User ManualTable of ContentsImportant Safety Instructions11Save These Instructions111.0 Liebert DS Components and Nomenclature13Figure 1 Downflow model component locations13Figure 2 Upflow model component locations14Figure 3 Liebert DS model number nomenclature152.0 Cooling Configurations163.0 Pre-Installation Guidelines173.1 Room Preparation173.2 Air Distribution-Downflow Units17Figure 4 Downflow unit ducting and plenum ducting173.3 Air Distribution-Upflow Units18Figure 5 Upflow ducting configurations183.4 Connections and System Setup193.5 Operating Conditions194.0 Liebert DS Dimensions and Weights20Table 1 Shipping dimensions-domestic and export, inches (mm)20Table 2 Shipping weights-approximate, kg20Figure 6 Cabinet and floor planning dimensions-downflow, air-cooled, 28-42kW (8-12 ton), semi-hermetic compressor models21Table 3 Weights for downflow, air-cooled, 28-42kW (8-12 ton), semi-hermetic compressor models21Figure 7 Cabinet and floor planning dimensions-downflow, air-cooled, 28-42kW (8-12 ton), scroll compressor models22Table 4 Weights for downflow, air-cooled, 28-42kW (8-12 ton), scroll compressor models22Figure 8 Cabinet and floor planning dimensions-downflow, water/glycol/GLYCOOL, 28-42kW (8-12 ton), all compressor models23Table 5 Weights for downflow, water/glycol/GLYCOOL, 28-42kW (8-12 ton), all compressor models23Figure 9 Cabinet and floor planning dimensions-downflow, air-cooled, 53-77kW (15-22 ton), semi-hermetic compressor models24Table 6 Weights for downflow, air-cooled, 53-77kW (15-22 ton), semi-hermetic compressor models24Figure 10 Cabinet and floor planning dimensions-downflow, air-cooled, 53-77kW (15-22 ton), scroll compressor models25Table 7 Weights for downflow, air-cooled, 53-77kW (15-22 ton), scroll compressor models25Figure 11 Cabinet and floor planning dimensions-downflow, water/glycol/GLYCOOL, 53-77kW (15-22 ton), all compressor models26Table 8 Weights for downflow, water/glycol/GLYCOOL, 53-77kW (15-22 ton), all compressor models26Figure 12 Cabinet and floor planning dimensions-downflow, air-cooled, 105kW (30 ton), all compressor models27Table 9 Weights for downflow, air-Cooled, 105kW (30 ton), all compressor models27Figure 13 Cabinet and floor planning dimensions-downflow, water/glycol/GLYCOOL, 105kW (30 ton), all compressor models28Table 10 Weights for downflow, water/glycol/GLYCOOL, 105kW (30 ton), all compressor models28Figure 14 Cabinet and floor planning dimensions-upflow, air-cooled 28-42kW (8-12 ton), semi-hermetic compressor models29Table 11 Weight for upflow, air-cooled, 28-42kW (8-12 ton), semi-hermetic compressor models29Figure 15 Cabinet and floor planning dimensions-upflow, air-cooled 28-42kW (8-12 ton), scroll or digital scroll compressor models30Table 12 Weight for upflow, air-cooled, 28-42kW (8-12 ton), scroll or digital scroll compressor models30Figure 16 Cabinet and floor planning dimensions-upflow, water/glycol/GLYCOOL, 28-42kW (8-12 ton), all compressor models31Table 13 Weights for upflow, water/glycol/GLYCOOL, 28-42kW (8-12 ton), all compressor models31Figure 17 Cabinet and floor planning dimensions-upflow, air-cooled, 53-77kW (15-22 ton), semi-hermetic compressor models32Table 14 Weights for upflow, air-cooled, 53-77kW (15-22 ton), semi-hermetic compressor models32Figure 18 Cabinet and floor planning dimensions-upflow, air-cooled, 53-77kW (15-22 ton), scroll or digital scroll compressor models33Table 15 Weight for upflow, air-cooled, 53-77kW (15-22 ton), scroll or digital scroll compressor models33Figure 19 Cabinet and floor planning dimensions-upflow, water/glycol/GLYCOOL, 53-77kW (15-22 ton), all compressor models34Table 16 Weights for upflow, water/glycol/GLYCOOL, 53-77kW (15-22 ton), all compressor models34Figure 20 Cabinet and floor planning dimensions-upflow, air-cooled, 105kW (30 ton), all35Table 17 Weights-upflow, air-cooled, 105kW (30 ton), all35Figure 21 Cabinet and floor planning dimensions-upflow water/glycol/GLYCOOL 105kW (30 ton), all compressors36Table 18 Weights-upflow water/glycol/GLYCOOL 105kW (30 ton), all compressors36Figure 22 Floor stand dimensions-downflow, 28-42kW (8-12 ton) models37Table 19 Floor stand and floor planning dimensions-downflow, 28-42kW (8-12 ton) models37Figure 23 Floor stand dimensions-downflow, 53-77kW (15-22 ton) models38Table 20 Floor stand and floor planning dimensions-downflow, 53-77kW (15-22 ton) models38Figure 24 Floor stand dimensions-downflow, 105kW (30 ton) models39Table 21 Floor stand and floor planning dimensions-downflow, 105kW (30 ton) models39Figure 25 Blower outlet and deck dimensions-upflow, 28-42kW (8-12 ton)40Table 22 Dimensions for upflow, 28-42kW (8-12 ton)40Figure 26 Blower outlet and deck dimensions-upflow, 53-77kW (15-22 ton)41Table 23 Blower outlet and deck dimensions for upflow, 53-77kW (15-22 ton)41Figure 27 Blower outlet and deck dimensions-upflow 105kW (30ton)42Table 24 Blower outlet and deck dimensions-upflow 105kW (30ton)42Figure 28 Rear return filter box dimensions43Table 25 Rear return filter box dimensions43Figure 29 Upflow unit plenum dimensions44Table 26 Upflow unit plenum dimensions445.0 Equipment Inspection and Handling455.1 Packaging Material45Safety Information45Figure 30 Equipment recommended for handling Liebert DS465.2 Unpacking the Unit46Figure 31 Removing packaging465.2.1 Removing the Unit from the Skid With a Forklift47Figure 32 Remove the unit from the skid475.2.2 Moving the Unit to the Installation Location with Piano Jacks48Figure 33 Moving the unit to its installation location485.2.3 Removing Piano Jacks485.2.4 Removing Liebert DS from Skid Using Rigging49Figure 34 Locate center of gravity marker and place slings49Figure 35 Using rigging to lift Liebert DS off skid505.3 Semi-Hermetic Compressor Spring Isolation System515.4 Placing the Unit on a Floor Stand51Figure 36 Setting the unit on a floor stand516.0 Disassembling the Liebert DS for Transport526.1 Required Equipment526.2 Disassembly-Downflow Units526.2.1 Remove the Compressor Assembly546.2.2 Remove the Filter and Electric Box Assembly546.3 Reassembly-Downflow Units556.3.1 Reconnecting Piping, Charging and Replacing Panels556.4 Reassembly Checklist56Figure 37 Component dimensions-downflow, air-cooled, 28-42kW (8-12 ton), semi-hermetic compressor models57Table 27 Component weights-downflow, air-cooled, 28-42kW (8-12 ton), semi-hermetic57Figure 38 Component dimensions-downflow, air-cooled, 28-42kW (8-12 ton), scroll/digital scroll compressor models58Table 28 Component weights-downflow, air-cooled, 28-42kW (8-12 ton), scroll/digital scroll58Figure 39 Component dimensions-downflow, water/glycol/GLYCOOL, 28-42kW (8-12 ton), all compressor models59Table 29 Component weights-downflow, water/glycol/GLYCOOL, 28-42kW (8-12 ton), all59Figure 40 Component dimensions-downflow, air-cooled, 53-77kW (15-22 ton), semi-hermetic compressor models60Table 30 Component weights-downflow, air-cooled, 53-77kW (15-22 ton), semi-hermetic60Figure 41 Component dimensions-downflow air-cooled, 53-77kW (15-22 ton), scroll/digital scroll compressor models61Table 31 Component weights-downflow, air-cooled, 53-77kW (15-22 ton), scroll/digital scroll61Figure 42 Component dimensions-downflow water/glycol, GLYCOOL, 53-77kW (15-22 ton), all compressor models62Table 32 Component weights-downflow water/glycol, GLYCOOL, 53-77kW (15-22 ton), all62Figure 43 Component dimensions-downflow, air-cooled, 105kW (30 ton), semi-hermetic compressor models63Table 33 Component weights-downflow, air-cooled, 105kW (30 ton), semi-hermetic compressors63Figure 44 Component dimensions-downflow, air-cooled, 105kW (30 ton), scroll compressor models64Table 34 Component weights-downflow, air-cooled, 105kW (30 ton), scroll compressor models64Figure 45 Component dimensions-downflow, water/glycol/GLYCOOL, 105kW (30 ton), all compressor models65Table 35 Component weights-downflow, water/glycol/GLYCOOL, 105kW (30 ton), all compressor models656.5 Disassembly-Upflow Units666.5.1 Remove Compressor Assembly676.5.2 Remove Blower and Electric Box Assembly676.6 Reassembly-Upflow Unit686.7 Reassembly Checklist68Figure 46 Component dimensions-upflow, air-cooled, 28-42kW (8-12 ton), semi-hermetic compressor models69Table 36 Component weights-upflow, air-cooled, 28-42kW (8-12 ton), semi-hermetic compressor models69Figure 47 Component dimensions-upflow, air-cooled, 28-42kW (8-12 ton), scroll/digital scroll compressor models70Table 37 Component weights-upflow, air-cooled, 28-42kW (8-12 ton), scroll/digital scroll compressor models70Figure 48 Component dimensions-upflow, water/glycol/GLYCOOL, 28-42kW (8-12 ton), all compressor models71Table 38 Component weights-upflow, water/glycol/GLYCOOL, 28-42kW (8-12 ton), all compressor models71Figure 49 Component dimensions-upflow, air-cooled, 53-77kw (15-22 ton), semi-hermetic compressor models72Table 39 Component weights-upflow air-cooled 53-77kw (15-22 ton), semi-hermetic compressor models72Figure 50 Component dimensions-upflow, air-cooled, 53-77kw (15-22 ton), scroll/digital scroll compressor models73Table 40 Component weights-upflow, air-cooled, 53-77kw (15-22 ton), scroll /digital scroll compressor models73Figure 51 Component dimensions-upflow water/glycol/GLYCOOL 53-77kw (15-22 ton), all compressor models74Table 41 Component weights-upflow water/glycol/GLYCOOL, 53-77kW (15-22 ton) all compressor models74Figure 52 Component dimensions-upflow, air-cooled, 105kW (30 ton), semi-hermetic compressor models75Table 42 Component weights-upflow, air-cooled, 105kW (30 ton), semi-hermetic compressor models75Figure 53 Component dimensions-upflow, air-cooled, 105kW (30 ton), scroll/digital scroll compressor models76Table 43 Component weights-upflow, air-cooled, 105kW (30 ton), scroll/digital scroll compressor models76Figure 54 Component dimensions-upflow, water/glycol/GLYCOOL, 105kW (30 ton), all compressor models77Table 44 Component weights-upflow, water/glycol/GLYCOOL, 105kW (30 ton), all compressor models777.0 Electrical Connections78Figure 55 Electrical field connections797.1 Electrical Field Connection Descriptions80Standard Electrical Connections80Optional Electrical Connections80Optional Low Voltage Terminal Package Connections818.0 Piping828.1 Fluid Connections828.1.1 Condensate Piping-Field-Installed82Gravity Drain82Figure 56 Gravity drain for downflow and upflow units83Condensate Pump838.1.2 Humidifier Supply Water-Optional Infrared848.1.3 Requirements of Systems Using Water or Glycol84General Guidelines84Leak Checking of Unit and Field Piping858.2 Refrigeration Piping858.2.1 Piping Guidelines-Air-Cooled Units86Table 45 Recommended refrigerant line sizes - OD copper (inches)*86Table 46 Indoor unit approximate refrigerant charge for R-22 or R-407C86Table 47 Line charges - refrigerant per 100 ft (30m) of Type “L” copper tube87Table 48 Outdoor condenser approximate refrigerant charge lb (kg) per circuit878.3 Dehydration/Leak Test and Charging Procedures for R-407C and R-22888.3.1 Air-Cooled Condenser with Fan Speed Head Pressure Control System88Fan Speed Control Piping88Fan Speed Control Materials Supplied88Fan Speed Control Leak Check and Evacuation Procedure88Fan Speed Charging89Table 49 Fan speed suction pressure transducer settings898.3.2 Air-Cooled Condenser with Lee-Temp “Flooded Condenser” Head Pressure Control System90Lee-Temp Piping90Lee-Temp Controlled Materials Supplied90Lee-Temp Leak Check and Evacuation Procedure90Lee-Temp Charging91Table 50 Lee-Temp suction pressure transducer settings91Lee-Temp Receiver Refrigerant Level919.0 Piping Schematics92Figure 57 Piping schematic-air-cooled, semi-hermetic compressor models92Figure 58 Piping schematic-air-cooled, scroll compressor models93Figure 59 Piping schematic-water/glycol, semi-hermetic compressor models94Figure 60 Piping schematic-water/glycol with scroll compressor models95Figure 61 Piping schematic-GLYCOOL semi-hermetic compressor models96Figure 62 Piping schematic-GLYCOOL with scroll compressor models97Figure 63 Piping schematic-water/glycol with digital scroll compressor models98Figure 64 GLYCOOL with digital scroll compressor models99Figure 65 Optional piping schematic for Econ-O-Coil100Figure 66 Primary connection locations-downflow, air-cooled, 28-42kW (8-12 ton), semi-hermetic compressor models101Figure 67 Primary connection locations-downflow, air-Cooled, 28-42kW (8-12 ton) with scroll compressor models102Figure 68 Primary connection locations-downflow water/glycol/GLYCOOL 28-42kW (8-12 ton), all compressor models103Figure 69 Primary connection locations-downflow, air-Cooled, 53-77kW (15-22 ton), semi-hermetic compressor models104Figure 70 Primary connection locations-downflow, air-Cooled, 53-77kW (15-22 ton) with scroll compressor models105Figure 71 Primary connection locations-downflow, water/glycol/GLYCOO,L 53-77kW (15-22 ton), all compressor models106Figure 72 Primary connection locations-downflow, air-cooled, 105kW (30 ton), all compressor models107Figure 73 Primary connection locations-downflow, air-cooled, 105kW (30 ton), all compressor models108Figure 74 Primary connection locations-upflow, air-cooled, 28-42kw (8-12 ton), semi-hermetic compressor models109Figure 75 Primary connection locations-upflow, air-Cooled, 28-42kW (8-12 ton), semi-hermetic compressor models110Figure 76 Primary connection locations-upflow, water/glycol/GLYCOOL, 28-42kW (8-12 ton), all compressor models111Figure 77 Primary connection locations-upflow, air-cooled, 53-77kW (15-22 ton), semi-hermetic compressor models112Figure 78 Primary connection locations-upflow, air-cooled, 53-77kW (15-22 ton), scroll compressor models113Figure 79 Primary connection locations-upflow, water/glycol/GLYCOOL, 53-77kW (15-22 ton), all compressor models114Figure 80 Primary connection locations-upflow, air-cooled, 105kW (30 ton), all115Table 51 Piping data-upflow, air-cooled 105kW (30 ton), all115Figure 81 Primary connection locations-upflow, water/glycol/GLYCOOL, 105kW (30 ton), all116Table 52 Piping data-upflow, upflow, water/glycol/GLYCOOL, 105kW (30 ton), all11610.0 Checklist for Completed Installation11710.1 Moving and Placing Equipment11710.2 Electrical11710.3 Piping11710.4 Other11711.0 Initial Startup Checks and Commissioning Procedure for Warranty Inspection11811.1 Information for Warranty Inspection-Remove Power From Unit Disconnect11911.2 Startup Checks Inspection With Panels Removed and Disconnect Off11911.3 Commissioning Procedure With Panels On120Return Completed Startup Form to Your Local Emerson Sales Office12012.0 Maintenance12112.1 Filters121Table 53 Filter quantities, downflow units121Table 54 Filter quantities, upflow units12112.1.1 Filter Replacement Procedure-Downflow Units12212.1.2 Filter Replacement Procedure-Upflow Units122Figure 82 Proper filter pleat direction12212.2 Blower Drive System12212.2.1 Upflow Motor Access123Figure 83 Upflow motor access12312.2.2 Belt Removal12312.2.3 Belt Installation and Tensioning123Figure 84 Auto-belt tensioning motor base124Blower Bearing Maintenance124Blower Bearing Inspection124Blower Bearing Replacement124Blower Motor124Blower Motor Lubrication124Blower Wheel12412.3 Humidifier12512.3.1 Infrared Humidifier12512.3.2 Cleaning Humidifier Pan and Float Switch125Figure 85 Correct orientation of float switch12512.3.3 Changing Humidifier Lamps12612.4 Condensate Drain and Condensate Pump Systems12612.4.1 Condensate Drain12612.4.2 Condensate Pump12612.5 Air-Cooled Condenser and Drycoolers12712.6 Reheat-Electric Reheat (Three-Stage and SCR)12712.7 Compressor12712.7.1 Compressor Oil127Table 55 Compressor oil types12712.7.2 Semi-Hermetic Compressors12712.7.3 Scroll and Digital Scroll Compressors12712.8 Compressor Replacement12812.8.1 Compressor Motor Burnout12812.8.2 Digital Compressor Unloading Solenoid(s)128Models 028, 035 and 042128Models 053, 070 and 07712812.8.3 Compressor Replacement Procedure12812.9 Facility Fluid and Piping Maintenance12812.10 Paradenser-Water-Cooled Condenser12912.10.1 Cleaning Instructions12912.11 Water/Glycol Control Valves12912.11.1 Regulating Valves - Semi Hermetic and Standard Scroll Compressors129Adjustment-Johnson Controls/Penn Johnson Valves129Table 56 Recommended refrigerant pressures129Testing Function of Valve130Location13012.11.2 Motor Ball Valve-Digital Scroll Compressors130Control130Control Method130Adjustment130Startup130Location130Manual Control13012.11.3 Drycooler Settings131Table 57 Water/glycol system conditions requiring optional settings for aquastats131Table 58 Aquastat settings-two-fan through four-fan drycoolers131Table 59 Aquastat settings-six-fan drycoolers131Table 60 Aquastat settings-eight-fan drycoolers13113.0 HVAC Maintenance Checklist132Filters132Blower Section132Reheat132Steam Generating Humidifier132Infrared Humidifier132Condensate Pump133Refrigeration Piping133Water-Cooled Condensers133Compressor Section133Electrical Panel133Controls133Air-Cooled Condenser / Drycooler134Glycol Pump134Size: 5.33 MBPages: 136Language: EnglishOpen manual