Liebert Precision Cooling System DS User Manual

Precision CoolingFor Business-Critical Continuity™Liebert® DS™User Manual28-105kW, 8-30 Tons, Upflow and Downflow, 50/60Hz

viiiTable 43 Component weights—upflow, air-cooled, 105kW (30 ton), scroll/digital scroll compressor models . . . . . . . . . . . . . . . . . . . . . .

Piping Schematics90Figure 65 Optional piping schematic for Econ-O-CoilDPN000805Rev. 1* Supplied with 10 feet (3m) extra thermistor wire for installati

Piping Schematics91Figure 66 Primary connection locations—downflow, air-cooled, 28-42kW (8-12 ton), semi-hermetic compressor modelsPoint DescriptionXi

Piping Schematics92Figure 67 Primary connection locations—downflow, air-Cooled, 28-42kW (8-12 ton) with scroll compressor modelsPoint DescriptionXinch

Piping Schematics93Figure 68 Primary connection locations—downflow water/glycol/GLYCOOL 28-42kW (8-12 ton), all compressor modelsPoint DescriptionXinc

Piping Schematics94Figure 69 Primary connection locations—downflow, air-Cooled, 53-77kW (15-22 ton), semi-hermetic compressor modelsPoint DescriptionX

Piping Schematics95Figure 70 Primary connection locations—downflow, air-Cooled, 53-77kW (15-22 ton) with scroll compressor modelsPoint DescriptionXinc

Piping Schematics96Figure 71 Primary connection locations—downflow, water/glycol/GLYCOO,L 53-77kW (15-22 ton), all compressor modelsPoint) Description

Piping Schematics97Figure 72 Primary connection locations—downflow, air-cooled, 105kW (30 ton), all compressor modelsPoint) Description)Xinches (mm)Yi

Piping Schematics98Figure 73 Primary connection locations—downflow, air-cooled, 105kW (30 ton), all compressor modelsPoint Description)Xinches (mm)Yin

Piping Schematics99Figure 74 Primary connection locations—upflow, air-cooled, 28-42kw (8-12 ton), semi-hermetic compressor modelsPoint DescriptionXinc

1IMPORTANT SAFETY INSTRUCTIONSSAVE THESE INSTRUCTIONSThis manual contains important safety instructions that should be followed during the installatio

Piping Schematics100Figure 75 Primary connection locations—upflow, air-Cooled, 28-42kW (8-12 ton), semi-hermetic compressor modelsPoint DescriptionXin

Piping Schematics101Figure 76 Primary connection locations—upflow, water/glycol/GLYCOOL, 28-42kW (8-12 ton), all compressor modelsPoint DescriptionXin

Piping Schematics102Figure 77 Primary connection locations—upflow, air-cooled, 53-77kW (15-22 ton), semi-hermetic compressor modelsPoint Description X

Piping Schematics103Figure 78 Primary connection locations—upflow, air-cooled, 53-77kW (15-22 ton), scroll compressor modelsPoint Description Xinches

Piping Schematics104Figure 79 Primary connection locations—upflow, water/glycol/GLYCOOL, 53-77kW (15-22 ton), all compressor modelsPoint Description X

Piping Schematics105Figure 80 Primary connection locations—upflow, air-cooled, 105kW (30 ton), allTable 51 Piping data—upflow, air-cooled 105kW (30 to

Piping Schematics106Figure 81 Primary connection locations—upflow, water/glycol/GLYCOOL, 105kW (30 ton), allTable 52 Piping data—upflow, upflow, water

Checklist for Completed Installation10710.0 CHECKLIST FOR COMPLETED INSTALLATION10.1 Moving and Placing Equipment___ 1. Unpack and check received mate

Initial Startup Checks and Commissioning Procedure for Warranty Inspection10811.0 INITIAL STARTUP CHECKS AND COMMISSIONING PROCEDURE FOR WARRANTY INSP

Initial Startup Checks and Commissioning Procedure for Warranty Inspection10911.1 Information for Warranty Inspection—Remove Power From Unit Disconnec

2!WARNINGRisk of high-speed moving parts. Can cause injury or death.Disconnect all local and remote electric power supplies before working in the unit

Initial Startup Checks and Commissioning Procedure for Warranty Inspection11011.3 Commissioning Procedure With Panels On1. Disconnect all power to the

Maintenance11112.0 MAINTENANCEThe Liebert DS product is a single component in the facility heat removal system. The system includes air distribution (

Maintenance11212.1.1 Filter Replacement Procedure—Downflow Units1. Disconnect power from the Liebert DS.2. Using a stepladder, remove filters from the

Maintenance11312.2.1 Upflow Motor Access1. Remove the lateral support (sheet metal channel) under electric box by removing two screws at each end.2. R

Maintenance114Figure 84 Auto-belt tensioning motor baseBlower Bearing Maintenance• Field lubrication is NOT required for the life of the bearing.• Bea

Maintenance11512.3 Humidifier12.3.1 Infrared HumidifierDuring normal humidifier operation, deposits of mineral solids will collect in humidifier pan a

Maintenance11612.3.3 Changing Humidifier Lamps1. Remove humidifier pan (see 12.3.2 - Cleaning Humidifier Pan and Float Switch, Steps 1 through 10).2.

Maintenance11712.5 Air-Cooled Condenser and Drycoolers• Clear coil surface of all debris that will inhibit airflow. • Check for bent or damaged coil f

Maintenance11812.8 Compressor ReplacementReplacement compressors are available through your local Emerson office. Compressors are shipped in reusable

Maintenance11912.10 Paradenser—Water-Cooled CondenserDuring normal Paradenser operation, deposits will collect on inside wall of condenser tubes. It m

Liebert DS Components and Nomenclature31.0 LIEBERT DS COMPONENTS AND NOMENCLATUREFigure 1 Downflow model component locations1192416101268713131451510.

Maintenance120To lower the head pressure setting, turn the square adjusting screw clockwise until the high pressure gauge indicates the desired settin

Maintenance12112.11.3Drycooler SettingsApplications with the Optional Stat Setting require field piping to be insulated to prevent condensa-tion. Tabl

HVAC Maintenance Checklist12213.0 HVAC MAINTENANCE CHECKLISTFilters___ 1. Check/replace filters___ 2. Grille area unrestricted___ 3. Wipe section clea

HVAC Maintenance Checklist123Condensate Pump___ 1. Check for debris in sump___ 2. Check operation of float(s) (free movement)Refrigeration Piping___ 1

HVAC Maintenance Checklist124Air-Cooled Condenser / Drycooler___ 1. Coil clean___ 2. Motor mounts tight___ 3. Bearings in good condition (motor)___ 4.

Ensuring The High AvailabilityOf Mission-Critical Data And Applications.Emerson Network Power, the global leader in enabling business-criticalcontinui

Liebert DS Components and Nomenclature4Figure 2 Upflow model component locations1. iCom Control Display2. Electric Box3. Filters4. Evaporator Coil5. M

Liebert DS Components and Nomenclature5Figure 3 Liebert DS model number nomenclature1D2S3043557U6A8A9010311I12*13*14*15*Air DistributionDS = Downflow

Cooling Configurations62.0 COOLING CONFIGURATIONSNOTEAll field-installed piping must comply with applicable local, state and federal codes.Air-CooledA

Pre-Installation Guidelines73.0 PRE-INSTALLATION GUIDELINES3.1 Room Preparation• Verify that the floor is level, solid and sufficient to support the u

Pre-Installation Guidelines83.3 Air Distribution—Upflow UnitsVarious configurations are available:• Front return• Rear return•Top-front supply• Top-re

Pre-Installation Guidelines93.4 Connections and System Setup• Plan the routing of wiring, piping and ductwork to the unit. See Figure 55 and Figures 6

Liebert DS Dimensions and Weights104.0 LIEBERT DS DIMENSIONS AND WEIGHTSTable 1 Shipping dimensions—domestic and export, inches (mm)Model Number028/03

Liebert DS Dimensions and Weights11Figure 6 Cabinet and floor planning dimensions—downflow, air-cooled, 28-42kW (8-12 ton), semi-hermetic compressor m

Liebert DS Dimensions and Weights12Figure 7 Cabinet and floor planning dimensions—downflow, air-cooled, 28-42kW (8-12 ton), scroll compressor modelsTa

Liebert DS Dimensions and Weights13Figure 8 Cabinet and floor planning dimensions—downflow, water/glycol/GLYCOOL, 28-42kW (8-12 ton), all compressor m

Liebert DS Dimensions and Weights14Figure 9 Cabinet and floor planning dimensions—downflow, air-cooled, 53-77kW (15-22 ton), semi-hermetic compressor

Liebert DS Dimensions and Weights15Figure 10 Cabinet and floor planning dimensions—downflow, air-cooled, 53-77kW (15-22 ton), scroll compressor models

Liebert DS Dimensions and Weights16Figure 11 Cabinet and floor planning dimensions—downflow, water/glycol/GLYCOOL, 53-77kW (15-22 ton), all compressor

Liebert DS Dimensions and Weights17Figure 12 Cabinet and floor planning dimensions—downflow, air-cooled, 105kW (30 ton), all compressor modelsTable 9

Liebert DS Dimensions and Weights18Figure 13 Cabinet and floor planning dimensions—downflow, water/glycol/GLYCOOL, 105kW (30 ton), all compressor mode

Liebert DS Dimensions and Weights19Figure 14 Cabinet and floor planning dimensions—upflow, air-cooled 28-42kW (8-12 ton), semi-hermetic compressor mod

iTABLE OF CONTENTSIMPORTANT SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1SAVE T

Liebert DS Dimensions and Weights20Figure 15 Cabinet and floor planning dimensions—upflow, air-cooled 28-42kW (8-12 ton), scroll or digital scroll com

Liebert DS Dimensions and Weights21Figure 16 Cabinet and floor planning dimensions—upflow, water/glycol/GLYCOOL, 28-42kW (8-12 ton), all compressor mo

Liebert DS Dimensions and Weights22Figure 17 Cabinet and floor planning dimensions—upflow, air-cooled, 53-77kW (15-22 ton), semi-hermetic compressor m

Liebert DS Dimensions and Weights23Figure 18 Cabinet and floor planning dimensions—upflow, air-cooled, 53-77kW (15-22 ton), scroll or digital scroll c

Liebert DS Dimensions and Weights24Figure 19 Cabinet and floor planning dimensions—upflow, water/glycol/GLYCOOL, 53-77kW (15-22 ton), all compressor m

Liebert DS Dimensions and Weights25Figure 20 Cabinet and floor planning dimensions—upflow, air-cooled, 105kW (30 ton), allTable 17 Weights—upflow, air

Liebert DS Dimensions and Weights26Figure 21 Cabinet and floor planning dimensions—upflow water/glycol/GLYCOOL 105kW (30 ton), all compressorsTable 18

Liebert DS Dimensions and Weights27Figure 22 Floor stand dimensions—downflow, 28-42kW (8-12 ton) modelsTable 19 Floor stand and floor planning dimensi

Liebert DS Dimensions and Weights28Figure 23 Floor stand dimensions—downflow, 53-77kW (15-22 ton) modelsTable 20 Floor stand and floor planning dimens

Liebert DS Dimensions and Weights29Figure 24 Floor stand dimensions—downflow, 105kW (30 ton) modelsTable 21 Floor stand and floor planning dimensions—

ii7.0 ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .687.1 Electrical Field Conn

Liebert DS Dimensions and Weights30Figure 25 Blower outlet and deck dimensions—upflow, 28-42kW (8-12 ton)Table 22 Dimensions for upflow, 28-42kW (8-12

Liebert DS Dimensions and Weights31Figure 26 Blower outlet and deck dimensions—upflow, 53-77kW (15-22 ton)Table 23 Blower outlet and deck dimensions f

Liebert DS Dimensions and Weights32Figure 27 Blower outlet and deck dimensions—upflow 105kW (30ton)Table 24 Blower outlet and deck dimensions—upflow 1

Liebert DS Dimensions and Weights33Figure 28 Rear return filter box dimensionsTable 25 Rear return filter box dimensionsCompressor Type Dimensions, in

Liebert DS Dimensions and Weights34Figure 29 Upflow unit plenum dimensionsTable 26 Upflow unit plenum dimensionsPlenum Dimensions, in (mm) Grille Size

Equipment Inspection and Handling355.0 EQUIPMENT INSPECTION AND HANDLINGUpon arrival of the unit and before unpacking it, verify that the labeled equi

Equipment Inspection and Handling36Figure 30 Equipment recommended for handling Liebert DSIf possible, transport the Liebert DS with a forklift or pal

Equipment Inspection and Handling375.2.1 Removing the Unit from the Skid With a Forklift1. Align a forklift with either the front or rear side of the

Equipment Inspection and Handling385.2.2 Moving the Unit to the Installation Location with Piano Jacks1. With the Liebert DS elevated, place two piano

Equipment Inspection and Handling395.2.4 Removing Liebert DS from Skid Using Rigging1. Space the slings equidistant on either side of the center of gr

iii12.5 Air-Cooled Condenser and Drycoolers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11712.6 Reheat—Electri

Equipment Inspection and Handling40Figure 35 Using rigging to lift Liebert DS off skidEqualDistanceEqualDistanceLiftingSlingLiftingSling 181659P1Rev.

Equipment Inspection and Handling415.3 Semi-Hermetic Compressor Spring Isolation SystemShipping blocks under all semi-hermetic compressors must be rem

Disassembling the Liebert DS for Transport426.0 DISASSEMBLING THE LIEBERT DS FOR TRANSPORTThe Liebert DS has a modular frame construction that allows

Disassembling the Liebert DS for Transport43NOTICEDo not lay the compressor section on its side. It must remain upright. The coil section also must re

Disassembling the Liebert DS for Transport4419. Cut the insulation and pull it back from the piping.20. Cut the refrigerant piping with a tubing cutte

Disassembling the Liebert DS for Transport456.3 Reassembly—Downflow Units1. Replace the top section.Make sure to clear the Schrader valves on the coil

Disassembling the Liebert DS for Transport466.4 Reassembly Checklist___ 1. Thread-cutting bolts reconnected and torqued to 225 in-lb. (25Nm)___ 2. Top

Disassembling the Liebert DS for Transport47Figure 37 Component dimensions—downflow, air-cooled, 28-42kW (8-12 ton), semi-hermetic compressor modelsTa

Disassembling the Liebert DS for Transport48Figure 38 Component dimensions—downflow, air-cooled, 28-42kW (8-12 ton), scroll/digital scroll compressor

Disassembling the Liebert DS for Transport49Figure 39 Component dimensions—downflow, water/glycol/GLYCOOL, 28-42kW (8-12 ton), all compressor modelsTa

ivFIGURESFigure 1 Downflow model component locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disassembling the Liebert DS for Transport50Figure 40 Component dimensions—downflow, air-cooled, 53-77kW (15-22 ton), semi-hermetic compressor modelsT

Disassembling the Liebert DS for Transport51Figure 41 Component dimensions—downflow air-cooled, 53-77kW (15-22 ton), scroll/digital scroll compressor

Disassembling the Liebert DS for Transport52Figure 42 Component dimensions—downflow water/glycol, GLYCOOL, 53-77kW (15-22 ton), all compressor modelsT

Disassembling the Liebert DS for Transport53Figure 43 Component dimensions—downflow, air-cooled, 105kW (30 ton), semi-hermetic compressor modelsTable

Disassembling the Liebert DS for Transport54Figure 44 Component dimensions—downflow, air-cooled, 105kW (30 ton), scroll compressor models Table 34 Com

Disassembling the Liebert DS for Transport55Figure 45 Component dimensions—downflow, water/glycol/GLYCOOL, 105kW (30 ton), all compressor modelsTable

Disassembling the Liebert DS for Transport566.5 Disassembly—Upflow UnitsFor detailed views of upflow units, see Figures 46 through 54.1. Remove the un

Disassembling the Liebert DS for Transport5719. Immediately cap off and seal all piping that has been cut, including the suction and liquid lines, th

Disassembling the Liebert DS for Transport586.6 Reassembly—Upflow Unit1. Reattach the top section using thread-cutting bolts; there are four on each s

Disassembling the Liebert DS for Transport59Figure 46 Component dimensions—upflow, air-cooled, 28-42kW (8-12 ton), semi-hermetic compressor modelsTabl

vFigure 37 Component dimensions—downflow, air-cooled, 28-42kW (8-12 ton), semi-hermetic compressor models . . . . . . . . . . . . . . . . . . . . . .

Disassembling the Liebert DS for Transport60Figure 47 Component dimensions—upflow, air-cooled, 28-42kW (8-12 ton), scroll/digital scroll compressor mo

Disassembling the Liebert DS for Transport61Figure 48 Component dimensions—upflow, water/glycol/GLYCOOL, 28-42kW (8-12 ton), all compressor modelsTabl

Disassembling the Liebert DS for Transport62Figure 49 Component dimensions—upflow, air-cooled, 53-77kw (15-22 ton), semi-hermetic compressor modelsTab

Disassembling the Liebert DS for Transport63Figure 50 Component dimensions—upflow, air-cooled, 53-77kw (15-22 ton), scroll/digital scroll compressor m

Disassembling the Liebert DS for Transport64Figure 51 Component dimensions—upflow water/glycol/GLYCOOL 53-77kw (15-22 ton), all compressor modelsTable

Disassembling the Liebert DS for Transport65Figure 52 Component dimensions—upflow, air-cooled, 105kW (30 ton), semi-hermetic compressor modelsTable 42

Disassembling the Liebert DS for Transport66Figure 53 Component dimensions—upflow, air-cooled, 105kW (30 ton), scroll/digital scroll compressor models

Disassembling the Liebert DS for Transport67Figure 54 Component dimensions—upflow, water/glycol/GLYCOOL, 105kW (30 ton), all compressor modelsTable 44

Electrical Connections687.0 ELECTRICAL CONNECTIONSThree-phase electrical service is required for all models. Electrical service must conform to nation

Electrical Connections69Figure 55 Electrical field connections787576949596 97 91111277929380817337C38C37B38B37 38 24707172505155 56888382 898459588516

viFigure 70 Primary connection locations—downflow, air-Cooled, 53-77kW (15-22 ton) with scroll compressor models . . . . . . . . . . . . . . . . . .

Electrical Connections707.1 Electrical Field Connection DescriptionsStandard Electrical Connections1. Primary high-voltage entrance—2-1/2" (64mm)

Electrical Connections71Optional Low Voltage Terminal Package Connections20. Remote unit shutdown - Two additional contact pairs available for unit sh

Piping728.0 PIPINGAll fluid and refrigeration connections to the unit, with the exception of the condensate drain, are sweat copper. Factory-installed

Piping73Figure 56 Gravity drain for downflow and upflow unitsCondensate Pump• 1/2" copper sweat connection is provided on units with optional fac

Piping748.1.2 Humidifier Supply Water—Optional Infrared• 1/4" supply line; maximum water pressure is 150 psi (1034kPa) • Size humidifier supply l

Piping75Leak Checking of Unit and Field PipingLiebert unit fluid systems are factory-checked for leaks and may be shipped with a nitrogen holding char

Piping768.2.1 Piping Guidelines—Air-Cooled Units• Indoor unit ships with a nitrogen holding charge; do not vent the evaporator until all refrigerant p

Piping77Table 47 Line charges - refrigerant per 100 ft (30m) of Type “L” copper tubeO.D. Liquid Line, lb (kg)1/2" 7.3 (3.3)5/8" 11.7 (5.3)7

Piping788.3 Dehydration/Leak Test and Charging Procedures for R-407C and R-228.3.1 Air-Cooled Condenser with Fan Speed Head Pressure Control SystemThe

Piping79Fan Speed Charging1. Check unit nameplate for refrigerant type to be used. Unit control configurations differ depending on refrigerant type.2.

viiTABLESTable 1 Shipping dimensions—domestic and export, inches (mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Table 2 Shippin

Piping808.3.2 Air-Cooled Condenser with Lee-Temp “Flooded Condenser” Head Pressure Control SystemThe Lee-Temp system consists of a modulating type hea

Piping818. After four hours, check the pressure readings and, if they have not changed, break vacuum with dry nitrogen. Pull a second (R-407C and R-22

Piping Schematics829.0 PIPING SCHEMATICSFigure 57 Piping schematic—air-cooled, semi-hermetic compressor modelsCondenser Coil(Lee-Temp)Condenser Coil(F

Piping Schematics83Figure 58 Piping schematic—air-cooled, scroll compressor modelsLee-Temp ReceiverFan SpeedLee-TempServiceValveExternal EqualizerLiqu

Piping Schematics84Figure 59 Piping schematic—water/glycol, semi-hermetic compressor modelsCompressorMufflerServiceValveCylinderUnloader (s)Evaporator

Piping Schematics85Figure 60 Piping schematic—water/glycol with scroll compressor modelsCOMPRESSORCUSTOMERHEAT REJECTIONCOOLING TOWERAND PUMPSYSTEMBY

Piping Schematics86Figure 61 Piping schematic—GLYCOOL semi-hermetic compressor modelsLIEBERTHEAT REJECTIONDRYCOOLER(Glycol)AquastatSensingBulbsHoseBib

Piping Schematics87Figure 62 Piping schematic—GLYCOOL with scroll compressor models3-WayChilled GlycolValve3-WayChilled GlycolValveNOTE: Schematic rep

Piping Schematics88Figure 63 Piping schematic—water/glycol with digital scroll compressor modelsSensing BulbCUSTOMERHEAT REJECTIONLIEBERTHEAT REJECTIO

Piping Schematics89Figure 64 GLYCOOL with digital scroll compressor modelsPARADENSER®CONDENSERLIEBERTHEAT REJECTIONLIEBERT DS UNIT(and associated pipi