wallbox Board)
OFF Position
ON Position
1
Disable Beeper
Enable Beeper
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
Microprocessor Control
3.17
Run Diagnostics (Available On Rev 1.001.0 and higher)
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.
Show Inputs
With the unit on and the fan running, the input states may be displayed for the following devices:
•
•
•
•
•
High Water Alarm: Normally off unless High Water Alarm is active.
High Head Pressure Alarm: Normally off unless High head Pressure alarm is active.
Custom alarm #1: Normally off unless this special customer selectable alarm is active.
Custom alarm #2: Normally off unless this special customer selectable alarm is active.
Power: Normally on unless unit is turned off through the wallbox or any of the following
optional devices: Firestat, Smoke Detector, High Water Alarm or Remote Shutdown
Test Outputs
When this feature is selected, the controller 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 and 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
Testing compressor output for more than a few seconds could
damage the compressor. To eliminate damaging the compressor
during testing, DO NOT test compressor output for more than a
few seconds.
CAUTION
Extended unit operation 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.
The outputs are as follows:
•
•
•
•
•
•
Normal Fan: Normal speed fan contactor
Humidifier: Humidifier contactor
Cool: Compressor contactor (Valve opens on chilled water units)
HGBP: Hot gas bypass valve
Reheat: Reheat contactor
Common Alarm: Common alarm relay
NOTE
Fan turned on with all loads.
Test Control Board
By selecting this function, the microcontroller will perform a self test lasting approximately 10
seconds. When the test is complete, the display will show the ROM checksum, ROM part number
and firmware revision number.
Microprocessor Control
39
Figure 17 Control Menu
Mini-Mate 2
Control Menu
Setpoints/Setup
Temp Setpt
Temp Sens
Hum Setpt
Hum Sens
Hi Temp Alm
Lo Temp Alrm
Hi Hum Alm
Lo Hum Alm
Status
Heat %
Dx Cool %
Dehumidify%
Humidify%
0
0
0
0
Active Alarms
No Alarms
or
Alarm 01 of 01
High Head
Status Display
75 F 50 %RH
NO ALARMS
Menu
Setpoints
Status
Active Alarms
Time
Date
Setback
Setup Operation
Setpoint Password
Setup Password
Calibrate Sensors
Alarm Enable
Alarm Time Delay
Common Alarm Enable
Custom Alarms
Custom Text
Diagnostics
End of Menu
Date
Setback
Wknd Time 1
Wknd Temp 1
Wknd Tsens 1
Wknd Humd 1
Wknd Hsens 1
Wknd Time 2
Wknd Temp 2
Wknd Tsens 2
Wknd Humd 2
Wknd Hsens 2
Wkdy Time 1
Wkdy Temp 1
Wkdy Humd 1
Wkdy Hsens 1
Wkdy Time 2
Wkdy Temp 2
Wkdy Tsens 2
Wkdy Humd 2
Wkdy Hsens 2
Setpoint Password
Enter New PSW
Setpt PSW = 000
Microprocessor Control
Calibrate sensors
Temp Cal
Hum Cal
Temp Delay
Hum Delay
Alarm Enable
Custom #1
Custom #2
High Temp
Low Temp
High Hum
Low Hum
Short Cycle
Loss Pwr
Time
Setup Operation
Restart TD
C/F Degrees
Humidity Control
Dipswch 00000000
Pos
12345678
40
Setup Password
Enter New PSW
Setup PSW = 000
Alarm Time Delay
Custom #1
Custom #2
High Temp
Low Temp
High Hum
Low Hum
Short Cyc
Loss Pwr
Common Alarm Enable
Hi Water
Hi Head
Custom #1
Custom #2
High Temp
Low Temp
High Hum
Low Hum
Short Cyc
Loss Pwr
Custom Alarms
Custom Alarm #1
Custom Alarm #2
Custom Text
Custom Text #1
Custom Text #2
Diagnostics
Test Inputs
Test Outputs
Test Microcontroller
Figure 18 Control Board (Inside Evaporator)
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 Terminal #4 Wallbox
TB3-3 — Connection to Terminal #3 Wallbox
TB3-2 — Connection to Terminal #2 Wallbox
TB3-1 — Connection to Terminal #1 Wallbox
P16 — Remote Sensor Connection
Figure 19 Wallbox Board
TB3 — 1
TB3 — 2
TB3 — 3
TB3 — 4
Wallbox
DIP Switches (1-8)
Wallbox Board
Microprocessor Control
41
4.0
SYSTEM PERFORMANCE MICROPROCESSOR CONTROLS
This section describes in detail how the Mini-Mate2 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 19
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 or Hot Water
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.
SCR Electric Reheat
The SCR (Silicon Controlled Rectifier) controller proportionally controls the stainless steel reheat
feature to maintain the selected room temperature. The rapid cycling made possible by the SCR
controller provides precise temperature control, while the constant element temperature
improves heater life. During operation of the SCR control, THE COMPRESSOR OPERATES
CONTINUOUSLY. The heaters are modulated to provide temperature control. The display status
will show when the unit is cooling and heating. The control will automatically lock the compressor cooling to “ON” position, except when the temperature falls below the low temperature alarm
set point. Cooling will then be disabled until the room temperature reaches the temperature set
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 set point).
As the return air humidity rises above the humidity set point, 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. Dehumidification will be disabled if the heating requirement
exceeds 125%. It is re-enabled when the heating requirement reaches 50%.
42
System Performance Microprocessor Controls
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.
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.
SET POINTS:
• Temperature Set point
• Temperature Sensitivity
• Humidity Set point
• Humidity Sensitivity
• High Temperature Alarm
• Low Temperature Alarm
• High Humidity Alarm
• Low Humidity Alarm
• ON/OFF STATUS and CONTROL
• SILENCE ALARM
System Performance Microprocessor Controls
43
5.0
ALARMS
The microprocessor control system will audibly and visually signal all ENABLED Alarms (including two (2) custom alarms). These special alarms can be chosen from the optional alarm list and/
or can have their own fully custom text. The custom alarm inputs are contact closures wired from
terminal TB1-1 through a normally open contact to either TB1-2 (alarm 1) or TB1-3 (alarm 2).
The alarms can be enabled or 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 can also be silenced through communications with a Liebert Site Product unit.
Many alarms will reset automatically when the alarm condition is no longer represented and only
after it has been acknowledged by being “Silenced.” The exceptions are:
1. software alarms, i.e., Loss of Power and Short Cycle alarms will reset automatically 30
seconds after being silenced or acknowledged
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. THE CUSTOMER MUST SPECIFY ALARM(S) 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 2 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 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 the 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 Level
The humidity level alarm may be activated under the following conditions:
• High: The room return air humidity exceeds the pre-set high humidity alarm set point. Is the
unit set up for dehumidification? Check DIP switch.
• Low: The room return air humidity decreases to the low humidity alarm set point. 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 set points. 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 set point.
Check for proper set point 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 set point.
Check for proper set point 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
Humidifier Problem Alarm
The Humidifier Problem Alarm will sound and display a message if any of the following humidifier conditions occur: overcurrent detection; fill system fault or end of cylinder life.
Check fault indicator LED on humidifier control board:
• Constant LED on = Overcurrent
• 1 second LED Flash = Fill System
• 1/2 second LED Flash = Replace Tank
5.1.6
High Water Alarm
A float switch in the evaporator pan will shutdown the evaporator on a high water level. Clear the
drain and reset power to the unit in order to clear the alarm.
5.1.7
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.
5.1.8
Short Cycle
A Short Cycle Alarm will occur if the compressor system has exceeded 10 cooling start attempts in
a one-hour period. This can be caused by low refrigerant level or room cooling load is small compared to capacity of the unit. Check for leaks, crimped lines and defective components. If room
load is low, increase temperature sensitivity to reduce cycle.
Alarms
45
5.2
Optional/Custom Alarms
5.2.1
Change Filter
Periodically, the return air filters in the evaporator must be changed. The Change Filter alarm
notifies the user that filter replacement is necessary. A differential air pressure switch closes
when the pressure drop across the filters becomes excessive. The switch is adjustable using the
procedure on the switch label.
5.2.2
Firestat
The optional firestat feature is a bi-metal operated sensing device with a closed switch under normal conditions. Connected between pins 1-8 and 1-9, this device will shut down the entire unit.
5.2.3
Smoke Detector
The smoke detector is located in the unit, the optional smoke detector power supply is located in
the electric panel. It constantly samples return air through a tube. No adjustments are required.
46
Alarms
6.0
SYSTEM OPERATION, 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 set points, which activates
each of the main functions.
6.1.2
Cooling
To test the cooling function, set the set point 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 set point to the desired
temperature.
6.1.3
Heating
Reheat may be tested by setting the set point 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 set point to the desired temperature.
6.1.4
Humidification
To check humidification, set the humidity set point at R.H. 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 set point to the desired humidity.
6.1.5
Dehumidification
The dehumidification performance can be tested by setting the humidity set point at R.H. 10%
below room relative humidity. The compressor should turn on. Upon completion of testing, return
humidity set point 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 on the printed circuit board. (Terminals TB1-4 and TB1-5 are fitted with a
jumper when no remote shutdown device is installed).
System Operation, Testing and Maintenance
47
6.2
Maintenance and Component Operation
6.2.1
Electric Panel
The electric panel should be inspected on a semi-annual 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.
Filters are replaced by opening the hinged door on the return air filter box.
6.2.3
Blower System
Monthly inspection of the blower package include: motor mounts, belts, fan bearings and impellers.
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. Motor
bearings are permanently sealed and self-lubricating and do NOT need lubricated.
The drive belt should be checked monthly for signs of wear and proper tension. Pressing on belts
midway between the sheave and pulley should produce from 1/2” to 1” (12 to 25 mm) of deflection.
Belts that are too tight can cause excessive bearing wear.
Belt tension can be adjusted by raising or lowering the fan motor base. Loosen nut above motor
mounting plate to remove belt. Turn nut below motor mounting plate to adjust belt tension. If belt
appears cracked or worn, it should be replaced with a matched belt (identically sized). With
proper care, a belt should last several years.
NOTE
After adjusting or changing the belt, always be certain that motor base
nuts are tightened. The bottom adjustment nut should be finger tight. The
top locking nut should be tightened with a wrench.
Air Distribution
Since all unit models are designed for constant volume air delivery, any unusual restrictions
within the air circuit must be avoided. High efficiency filters can reduce air performance and
evaporator capacity.
6.2.4
Blower Removal
If the blower or bearings must be removed or serviced, use the following procedure.
1. Remove the main center section of the three-piece electric panel by first marking and
disconnecting all power and control wiring entering the panel.
2. Remove the panel by removing screws from top and bottom sections
3. Remove the blower motor from the blower sled.
4. Remove the four bolts holding the blower sled to the base isolators.
5. Slide the blower/sled assembly forward and rotate 90°.
!
CAUTION
Protect refrigerant and water piping from damage.
6. Slide the blower/sled assembly from unit after ensuring that the refrigerant and water piping
are protected from damage.
7. Reinstall by reversing this procedure.
48
System Operation, Testing and Maintenance
6.2.5
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 20). The highpressure switch will shut the compressor down at its cut-out setting.
Table 20
Typical Discharge Pressures
System Design
psig
(kPa)
Air Cooled
180-275
(1242-1895)
Water Cooled
65ºF 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.
Coaxial Condensers (Water/Glycol Cooled Condensing Units)
Each water or glycol-cooled condensing unit 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 (water/glycol condensing units)
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 water regulating valve is designed to begin opening at 180 psi (1240 kPa) and to be fully
opened at 240 psi (1655 kPa). The valve is factory-set and should not need adjustment.
System Operation, Testing and Maintenance
49
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
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 downsteam of all these connections to control
superheat at the compressor inlet. Superheat settings for the liquid quenching valve are chosen to
maintain consistency with the system expansion valve. During hot gas bypass operation higher
superheats, 50-60°F (19 to 15°C), may be observed at the compressor. The liquid quenching valve
is internally equalized and superheat is not adjustable.
Adjustment
1. Install the suction and discharge pressure gauge.
2. Adjust temperature setpoint to call for cooling so that the refrigeration compressor will run
continuously.
3. Remove the TOP adjusting nut from the valve.
4. Insert an Allen wrench in the brass hole at top of valve in adjusting port and turn
CLOCKWISE if a higher evaporator temperature is required. Adjust no more than 1/4 turn at
a time. Let the system stabilize for 15 minutes before determining if additional adjustment 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.
50
System Operation, 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.
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 it 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 (1034kPa) pressure.
6. Follow manufacturer's instructions for clean out kits.
7. Evacuate the system twice to 1500 microns and the third time to 500 microns. Break the
vacuum each time with clean, dry refrigerant to 2 psig (13.8 kPa).
8. Charge the system with refrigerant (R-22) based on requirements of the evaporator,
condensing unit and lines. Refer to the installation manual or the unit nameplate.
9. Apply power and operate the system. Check for proper operation. Refer to Table 20 for
discharge pressure.
System Operation, Testing and Maintenance
51
6.2.6
Steam Generating Humidifier-Operation Procedures
Steam generating humidifiers operate efficiently over a wide range of water quality conditions
and automatically adjust to changes in the conductivity of water. The system will automatically
drain and refill to maintain a current set point and alert the operator when the humidifier canister needs to be replaced.
The humidifier RUN/DRAIN switch is located in the humidifier assembly. This switch should be
in the RUN position when the humidifier is in normal operation and in the DRAIN position during service. The electronic control board for the humidifier is also located in the humidifier assembly. When the unit is energized, power is available to humidifier. Operation involves the following
steps:
1. During start-up, when the humidity control calls for humidification, the fill valve will open,
allowing water to enter the canister. When the water level reaches the electrodes, current
flows and the water will begin to warm. The canister fills until the amperage reaches the set
point and the fill valve closes. As the water warms, its conductivity increases and the current
flow, in turn, rises. If the amperage reaches 115% of the normal operating amperage, the
drain valve opens and flushes some of the water out of the canister. This reduces electrode
contact with the water and lowers the current flow to the amperage set point. Boiling soon
commences and the canister operates normally.
2. If the conductivity of the water is low, the canister fills and the water level reaches the
canister full electrode before the amperage set point is reached. The humidifier stops filling to
prevent overflow. Boiling should commence in time. As water is boiled off, the mineral
concentration in the canister increases and current flow also increases. The canister
eventually reaches full output and goes to normal operation. No drain is permitted until then.
3. When full output is reached the circuit board starts a time cycle which is factory-set at 60
seconds. During this repeating time cycle, the fill valve will open periodically to replenish the
water being boiled off and maintain a “steady state” output at the set point. The amperage
variance will depend on the conductivity of the water.
4. After a period of time, the mineral concentration in the canister becomes too high. When this
occurs, the water boils too quickly. As the water quickly boils off and less of the electrode is
exposed, the current flow decreases. When the current crosses the low threshold point
(factory-set at 85%) before the end of the time cycle, the drain valve opens, draining the
mineral laden water out and replacing it with fresh water. This lowers the mineral
concentration and returns the canister to “steady state” operation and prolongs canister life.
The frequency of drains depends on water conductivity.
5. Over a period of time, the electrode surface will become coated with a layer of insulating
material, which causes a drop in current flow. As this happens, the water level in the canister
will slowly rise exposing new electrode surface to the water to maintain normal output.
Eventually, the steady state water level will reach the canister full electrode and indicate so
by activating the canister full alarm. At this point, all of electrode surface has been used up
and the canister should be replaced.
6. After the entire electrode surface has been coated, the output will slowly decrease. During
these last hours of electrode life, the mineral concentration can increase and arcing can occur.
If the electrodes start to arc, turn off the humidifier immediately and replace the canister
with the identical part.
52
System Operation, Testing and Maintenance
Replacing the Humidifier Canister
The proper procedure to replace the humidifier canister is:
1. Turn off the humidifier by lowering the humidity set point below the ambient humidity level.
Record the original set point.
2. Place the RUN/DRAIN switch in the DRAIN position to drain the water from the canister.
3. Return the RUN/DRAIN switch to the RUN position after the canister has drained.
4. Turn OFF the power at the main unit.
5. Remove the cover from the humidifier cabinet.
6. 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 two (2)
power wires and the canister full wire. Do not loosen the screws that secure the electrodes.
WARNING
CANISTER AND STEAM HOSE MAY BE HOT! ALLOW TIME FOR
THE HUMIDIFIER TO COOL BEFORE REPLACING PARTS.
!
7. Loosen the steam outlet hose clamps and slide the steam hose away from the canister fitting.
Release the canister clamp along the base of the canister.
8. Remove the canister.
9. Reverse previous steps to reassemble humidifier, paying special attention to the following:.
WARNING
HAZARDOUS VOLTAGE! USE EXTREME CAUTION. CIRCUIT
BOARD ADJUSTMENT SHOULD BE PERFORMED BY
QUALIFIED PERSONNEL ONLY.
!
POWER SHOULD BE DISCONNECTED PRIOR TO THE
PROCEDURE.
6.2.7
Circuit Board Adjustments
The humidifier control board governs humidifier operation. There are three potentiometers
mounted on the board and can be used to adjust for extreme water conductivity conditions.
POT2 controls the amperage at which the drain will energize and is clearly marked in percentages. This adjustment is factory-set at 85%, which indicates that the unit will drain when the
amperage falls off to 85% of the capacity set point. Raising the value increases the frequency of
drain cycles. Lowering the value decreases the frequency of drain cycles.
The frequency should be increased for highly conductive water and decreased for less conductive
water. If adjustment is necessary and a change of three to four percent in either direction does not
permit normal operation of the unit, consult your Liebert supplier.
The POT1 controls the duration of the drain cycle. This adjustment is factory-set at 60 seconds
(1 VDC) and should not be readjusted without consulting your Liebert supplier.
The DIP switch settings are used to set the capacity of the humidifier. If the humidifier is
replaced in the field the DIP switches should be set to the required settings described below.
Table 21
Humidifier Control Board DIP Switch Settings
Voltage
SW1
SW2
SW3
SW4
Amps
208
On
On
On
Off
8.9
240
Off
On
On
Off
8.5
380/415
Off
Off
Off
Off
5.2
460
On
On
On
Off
4.5
575
On
On
Off
Off
3.4
System Operation, Testing and Maintenance
53
7.0
MAINTENANCE INSPECTION CHECKLIST
Liebert Mini-Mate2
Date:____________________________________
Prepared By:____________________________________
Model #:_________________________________
Serial Number:__________________________________
NOTE
Reheat element sheaths and fins are manufactured with stainless steel.
Regular inspections are necessary to assure proper cleanliness of the
reheating element. Should inspection reveal corrosion particles on the
reheating element or adjoining surfaces (including ducts and plenums),
appropriate cleaning should be performed. Periodic reheating element
replacement may be required to meet specific application requirements.
Monthly
Filters
Humidifier
___ 1. Check for restricted airflow
___ 1. Check canister for mineral deposits
___ 2. Check for filter
___ 2. Check condition of electrodes
___ 3. Wipe section clean
___ 3. All hoses and fittings tight
Fan Section
___ 4. Check water make-up valve for leaks
___ 1. Impellers free of debris and
move freely
___ 2. Bearings in good condition
___ 3. Check belt tension and
condition
Semiannually
Compressor Section
Flood Back Head Pressure Control
___ 1. Signs of oil leaks
___ 1. Check refrigerant level
___ 2. Vibration isolation
Water or Glycol Cooled Condensing Unit
Refrigeration Cycle
___ 1. Water valve adjustment
___ 1. Suction pressure
___ 2. Water flow
___ 2. Head pressure
___ 3. Water leaks
___ 3. Superheat
Glycol Pump (if applicable)
___ 4. Evaporator coil clean
___ 5. Insulation intact
Air Cooled Condensing Unit (if
applicable)
___ 1. Condenser coil clean
___ 2. Motor mount tight
___ 3. Refrigerant lines properly
supported
___ 1. Glycol leaks
___ 2. Pump operation
___ 3. Glycol solution
___ 4. pH level
Electric Panel
___ 1. Check electrical connections
___ 2. Operational sequence
Electric Reheat
___ 1. Check element for corrosion
Notes:
Signature:________________________________________________________________
Make photocopies of this form for your records
54
Maintenance Inspection Checklist
8.0
TROUBLESHOOTING
Table 22
Symptom
Unit will not start
No cooling
Compressor high
head pressure
Humidifier does
not operate
Troubleshooting
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 closed
because of high water in the
condensate pan
Has rubber band been removed from float switch? Check drain
and line. Access through left panel. Power must be cycled at the
disconnect to reset.
Jumper not in place
Check terminal TB1-4 and TB1-5 for jumper or N/C contact.
Check pins 1-8 and 1-9 for jumper or N/C firestat contact. Check
pins 5-4 and 5-5 for jumper or N/C smoke detector contact.
Cooling not displayed at the
control panel
Adjust TEMP control set point 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 24 VAC ± 2 VAC at terminals P4-8 and P4-4. If voltage,
check contactor. If no voltage at P4-8 and P4-4, check at
terminals P2-3 and P2-8. If voltage, check freeze stat.
Compressor high head
pressure
See below for cause.
Plugged filter/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 Table 21.
“HUMIDIFY” not displayed
at control panel
Increase humidity control set point and sensitivity to require
humidification.
Defective board
Check voltage at P3-1 and P1-9 on interface board for 24 VAC
± 2 VAC. If no voltage, check wiring and/or replace board. Check
wiring from control panel to board.
Failed humidity sensor
Humidity display will indicate dashes. Check wiring from
temperature/humidity board to the control board and from the
wall box to the control board. Replace wallbox or temperature/
humidity circuit board (if remote).
No water flow
Make sure switch is in Run position. Check humidifier water
supply (including filter screen) and check nylon overflow line if
canister is full.
Canister fill rate is not
keeping up with the steam
output
Check fill valve screen opening and capillary tube for
obstructions. Check water supply pressure (minimum 10 PSIG).
Troubleshooting
55
Table 22
Troubleshooting
Symptom
Reheat will not
operate
Cooling cycle too
short
Display freezes
and control pads
do not respond
Condensate
pump does not
operate
Continuous
Cooling
Continuous
Heating
Dehumidification
Humidification
56
Possible Cause
Check Or Remedy
DIP switch not set to enable
reheat option
See DIP switch settings Table 21.
HEAT not displayed at the
control panel
Increase temperature set point to require heating.
Reheat safety open,
defective reheat contact or
defective board
Check voltage at P2-1 and P1-9 on interface board for 24 VAC ±
2 VAC. If voltage, check reheat contactor and reheat safety. If no
voltage, check wiring and/or replace board.
Element is burned out
Turn off power. Check element continuity with Ohm meter.
Sensor response delay too
short
Increase sensor response delay. See 3.11 - Calibrate Sensors.
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.
Open or short circuit in
wiring
Find open or short circuit and repair power to pump.
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.
Shorted wiring or failed
control board
Check wiring and/or replace control board.
Troubleshooting
®
ENVIRONMENTAL CONTROL
MINI-MATE2
INSTALLATION, OPERATION & MAINTENANCE MANUAL
The Company Behind the Products
Technical Support
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:
United States
1050 Dearborn Drive
P.O. Box 29186
Columbus, OH 43229
1-800-877-9222
Outside the United States
1-800-888-0246
•
•
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•
•
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While every precaution has been taken to ensure
the accuracy and completeness of this literature,
Liebert Corporation assumes no responsiblity and
disclaims all liability for damages resulting from
use of this information or for any errors or
omissions.
© 2001 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-10532 (6/01)
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3-Phase UPS
1-800-543-2378
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1-800-543-2778
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E-mail
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