Liebert Air-Cooled, Direct-Drive Drycooler

Transcription

1 Liebert ir-cooled, Direct-Drive Drycooler 50 Hz & 60 Hz User Manual

2 Technical Support Site If you encounter any installation or operational issues with your product, check the pertinent section of this manual to see if the issue can be resolved by following outlined procedures. For additional assistance, visit

3 TBLE OF CONTENTS Important Safety Instructions 1 1 Introduction Product Description and Features Drycooler Control Options Fan Speed DSF, DDF Fan Cycling Control (D)DNT, DSO, DDO Main Fan Control (D)DNL No Controls - (D)DNC Pump Controls Typical System Configurations 7 2 Site Preparation Site Considerations Dimensions and Weights Pump Packages and Expansion Tank 25 3 Installation Equipment Inspection Packing Material Handling Unit on the Skid Unit Storage Unpacking the Drycooler ll Sizes Preparing 1- to 4-fan Drycooler for Moving and Installation Preparing 6- and 8-fan Drycoolers for Moving and Installation Mounting the Drycooler 39 4 Piping Piping Guidelines Expansion Tanks, Fluid Relief Valves, ir Management and Other Devices Filling Instructions Preparing the System for Filling Glycol Solutions Filling the System 47 5 Electrical Data Electrical Supply Preparation Line Voltage Wiring Low Voltage Control Wiring 58 6 Checklist for Completed Installation Moving and Placing Equipment Electrical Piping Other 67 7 Operation 69 Vertiv Liebert Drycooler User Manual 3

4 7.1 Startup Checklist Startup Drycooler quastat Setpoints 69 8 Troubleshooting 73 9 System Maintenance General Procedures Drycooler Coil Cleaning Preventive Maintenance Checklist 77 Vertiv Liebert Drycooler User Manual 4

5 IMPORTNT SFETY INSTRUCTIONS Save These Instructions This manual contains important safety instructions that should be followed during the installation and maintenance of the Liebert Drycooler. Read this manual thoroughly before attempting to install or operate this unit. Only qualified personnel should move, install or service this equipment. dhere to all warnings, cautions and installation, operating and safety instructions on the unit and in this manual. Follow all operating and user instructions. WRNING! rc flash and electric shock hazard. Open all electric power supplies, verify with a voltmeter that power is Off and wear personal protective equipment per NFP 70E before working within the electric control enclosure. Failure to comply can cause serious injury or death. Customer must provide earth ground to unit, per NEC, CEC and local codes, as applicable. Customer must provide earth ground to unit, per NEC, CEC and local codes, as applicable. Before proceeding with installation, read all instructions, verify that all the parts are included and check the nameplate to be sure the voltage matches available utility power. The line side of the disconnect switch on the front of the unit contains live high-voltage. The only way to ensure that there is NO voltage inside the unit is to install and open a remote disconnect switch. Refer to unit electrical schematic. Follow all local codes. WRNING! Risk of contact with high-speed, moving parts. Can cause serious injury or death. Disconnect all local and remote electric power supplies before working in the unit. Do not operate this unit with any or all cabinet panels and/or blower guards removed. CUTION: Risk of contact with hot surfaces. Can cause injury. Blower motors and other components may become extremely hot during normal operation. Wear thermally-insulated gloves and appropriate protective clothing and allow time for components to cool when working within the cabinet or electric control enclosure. Vertiv Liebert Drycooler User Manual 1

6 CUTION: Risk of contact with sharp edges, splinters and exposed fasteners. Can cause personal injury. Only properly trained and qualified personnel wearing appropriate safety headgear, gloves, shoes and glasses should attempt to move, lift, remove packaging from or prepare unit for installation. NOTICE NOTICE NOTICE NOTICE Risk of clogged or leaking coolant fluid lines. Can cause equipment and building damage. Improper installation, application and service practices can result in coolant fluid leakage from the unit that can result in severe property damage. Vertiv recommends installing leak-detection equipment for unit and supply lines. Risk of a leaking coil due to freezing and/or corrosion. Can cause equipment and building damage. Cooling coils and piping systems that are connected to open cooling towers or other open water/glycol systems are at high risk for freezing and premature corrosion. Fluids in these systems must contain the proper antifreeze and inhibitors to prevent freezing and premature coil corrosion. The water or water/glycol solution must be analyzed by a competent watertreatment specialist before start-up to establish the inhibitor requirement. The water or water/glycol solution must be analysed every 6 months to determine the pattern of inhibitor depletion. The complexity of water-caused problems and their correction makes it important to obtain the advice a a water-treatment specialist and follow a regularly-scheduled maintenance program. Risk of excessive coolant fluid pressure, improper piping material, and unsupported piping. Can cause piping rupture, coolant fluid leaks and building and/or equipment damage. To avoid the possibility of burst pipes, the system installer must supply and install a relief valve in the system. Galvanized pipe must not be used in glycol systems. To help prevent piping failures, supply and return lines must be supported such that their weight does not bear on the piping of the unit or pumps. Risk of frozen coolant fluid. Can cause piping rupture, coolant fluid leaks and building damage. Immediately following the use of water for leak testing or system cleaning, charge the tested system with the proper percentage of glycol and water for your coldest design ambient. Complete system drain-down cannot be ensured and damage to the system could result from freezing of residual water. Vertiv Liebert Drycooler User Manual 2

7 NOTICE Risk damage from forklift. Can cause unit damage. Keep the forklift tines level and at a height that will fit under the skid and/or unit to prevent exterior and/or underside damage. NOTICE Risk of improper storage. Can cause unit damage. Keep unit protected from freezing temperatures and contact damage. Vertiv Liebert Drycooler User Manual 3

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9 1 INTRODUCTION 1.1 Product Description and Features The Liebert drycooler is a low-profile, direct-drive propeller fan-type air-cooled unit. Constructed with an aluminum cabinet and a copper-tube aluminum fin coil, the unit is quiet and corrosion resistant. ll electrical connections and controls are enclosed in an integral NEM 3R rated electrical panel section of the drycooler. Figure 1.1 Liebert three-fan drycooler Vertiv Liebert Drycooler User Manual 5

10 Figure 1.2 Product model nomenclature 1.2 Drycooler Control Options Fan Speed DSF, DDF vailable only on single-fan standard drycoolers with integral pump controls. Fan speed control provides an infinite number of speed variations on specially designed, single-phase, permanent split capacitor motor, by monitoring leaving fluid temperature. Fan speed control provides air delivery in direct proportion to heat rejection requirements of the system. The control is adjustable to maintain the temperature of the fluid leaving the drycooler. Either of two temperature ranges can be field-selected: 30 to 60 F (-1 to 16 C) for GLYCOOL applications or 70 to 100 F (21 to 38 C) for glycol applications Fan Cycling Control (D)DNT, DSO, DDO vailable on all sizes of standard sound and Quiet-Line drycoolers. thermostatic control cycles the fan on a single-fan drycooler in response to leaving fluid temperatures. Two or more thermostats are employed on drycoolers with two or more fans to cycle fans or groups of fans in response to leaving fluid temperatures. The thermostat setpoints are listed on the factory-supplied schematic. They typically range from 35 to 45 F (2 to 7 C) for GLYCOOL applications and 65 to 75 F (18 to 24 C) for glycol applications Main Fan Control (D)DNL vailable on all sizes of standard-sound and Quiet-Line drycoolers without pump controls. ll fans run when an external contact closure completes internal 24VC circuit No Controls - (D)DNC vailable on all sizes of standard-sound and Quiet-Line drycoolers without pump controls. ll fans are activated at full speed when power is applied to the drycooler. Vertiv Liebert Drycooler User Manual 6

11 1.2.5 Pump Controls vailable on all Fan Speed and Fan Cycling Control drycoolers. Controls for pump(s) up to 7.5hp are built into the same integral electric panel as the drycooler fan controls. Pump fuses, overload heaters and flow switch (dual pump control models) are included with the Liebert pump packages or must be fieldsupplied for field-supplied pumps. Dual pump option Provides controls for primary and standby pump. The flow switch senses loss of flow and switches to the standby pump for continuous system operation in the event of a pump failure. n internal switch allows manual selection of the lead/lag pump. 1.3 Typical System Configurations The standard glycol-cooled precision air conditioning system includes these major components: indoor air conditioning unit with heat exchangers (refrigerant/glycol) glycol regulating valve outdoor air-cooled drycooler glycol pump(s) expansion/compression tank pump controls interconnection piping unit interlock control wiring Figure 1.3 on the next page and Figure 1.6 on page 11 show a single unit to drycooler loop arrangement. Figure 1.11 on page 16 shows a typical configuration of multiple indoor units and multiple outdoor drycoolers using a dual pump package and on a common piping loop. dditional field-supplied components, such as valves, expansion tank, strainers and flow or pressure switches are also shown in Figure 1.3 on the next page, Figure 1.6 on page 11 and Figure 1.11 on page 16. These components are necessary and should be included when designing a system with one indoor and one outdoor unit on a piping loop or a system using multiple indoor and outdoor units on a common piping loop. Larger systems may also benefit from an air separator (not shown). See Installation on page 29 for further details on required components. Vertiv Liebert Drycooler User Manual 7

12 Figure 1.3 Piping diagram, Liebert DS glycol semi-hermetic compressor models Vertiv Liebert Drycooler User Manual 8

13 Figure 1.4 Piping diagram, Liebert DS with water/glycol with scroll compressor models Vertiv Liebert Drycooler User Manual 9

14 Figure 1.5 Piping diagram, Liebert DS with water/glycol with digital scroll compressor models Vertiv Liebert Drycooler User Manual 10

15 Figure 1.6 Piping diagram, Liebert DS with GLYCOOL with digital scroll compressors Vertiv Liebert Drycooler User Manual 11

16 Figure 1.7 Piping diagram, Liebert DS with GLYCOOL with semi-hermetic compressor models Vertiv Liebert Drycooler User Manual 12

17 Figure 1.8 Piping diagram, Liebert DS with GLYCOL with scroll compressor models Vertiv Liebert Drycooler User Manual 13

18 Figure 1.9 Piping diagram, Liebert PDX with water/glycol Vertiv Liebert Drycooler User Manual 14

19 Figure 1.10 Piping diagram, Liebert PDX with GLYCOOL Vertiv Liebert Drycooler User Manual 15

20 Figure 1.11 Typical piping arrangement, multiple drycoolers and multiple indoor units Vertiv Liebert Drycooler User Manual 16

21 2 SITE PREPRTION 2.1 Site Considerations The drycoolers and pumps should be installed in a location offering maximum security and access for maintenance. void ground level sites with public access and areas that contribute to heavy snow or ice accumulations. Utilize Piggyback drycoolers whenever interior building locations must be used. To ensure adequate air supply, Vertiv recommends that the drycoolers be located in an area with clean air, away from loose dirt and foreign matter that may clog the coil. In addition, drycoolers should not be located near steam, hot air or fume exhausts. Drycoolers must not be installed in a pit, where discharge air is likely to be recirculated through the drycooler or installed where objects restrict the air inlet free area. lso, the drycoolers should be located no closer than 3 feet (1m) from a wall, obstruction or adjacent unit (see Figure 2.1 on page 21, Figure 2.2 on page 22 or Figure 2.3 on page 23). The drycooler must be installed on a level surface to ensure proper glycol flow, venting and drainage. For roof installation, mount the drycooler on suitable curbs or other supports in accordance with local codes. llow adequate space for pump packages, expansion/compression tanks, piping and additional field supplied devices. When mounting pump packages, mount on level surface or suitable curbs that will allow cooling ventilation air to enter from underneath the pump package frame and exit through the louvers. The drycooler must be installed in a vertical air-flow orientation to maintain NEM 3R rating of electrical box. The unit is CS c-us Certified for vertical air flow only and has not been tested for any other orientation. Vertiv Liebert Drycooler User Manual 17

22 2.2 Dimensions and Weights Table 2.1 Standard Drycooler net weights, shipping weights, dimensions and volume, approximate Domestic Packed Export Packed Model No. of Fans Dry Weight lb (kg) Weight Dimension (LxWxH) Volume Weight Dimension (LxWxH) Volume lb. (kg) in. (cm) ft 3 (m 3 ) lb. (kg.) in. (cm) ft 3 (m 3 ) *D** (161) 510 (231) 617 (280) *D** (170) 530 (240) 637 (289) *D** (179) 550 (249) 62x36x63 (157x91x160) 81 (2.3) 657 (298) 63x37x64 (160x94x163) 86 (2.5) *D** (188) 570 (259) 677 (307) *D** (197) 590 (268) 697 (316) *D** (227) 757 (343) 914 (415) *D**174 *D** (245) 580 (263) 797 (362) 837 (380) 102x36x63 (259x91x160) 134 (3.8) 954 (433) 994 (451) 103x37x64 (262x94x163) 141 (4.0) *D** (281) 877 (398) 1034 (469) *D** (333) 1104 (501) 1282 (582) *D** (361) 1164 (528) 142x36x63 (361x91x160) 186 (5.3) 1342 (609) 143x37x64 (363x94x163) 196 (5.6) *D** (388) 1224 (555) 1402 (636) Vertiv Liebert Drycooler User Manual 18

23 Table 2.1 Standard Drycooler net weights, shipping weights, dimensions and volume, approximate (continued) Domestic Packed Export Packed Model No. of Fans Dry Weight lb (kg) Weight Dimension (LxWxH) Volume Weight Dimension (LxWxH) Volume lb. (kg) in. (cm) ft 3 (m 3 ) lb. (kg.) in. (cm) ft 3 (m 3 ) *D** (426) 1401 (635) 1658 (752) *D**419 *D** (463) 1050 (476) 1481 (672) 1511 (685) 182x36x63 (462x91x160) 239 (6.7) 1738 (788) 1768 (802) 183x37x64 (465x94x163) 251 (7.0) *D** (499) 1561 (708) 1818 (825) *D** (808) 2223 (1008) 2948 (1337) *D** (831) 2273 (1031) 142x36x94 (361x91x239) 278 (7.9) 2998 (1360) 143x37x95 (363x94x241) 291 (8.2) *D** (854) 2323 (1054) 3048 (1383) *D** (1022) 2815 (1277) 3769 (1710) *D** (1058) 2895 (1313) 182x36x94 (462x91x239) 356 (10.0) 3849 (1746) 183x37x95 (465x94x241) 372 (10.5) *D** (1103) 2995 (1359) 3949 (1791) Vertiv Liebert Drycooler User Manual 19

24 Table 2.2 Liebert Quiet-Line Drycooler net weights, shipping weights, dimensions and volume, approximate Domestic Packed Export Packed Model No. of Fans Dry Weight lb (kg) Weight Dimension (LxWxH) Volume Weight Dimension (LxWxH) Volume lb. (kg) in. (cm) ft 3 (m 3 ) lb. (kg.) in. (cm) ft 3 (m 3 ) *D** (170) 530 (240) 637 (289) *D** (179) 550 (249) 62x36x63 (157x91x160) 81 (2.3) 657 (298) 63x37x64 (160x94x163) 86 (2.5) *D** (188) 570 (259) 677 (307) *D** (227) 757 (343) 914 (415) *D** (245) 797 (362) 102x36x63 (259x91x160) 134 (3.8) 954 (433) 103x37x64 (262x94x163) 141 (4.0) *D** (263) 837 (380) 994 (451) *D** (333) 1104 (501) 1282 (582) *D** (361) 1164 (528) 142x36x63 (361x91x160) 186 (5.3) 1342 (609) 143x37x64 (363x94x163) 196 (5.6) *D** (388) 1224 (555) 1402 (636) *D**205 *D** (426) 1020 (463) 1401 (635) 1481 (672) 182x36x63 (462x91x160) 239 (6.7) 1658 (752) 1738 (788) 183x37x64 (465x94x163) 251 (7.0) *D**347 *D** (808) 1880 (854)) 2223 (1008) 2323 (1054) 142x36x94 (361x91x239) 278 (7.9) 2948 (1337) 3048 (1383) 143x37x95 (363x94x241) 291 (8.2) *D**453 *D** (1022) 2430 (1103) 2815 (1277) 2995 (1359) 182x36x94 (462x91x239) 356 (10.0) 3769 (1710) 3949 (1791) 183x37x95 (465x94x241) 372 (10.5) Vertiv Liebert Drycooler User Manual 20

25 Figure 2.1 Drycooler planning dimensional data 1- and 2-fan units Vertiv Liebert Drycooler User Manual 21

26 Figure 2.2 Drycooler planning dimensional data 3- and 4-fan units Vertiv Liebert Drycooler User Manual 22

27 Figure 2.3 Drycooler planning dimensional data 6- and 8-fan units Vertiv Liebert Drycooler User Manual 23

28 Figure 2.4 Typical drycooler footprint dimensions Vertiv Liebert Drycooler User Manual 24

29 2.3 Pump Packages and Expansion Tank Table 2.3 Pump piping and electrical data Connections Electrical Data HP Pump Suct. Conn., in. Pump Disc. Conn., in. Hz FL PH 208 Volts 230 Volts 460 Volts 575 Volts 3/ / /4 3/4 1-1/ / / / Volts 220 Volts 380/415 Volts / /2 1-1/4 3/ / / / / / / 7.47 Vertiv Liebert Drycooler User Manual 25

30 Figure 2.5 Single-pump package and mounting Mounting-hole Dimensional Data, in. (mm) Pump package B C Single ( HP) 15-1/4 (387) 2-1/2 (64) 22-1/2 (572) Vertiv Liebert Drycooler User Manual 26

31 Figure 2.6 Dual-pump package and mounting Mounting-hole Dimensional Data, in. (mm) Pump package B C Dual ( HP) 30-1/4 (768) 2-1/2 (64) 22-1/2 (572) Dual (7.5 HP) 39-5/16 (999) 1-3/4 (45) 26-7/8 (683) Vertiv Liebert Drycooler User Manual 27

32 Expansion Tank This tank, included in a standard pump package, has an internal volume of 8.8 gal. (33 l) and a maximum pressure of 100 psi (690 kpa). This tank is sized for a typical open system with a fluid volume of less than 75 gal. (280l). When used in a closed system, volumes of up to 140 gal. (530 l) can be accommodated. The use of a safety relief valve, field supplied, is recommended for systems closed to atmospheric venting. Other piping accessories for filling, venting, or adjusting the fluid in the system, are recommended, but not included. Figure 2.7 Expansion tank Vertiv Liebert Drycooler User Manual 28

33 3 INSTLLTION Safety Information WRNING! rc flash and electric shock hazard. Open all electric power supplies, verify with a voltmeter that power is Off and wear personal protective equipment per NFP 70E before working within the electric control enclosure. Failure to comply can cause serious injury or death. Customer must provide earth ground to unit, per NEC, CEC and local codes, as applicable. Before proceeding with installation, read all instructions, verify that all the parts are included and check the nameplate to be sure the voltage matches available utility power. The line side of the disconnect switch on the front of the unit contains live high-voltage. The only way to ensure that there is NO voltage inside the unit is to install and open a remote disconnect switch. Refer to unit electrical schematic. Follow all local codes. WRNING! Risk of improper handling. Can cause equipment damage, injury or death. Read all of the following instructions before attempting to move, lift, remove packaging from or preparing unit for installation. WRNING! Risk of heavy unit falling or tipping over. Can cause property damage, serious injury or death. Confirm that all components of the lifting system are rated for the weight of the drycooler by an OSH Certified rating organization before attempting to lift and/or move the drycooler. See Table 2.1 on page 18 and Table 2.2 on page 20 for the drycooler weights. WRNING! Risk of contact with sharp edges, splinters and exposed fasteners. Can cause personal injury. Only properly trained and qualified personnel wearing appropriate safety headgear, gloves, shoes and glasses should attempt to move, lift, remove packaging from or prepare unit for installation. NOTICE Risk of improper forklift handling. Can cause unit damage. Keep the forklift tines level and at a height that will fit under the skid. Vertiv Liebert Drycooler User Manual 29

34 NOTICE Risk of improper storage. Can cause unit damage. Keep unit protected from freezing temperatures and contact damage. 3.1 Equipment Inspection Before unpacking the unit, verify that the labeled equipment matches the bill of lading. Carefully inspect all items for damage, either visible or concealed. Report any damage immediately to the carrier and your local Vertiv representative. File a damage claim with the carrier and send a copy to your local Vertiv representative. 3.2 Packing Material ll material used to package this unit is recyclable. Please save it for future use or dispose of the material appropriately. Figure 3.1 Equipment recommended for handling a Liebert drycooler WRNING! Risk of heavy unit falling or tipping over. Can cause property damage, serious injury or death. Confirm that all components of the lifting system are rated for the weight of the drycooler by an OSH Certified rating organization before attempting to lift and/or move the drycooler. See 2.2 on page 18 and Table 2.2 on page 20 for the drycooler weights. 3.3 Handling Unit on the Skid Transport unit using a fork lift or a crane with sling and spreader bars. Using a forklift NOTICE Risk of improper forklift handling. Can cause unit damage. Keep the forklift tines level and at a height that will fit under the skid. Make sure the forks (if adjustable) are spread to the widest allowable distance to still fit under the skid. Type of forklift used will depend on the terrain the unit is to be moved across during handling. Minimum forklift fork length: Vertiv Liebert Drycooler User Manual 30

35 for 1-fan and 2-fan units 48 in. (1219 mm) for 3-fan and 4-fan units 72 in. (1829 mm) for 6-fan units 72 in. (1829 mm) for 8-fan units 96 in. (2438 mm) When moving the packaged unit, do not lift it any higher than 6 in. (152 mm). If the unit must be lifted higher than 6 in. (152 mm), great care must be exercised and no one may be closer than 20 ft (5 m) to the lift point. Using a forklift to move the unit, lift fron one end only, and do not raise the end more than 6 in. (152 mm), Figure 3.2 below Figure 3.2 Forklift position with 1- to 8-fan drycoolers Using a Crane Verify that the crane and slings rated for the unit weight. Spreader bars must be used for sling stability and to keep the slings from pressing against the unit. Make sure spreader bars are wider than the unit. Place the slings near the ends and in the middle of the unit, under the top deck boards of the skid. 3.4 Unit Storage Store the drycooler in the original packaging in an area protected from excessive dirt, debris and contact damage until final installation 3.5 Unpacking the Drycooler ll Sizes CUTION: Risk of contact with sharp edges, splinters and exposed fasteners. Can cause personal injury. Only properly trained and qualified personnel wearing appropriate safety headgear, gloves, shoes and glasses should attempt to move, lift, remove packaging from or prepare unit for installation. Refer to Figure 3.3 on the next page for the following steps: 1. For domestic packaging: Remove the fastener climps from the top and sides of the unit. Remove all screws and wasther from the wooden fencing. Vertiv Liebert Drycooler User Manual 31

36 Remove the fence or For export packaging, remove the crate. 2. Carefully remove the steel straps securing the unit to the skid. WRNING! Risk of unsecured strap ends with sharp edges flying uncontrollably in any direction when cut. Can cause serious injury. Secure both ends of each strap when cutting and wear OSH approved protective headgear, gloves and eye protection when working with the securing straps. 3. Set the legs aside, but keep accessible. Depending on the number of fans, more or less steel straps may be removed at this step. Figure 3.3 Removing protective material Vertiv Liebert Drycooler User Manual 32

37 3.6 Preparing 1- to 4-fan Drycooler for Moving and Installation The following procedure is one recommended method for removing a unit from the shipping skid. Other methods may be used, provided that they are safe for personnel, the unit and equipment. 1. ttach legs to the unit at indicated locations, using the fasteners provided with the legs, Figure 3.4 below. Recommended tools for attachment is a 5/8 socket and ratchet. More legs may be available for installation than are shown. This will depend on the unit type and number of fans. Figure 3.4 ttaching legs to 1- to 4-fan drycoolers NOTICE 2. Place slings around the unit between the unit and the top deck boards of the skid as shown in Figure 3.5 on the next page: 1-fan, 2-fan and 3-fan units: against the inside of the attached legs. 4-fan units: against the outside of the attached eye bolts. 3. Use spreader bars, a lift beam and a crane to lift the unit off the skid. Make sure spreader bars are wider than the unit to prevent crushing force. Risk of improper lifting. Can cause equipment damage. Make sure that the spreader bars wider are than the unit. If the spreader bars are too short, the slings may crush the unit. Vertiv Liebert Drycooler User Manual 33

38 Figure 3.5 Securing slings to 1- to 4-fan drycoolers for lifting off skid 4. Lift the unit 24" (610mm) off the top deck of the skid. 5. Remove the skid from under the unit. 6. To rotate the unit, a mechanized method is recommended, but if one is not available, use a minimum of four properly-protected individuals to rotate the elevated unit 90 degrees so the unit legs are pointing toward the ground, Figure 3.6 below. 7. Set the upright unit on the ground so the legs support unit weight. 8. Remove the straps from around unit. Figure 3.6 Rotate and set drycooler on ground or level surface NOTICE 9. Refer to Figure 3.7 on the facing page to attach rigging for lifting. Spreader bars are still required. Make sure that the spreader bars are wider than the unit. 1-fan, 2-fan and 3-fan units: Route the straps through the large holes in the side of the legs. 4-fan units: Secure straps or chains to the eye bolts on top of the unit. Risk of improper lifting. Can cause equipment damage. Vertiv Liebert Drycooler User Manual 34

39 Make sure that the spreader bars wider are than the unit. If the spreader bars are too short, the slings may crush the unit. The unit is ready to be lifted and moved to its installation location. Figure 3.7 Rigging to lift 1- to 4-fan drycoolers 3.7 Preparing 6- and 8-fan Drycoolers for Moving and Installation The following procedure is one recommended process for removing a unit from the shipping skid. Other methods may be used, provided that the methods are safe for personnel, the drycooler and equipment. 1. Refer to Figure 3.8 on the next page to attach the legs to the higher side of the unit: Use four (4) fasteners per leg. Fasteners are provided with the legs. Recommended tools for attachment is a 5/8 socket and ratchet. More legs may be required for installation than shown in Figure 3.8 on the next page. Refer to the anchor plan corresponding to your unit s number of fans in Figure 2.3 on page 23. Vertiv Liebert Drycooler User Manual 35

40 Figure 3.8 ttach legs to higher side of 6- or 8-fan drycooler 2. ttach slings or chains to the unit lift rails as shown in Figure 3.9 on the facing page. Mechanically lower the unit in order to rest on the attached legs. Make sure not to damage the opposite side of the unit. Vertiv Liebert Drycooler User Manual 36

41 Figure 3.9 Use sling to lower side with legs attached 3. Move the slings or chains to the lift rail side that is resting on the skid, Figure 3.10 on the next page. Mechanically lift the unit to a point where the side being lifted is just high enough to allow for safe attachment of the remaining unit legs. Move the skid out the way and attach remaining legs. Vertiv Liebert Drycooler User Manual 37

42 Figure 3.10 Move sling to side resting on skid and lift to remove skid/install legs NOTICE 4. Set the upright unit on the ground so that the legs support the unit s weight. 5. Reposition and add straps and spreader bars to prepare the unit for lifting to installation location, Figure 3.11 on the facing page. Use the support channels located under the unit to attach straps or chains. Spreader bars are still required. Make sure spreader bars are wider than the unit to keep the straps from pressing on the sides of the unit. Risk of improper lifting. Can cause equipment damage. Make sure that the spreader bars wider are than the unit. If the spreader bars are too short, the slings may crush the unit. The unit is ready to be lifted and moved to its installation location. Vertiv Liebert Drycooler User Manual 38

43 Figure 3.11 Rigging 6- and 8-fan drycooler for lifting 3.8 Mounting the Drycooler The drycooler must be installed so that it is level within 1/2 (13mm) to ensure proper glycol flow, venting and drainage. For roof installation, mount the drycooler on suitable curbs or other supports; follow all local and national codes. Secure the legs to the mounting surface using a field-supplied 1/2 (13mm) diameter bolt in each of the two 9/16 (14mm) holes in each leg. See Figure 2.1 on page 21Figure 2.2 on page 22 andfigure 2.3 on page 23 for anchor dimensions. Vertiv Liebert Drycooler User Manual 39

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45 4 PIPING CUTION: Risk of explosive discharge of high pressure gas and flying projectiles. Can cause building and/or piping damage and personal injury. Units are shipped from the factory with a pressurized dry nitrogen holding charge. Carefully relieve the pressure before cutting into the piping system. NOTICE Risk of excessive coolant fluid pressure, improper piping material, and unsupported piping. Can cause piping rupture, coolant fluid leaks and building and/or equipment damage. To avoid the possibility of burst pipes, the system installer must supply and install a relief valve in the system. Galvanized pipe must not be used in glycol systems. To help prevent piping failures, supply and return lines must be supported such that their weight does not bear on the piping of the unit or pumps. 4.1 Piping Guidelines Piping between the drycooler, the pump and the indoor unit is required to complete the system and is to be provided and installed by the system installer. Use prevailing good-piping practices. ll fluid piping must comply with local codes. Properly sized pipes will help reduce pumping power and operating costs. Pipe material choices are typically copper, plastic or steel/black iron. Consult glycol and pipe manufacturing literature for compatibility and sizing assistance. Galvanized piping should not be used. ny copper piping installed should be L or K refrigerant grade copper. See Figure 1.11 on page 16 for a typical piping diagram, depicting multiple indoor units, multiple drycoolers and dual pumps. Single indoor unit/pump/drycooler systems are also possible. Drycooler supply and return connections vary in size and number. Refer to Table 4.1 on page 44 and Table 4.2 on page 45. Drycoolers with 4 or more total connection pipes need all drycooler inlet pipes connected to the system supply main pipe and all outlet pipes connected to the system return main pipe. Vertiv recommends installing manual service shutoff valves at the supply and return connections of each drycooler and indoor cooling unit. The shutoff valves permit isolating equipment for routine maintenance and for repairs. Do not hang or suspend piping from the drycooler-tube sheets protruding below the finned sections of the coil. Pump packages with multiple pumps require a check valve at the discharge of each pump to prevent back-flow through the standby pump(s). To extend the service life of the drycooler and the system's pumps, install filters/strainers in the supply line to the pumps. These filters should have a mesh screen and be a type that can be easily replaced or cleaned. Installing hose bibs at the lowest point of the system will facilitate filling. Keep piping runs as straight as possible; avoid unnecessary bends and minimize additional fittings. Vertiv Liebert Drycooler User Manual 41

46 llow for pipe expansion from warm fluids. Piping should be isolated from the building with vibrationisolating supports. Use soft, flexible material to seal between pipes and wall openings to prevent pipe damage. Consideration of the minimum glycol temperature to be supplied from the drycooler and the pipe routing will determine if the glycol supply and return lines should be insulated. Insulation will prevent condensation on the glycol lines in low ambient conditions. Completed piping system should provide maximum leak-prevention. Welded or high-temperature soldered joints should be used where possible. Threaded pipe joints, if needed, can be made with tightly drawn Teflon tape. Clean and prepare all pipe connections before joining. Be careful not to allow solder/joining debris to get inside the lines during the connection process. 4.2 Expansion Tanks, Fluid Relief Valves, ir Management and Other Devices n expansion tank must be provided for expansion and contraction of the fluid due to temperature change in this closed system. Vents are required at system high points to vent trapped air when filling the system. fluid pressure relief valve is also a necessary piping component. ll systems must have an air management system to ensure proper component operation and system performance. There are several methods that can be used to manage the air within a closed loop hydronic system. Depending on the method chosen, the system may include one or more of the following ancillary components: tank-steel (expansion, compression, diaphragm or bladder), air separator and air vent. Consult your local engineer to determine which method will be used and where these components must be installed. Depending on the complexity of the system, various other devices may be specified refer to site-specific drawings. Some of the devices that may be required are: pressure gauges, flow switches, automatic air separator, tempering valves, standby pumps and sensors for electrical controls. NOTICE Risk of frozen coolant fluid. Can cause piping rupture, coolant fluid leaks and building damage. Immediately following the use of water for leak testing or system cleaning, charge the tested system with the proper percentage of glycol and water for your coldest design ambient. Complete system drain-down cannot be ensured and damage to the system could result from freezing of residual water. Vertiv Liebert Drycooler User Manual 42

47 Figure 4.1 Piping connection locations for 1-, 2-, 3- and 4-fan drycoolers Figure 4.2 Piping connection locations for 6- and 8-fan drycoolers Vertiv Liebert Drycooler User Manual 43

48 Table 4.1 Standard drycooler piping connection sizes and internal volume Model # No. of Internal Coil Circuits No. of Fans Internal Volume, gal. (L) No. of Inlets/Outlets Inlet & Outlet Connection Size ODS Copper, in. IDS Copper, in * 1.2 (4.6) 1/1 1-3/ , 8* 2.4 (9.2) 1/1 1-3/ , 12*, (13.9) 1/1 1-5/ /1 1-3/8 4.9 (18.6) 16* 1/1 2-1/8 8 1/1 1-3/8 5.8 (22.0) 16*, 26 1/1 2-1/ , 16* 4.8 (18.2) 1/1 2-1/ , 16*, (26.2) 1/1 2-1/ (34.0) 1/1 1-3/8 16*, (34.0) 1/1 2-1/ , 26* 11.1 (42.1) 1/1 2-1/ , 24* 10.0 (37.9) 1/1 2-1/ , 32* 13.1 (49.6) 1/1 2-1/8 3 16, 32* 1/1 2-1/ (73.3) 48 1/1 2-5/ , 24* 13.1 (49.6) 1/1 2-1/ , 32* 17.4 (65.9) 1/1 2-1/ /1 2-1/ (83.3) * 1/1 2-5/ , 32 1/1 2-1/ (99.6) 48* 1/1 2-5/ , 64* 27.0 (102.2) 2/2 2-1/ , 52* 2/2 2-1/ (124.9) /4 2-1/8 32, 64* 2/2 2-1/ (151.4) 96 4/4 2-1/ , 64* 35.0 (132.5) 2/2 2-1/ /2 2-1/ (166.5) 80* 8 4/4 2-1/8 32, 64 2/2 2-1/ (196.8) 96* 4/4 2-1/8 * = Standard Circuiting Vertiv Liebert Drycooler User Manual 44

49 Table 4.2 Liebert Quiet-Line drycooler piping connection sizes and internal volume Model # No. of Internal Coil Circuits No. of Fans Internal Volume gal. (L) No. of Inlets/Outlets Inlet & Outlet Connection Size ODS Copper, in. IDS Copper, in , 8* 2.4 (9.2) 1/1 1-3/ * 1/1 1-5/8 3.7 (13.9) /1 2-1/8 8 1/1 1-3/8 4.9 (18.6) 16* 1/1 2-1/ , 16* 4.8 (18.2) 1/1 2-1/ *, (26.2) 1/1 2-1/ *, (34.0) 1/1 2-1/ , 24* 10.0 (37.9) 1/1 2-1/ , 32* 13.1 (49.6) 1/1 2-1/8 3 16, 32* 1/1 2-1/ (73.3) 48 1/1 2-5/ , 24* 13.1 (49.6) 1/1 2-1/ , 32* 17.4 (65.9) 1/1 2-1/ , 64* 27.0 (102.2) 2/2 2-1/ , 64* 6 2/2 2-1/ (148.8) 96 4/4 2-1/ , 64* 35.0 (132.5) 2/2 2-1/ , /2 2-1/ (196.8) 96* 4/4 2-1/8 * = Standard circuiting 4.3 Filling Instructions Preparing the System for Filling It is important to remove any dirt, oil or metal filings that may contaminate the cooling system piping in order to prevent contamination of the fresh glycol solution and fouling of the drycooler piping. The system should be flushed thoroughly using a mild cleaning solution or high-quality water and then completely drained before charging with glycol. Cleaning new systems is just as important as cleaning old ones. New systems can be coated with oil or a protective film; dirt and scale are also common. ny residual contaminants could adversely affect the heat transfer stability and performance of your system. In many cases, in both old and new systems, special cleaners are needed to remove scale, rust and hydrocarbon foulants from pipes, manifolds and passages. Clean heat transfer surfaces are important in maintaining the integrity of the heating/cooling system. For more information on cleaners and degreasers, contact your sales representative. Follow the manufacturer s instructions when using these products. Vertiv Liebert Drycooler User Manual 45

50 Calculate the internal volume of the system as closely as possible. The drycooler volumes are shown in 4.2 on page 42 and Table 4.2 on the previous page. Use Table 4.4 on page 48 for field-installed piping volumes. Indoor unit volumes are found in their user manuals Glycol Solutions NOTE: Glycol solutions should be considered for the protection of the coil. When glycol solutions are not used, damage can occur either from freezing or from corrosion from water. When considering the use of any glycol products in a particular application, you should review the latest Material Safety Data Sheets and ensure that the use you intend can be accomplished safely. For Material Safety Data Sheets and other product safety information, contact the supplier nearest you. Before handling any other products mentioned in the text, you should obtain available product safety information and take necessary steps to ensure safety of use. NOTICE Risk of mishandled glycol products. Can cause environmental damage. When mishandled, glycol products pose a threat to the environment. Before using any glycol products, review the latest Material Safety Data Sheets and ensure that you can use the product safely. Glycol manufacturers request that the customer read, understand and comply with the information on the product packaging and in the current Material Safety Data Sheets. Make this information available to anyone responsible for operation, maintenance and repair of the drycooler and related equipment. No chemical should be used as or in a food, drug, medical device, or cosmetic, or in a product or process in which it may contact a food, drug, medical device, or cosmetic until the user has determined the suitability and legality of the use. Since government regulations and use conditions are subject to change, it is the user's responsibility to determine that this information is appropriate and suitable under current, applicable laws and regulations. NOTICE Risk of using the wrong type of glycol. Can cause piping damage, coolant fluid leaks, and substantial building damage. utomotive antifreeze is unacceptable and must NOT be used. Typical inhibited formula ethylene glycol and propylene glycol manufacturers and suppliers are Union Carbide (Ucartherm) and Dow Chemical (Dowtherm SR-1, Dowfrost). These glycols are supplied with corrosion inhibitors and do not contain a silicone anti-leak formula. Commercial ethylene glycol and propylene glycol, when pure, are generally less corrosive to the common metals of construction than water itself. queous solutions of these glycols, however, assume the corrosivity of the water from which they are prepared and may become increasingly corrosive with use when not properly inhibited. There are two basic types of additives: Corrosion inhibitors and Environmental stabilizers Vertiv Liebert Drycooler User Manual 46

51 The corrosion inhibitors function by forming a surface barrier that protects the metals from attack. Environmental stabilizers, while not corrosion inhibitors in the strictest sense of the word, decrease corrosion by stabilizing or favorably altering the overall environment. n alkaline buffer, such as borax, is a simple example of an environmental stabilizer, since its prime purpose is to maintain an alkaline condition (ph above 7). The percentage of glycol to water must be determined by using the lowest design outdoor temperature in which the system is operating. Table 4.3 below indicates the solution volume of inhibited glycol required to provide freeze protection at various ambient temperatures. Table 4.3 Glycol concentrations for freeze protection by ambient temperatures Coolant Type Propylene Glycol % by Volume Ethylene Glycol % by Volume Temperature, F ( C 20 (-7) 10 (-12) 0 (-18) -10 (-23) -20 (-29) -30 (-34) -40 (-40) -50 (-46) 18 * 29* * 26* Based on Dowfrost (PG) and Dowtherm SR-1 (EG) product literature. * Inhibitor levels should be adjusted to properly protect the system if solution concentrations are less than 30%. NOTICE Risk of corrosive dilution water. Can cause piping system damage, coolant fluid leaks and substantial building damage. The quality of water used for dilution must be considered because water may contain corrosive elements that reduce the effectiveness of the inhibited formulation. Surface water that is classified as soft (low in chloride and sulfate ion content less than 100 ppm each) should be used Filling the System Installation of hose bibs at the lowest point of the system is recommended. When filling a glycol system keep air to a minimum. ir in glycol turns to foam and is difficult and timeconsuming to remove. (nti-foam additives are available and may be considered.) Open all operating systems to the loop. With the top vent(s) open, fill the system from the bottom of the loop. This will allow the glycol to push the air out of the top of the system, minimizing trapped air. Fill to approximately 80% of calculated capacity. Fill slowly from this point, checking fluid levels until full. NOTE: For glycol solution preparation and periodic testing, follow manufacturer s recommendations. Do not mix products of different manufacturers. Vertiv Liebert Drycooler User Manual 47

52 Table 4.4 Volume in standard Type "L" copper piping Diameter (in.) Volume Outside Inside gal/ft l/m 1-3/ / / / / / / Vertiv Liebert Drycooler User Manual 48

53 5 ELECTRICL DT 5.1 Electrical Supply Preparation Line voltage electrical service is required for all models. Refer to equipment nameplate regarding wire size and circuit protection requirements. Electrical service must conform to national and local electrical codes. Refer to Figure 5.1 on page 61 and Figure 5.2 on page 62 for electrical service entrances into unit. Refer to electrical schematic when making connections. Each unit is shipped from the factory with all internal unit wiring completed. WRNING! rc flash and electric shock hazard. Open all electric power supplies, verify with a voltmeter that power is Off and wear personal protective equipment per NFP 70E before working within the electric control enclosure. Failure to comply can cause serious injury or death. Customer must provide earth ground to unit, per NEC, CEC and local codes, as applicable. Before proceeding with installation, read all instructions, verify that all the parts are included and check the nameplate to be sure the voltage matches available utility power. The line side of the disconnect switch on the front of the unit contains live high-voltage. The only way to ensure that there is NO voltage inside the unit is to install and open a remote disconnect switch. Refer to unit electrical schematic. Follow all local codes. WRNING! Risk of contact with high speed moving parts. Can cause injury or death. The fan(s) blades can start to rotate unexpectedly when the power is On. Disconnect all local and remote electrical power supplies before working within the fan compartment. Use a voltmeter to verify that the electrical power is Off before performing any electrical and/or mechanical service and/or maintenance operations. Each unit is shipped from the factory with all internal unit wiring completed. Refer to the electrical schematic supplied with the drycooler when making line voltage supply, low voltage indoor unit interlock and any low voltage alarm connections. ll wiring must be done in accordance with all applicable local, state and national electrical codes. For electrical characteristics, refer to on the next page, Table 5.2 on page 52, on the next page and5.1.1 on the next page. Vertiv Liebert Drycooler User Manual 49

54 5.1.1 Line Voltage Wiring WRNING! Risk of electrical fire and short circuit. Can cause property damage, injury or death. Select and install the electrical supply wire and overcurrent protection device(s) according to the specifications on the unit nameplate(s), per the instructions in this manual and according to the applicable national, state and local code requirements. Use copper conductors only. Make sure all electrical connections are tight. Unit-specific wiring diagrams are provided on each unit. WRNING! rc flash and electric shock hazard. Open all electric power supplies, verify with a voltmeter that power is Off and wear personal protective equipment per NFP 70E before working within the electric control enclosure. Failure to comply can cause serious injury or death. Customer must provide earth ground to unit, per NEC, CEC and local codes, as applicable. Before proceeding with installation, read all instructions, verify that all the parts are included and check the nameplate to be sure the voltage matches available utility power. The line side of the disconnect switch on the front of the unit contains live high-voltage. The only way to ensure that there is NO voltage inside the unit is to install and open a remote disconnect switch. Refer to unit electrical schematic. Follow all local codes. NOTE: Installation and service of this equipment should be done only by properly trained and qualified personnel who have been specially trained in the installation of air conditioning equipment. NOTE: Use copper wiring only. Make sure that all connections are tight. Drycooler rated voltage should be verified with available power supply upon receipt of unit but before installation. Refer to the unit electrical schematic and serial tag for specific electrical requirements. ll wiring must be done in accordance with all applicable local, state and national electrical codes. Line voltage electrical service is required for all drycoolers at the location of the drycooler. If the drycooler contains pump controls, the pump package voltage must match the drycooler voltage. See the unit's serial tag for specific electrical requirements of the drycooler and any pump package. unit disconnect is standard on drycoolers with internal pump controls and optional on all other drycoolers. Site disconnect (s) may also be required per local code to isolate the drycooler/pumps for maintenance. Refer to Figure 5.1 on page 61 andfigure 5.2 on page 62 for electrical service entrances into unit. manual electrical disconnect switch should be installed in accordance with local codes. Consult local codes for external disconnect requirements. Route the supply power to the site disconnect switch and then to the drycooler. Route the conduit through the hole provided in the cabinet. Connect earth ground to lug provided near terminal board. Vertiv Liebert Drycooler User Manual 50

55 Table Hz electrical values - Drycoolers without pump controls # of Fans Mode # Voltage Phase FL WS OPD Standard Models 1 33, 69, 92, 109, / / , 174, 197, / , 310, / , 419, 466, / , 650, / , 880, Quiet-Line Models 208/ , 57, / , 111, / , 173, Vertiv Liebert Drycooler User Manual 51

56 Table Hz electrical values - Drycoolers without pump controls (continued) # of Fans Mode # Voltage Phase FL WS OPD 208/ , / , / , Values are calculated per UL OPD values may be adjusted higher than calculations to compensate for maximum anticipated application temperatures. Table Hz electrical values - Drycoolers without pump controls # of Fans Model # Voltage Phase FL Standard Models 1 33, 69, 92, 109, / / , 174, 197, / , 310, / , 419, 466, / , 650, / , 880, / Quiet-Line Model 1 40, 57, / , 111, / , 173, / , / , / , / Vertiv Liebert Drycooler User Manual 52

57 5 Electrical Data...53 Table Hz Electrical values Standard drycoolers with integral pump controls # of Fans Model# 33,69,92,109, ,174,197, ,310, ,419,466, ,650, ,880,940 Pumphp Ph FL WS OP D Ph FL WS OP D Ph FL WS OP D Ph FL WS OP D Ph FL WS OP D Ph FL WS OP D 208/230/ * * * / *

58 54...Liebert Drycooler User Manual Table Hz Electrical values Standard drycoolers with integral pump controls (continued) # of Fans Model# 33,69,92,109, ,174,197, ,310, ,419,466, ,650, ,880,940 Pumphp Ph FL WS OP D Ph FL WS OP D Ph FL WS OP D Ph FL WS OP D Ph FL WS OP D Ph FL WS OP D 575/ Values are calculated per UL Pump FL values used are based on NEC tables for motor horsepower. OPD values may be adjusted higher than calculations to compensate for maximum anticipated application temperatures. * May require electrical component(s) with higher capacity in the drycooler. Consult factory representatives for assistance before ordering.

59 5 Electrical Data...55 Table Hz pump FL values Pump Input Power, Volts hp 208/ / Values based on NEC handbook values for 3-phase motors.

60 56...Liebert Drycooler User Manual Table Hz Electrical values - Liebert Quiet-Line drycoolers with integral pump controls # of Fans Model# 40,57,60 80,111, ,173, , , ,498 Pumph p P h FL WS OP D P h FL WS OP D Ph FL WS OP D P h FL WS OP D P h FL WS OP D P h FL WS OP D 208/230/3/ * * * /3/ *

61 5 Electrical Data...57 Table Hz Electrical values - Liebert Quiet-Line drycoolers with integral pump controls (continued) # of Fans Model# 40,57,60 80,111, ,173, , , ,498 Pumph p P h FL WS OP D P h FL WS OP D Ph FL WS OP D P h FL WS OP D P h FL WS OP D P h FL WS OP D 575/3/ Values are calculated per UL Pump FL values used are based on NEC tables for motor horsepower. OPD values may be adjusted higher than calculations to compensate for maximum anticipated application temperatures. * May require electrical component(s) with higher capacity in the drycooler. Consult factory representatives for assistance before ordering.

62 5.1.2 Low Voltage Control Wiring NOTICE Risk of control malfunction. Can cause improper unit operation. Make sure that all low voltage electrical wiring has been performed per the schematic diagram provided and that all low voltage wiring connections are tight. control interlock between the drycooler and the indoor cooling units is required. Field-supplied copper wire is required for connection between like-numbered Terminals 70 & 71 on both units for remote On/Off control of the drycooler, synchronized with the indoor unit. Wiring must be sized and selected for insulation class per NEC and other local codes. See Table 5.6 below and Table 5.7 on the facing page for recommended wire sizing for control wiring (24 VC) runs up to 150 ft (45.7m). Contact the factory for assistance with longer wiring runs. See Figure 5.1 on page 61 and Figure 5.2 on page 62 and indoor unit manual for location of terminals on drycoolers and indoor units. Refer to the electrical schematics supplied with the drycooler and indoor units for proper wiring of Terminals 70 & 71. Table 5.6 Minimum recommended control circuit wire size, WG, 60 Hz models Drycooler Types With Pump Controls Control Wire DSF DDF DSO DDO Run, ft (m) Number of Fans Number of Fans (0-7.6) ( ) ( ) ( ) ( ) ( ) Vertiv Liebert Drycooler User Manual 58

63 Drycooler Types Without Pump Controls Control Wire Run, ft (m) (D)DNL Number of Fans (D)DNT & (0-7.6) ( ) ( ) ( ) ( ) ( ) Data based on 16 WG min. wire size, 0.4 mp per contactor, 1 to 1.5 Volt maximum drop & 104 F (40 C) average ambient temperature Table 5.7 Minimum recommended control circuit wire size, mm 2, 50Hz models Drycooler Types With Pump Controls Control Wire Run, m (ft) DSF DDF DSO DDO Number of Fans (0-25) (26-50) (51-75) (76-100) ( ) ( ) Vertiv Liebert Drycooler User Manual 59

64 Drycooler Types Without Pump Controls Control Wire Run, m (ft) (D)DNL Number of Fans (D)DNT & (0-25) (26-50) (51-75) (76-100) ( ) ( ) Table based on 1.0 mm 2 min. wire size, 0.5 mp per contactor, 1 to 1.5 Volt maximum drop & 40 C (104 F) average ambient temperature Vertiv Liebert Drycooler User Manual 60

65 Figure 5.1 Electrical field connections, 1-fan DSF/DDF drycooler with pump control Vertiv Liebert Drycooler User Manual 61

66 Figure 5.2 Electrical field connections, 1-, 2-, 3- and 4-fan DSO/DDO drycooler with pump control Vertiv Liebert Drycooler User Manual 62

67 Figure 5.3 Electrical field connections, 6- and 8-fan DSO/DDO drycooler with pump control Vertiv Liebert Drycooler User Manual 63

68 Figure 5.4 Electrical field connections, 6- and 8-fan DDNC drycooler without pump control Vertiv Liebert Drycooler User Manual 64

69 Figure 5.5 Electrical field connections, 6- and 8-fan DDNL/DDNT drycooler without pump control Vertiv Liebert Drycooler User Manual 65

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71 6 CHECKLIST FOR COMPLETED INSTLLTION NOTE: fter installation, proceed with the following list to verify that the installation is complete. Complete and return the Warranty Inspection Check Sheet which is shipped with the unit and return to the address indicated on the check sheet. 6.1 Moving and Placing Equipment 1. Unpack and check received material. 2. Proper clearance for service access has been maintained around the equipment. 3. Equipment is level and mounting fasteners are tight. 6.2 Electrical 6.3 Piping 6.4 Other 1. Line voltage connected and matches equipment nameplate. 2. Power line circuit breakers or fuses have proper ratings for equipment installed. 3. Control wiring connections completed between indoor cooling unit and drycooler. 4. ll internal and external high and low voltage wiring connections are tight. 5. Drycooler to pump wiring is completed and checked for proper phase rotation (as required). 6. Monitoring wiring connections completed, when equipped, to indoor cooling unit or external monitoring panel. 7. Confirm that unit is properly grounded to an earth ground. 8. Control transformer setting matches incoming power. 9. Electrical service conforms to national and local codes. 10. Check fans for proper phase rotation. Blades should rotate clockwise when viewing the unit from the fan guard side. 1. Piping is properly sized for energy efficiency. 2. Piping is completed to corresponding indoor cooling unit glycol drycooler circuit. 3. Piping is routed to reduce potential of rub-through or chaffing. 4. Piping leak-checked, evacuated and charged with appropriate glycol/water mixture. 5. Piping is insulated, if required, to prevent damage caused by condensation. 1. Fans rotate freely and in proper direction. 2. djust aquastat setpoints to match setpoints on the electrical schematic supplied with the drycooler to match indoor unit coil and fluid regulating valve types and number of drycoolers on loop. 3. Foreign material removed from in and around all equipment installed (construction materials, construction debris, etc.). 4. Installation materials and tools have been removed from in and around all equipment (literature, shipping materials, tools, etc.). 5. Blank warranty-inspection sheet (PSWI CO) located, ready for completion by installer or startup technician. Vertiv Liebert Drycooler User Manual 67

72 Vertiv Liebert Drycooler User Manual 68

73 7 OPERTION WRNING! Risk of electric shock. Can cause injury or death. Open all local and remote electric power-supply disconnect switches and verify that power is off before working within all electrical-connection enclosures. Unit contains potentially lethal electrical voltage. Only properly trained and qualified personnel may perform repair, maintenance and cleaning operations. The fans may start unexpectedly. Disconnect power supply before working on unit. Line side of factory disconnect remains energized when disconnect is off. Use a voltmeter to make sure power is turned off before checking any electrical connections or functions. 7.1 Startup Checklist Refer to Checklist for Completed Installation on page 67 and verify that all installation items have been completed prior to proceeding. Turn the drycooler disconnect ON. Indoor units should then be turned on and set for cooling to allow operation of drycooler fan and pump controls. Check the fans for proper rotation (air discharging up). Check the pumps for proper rotation. NOTICE 7.2 Startup Risk of overheated pump seals. Can cause piping system damage, coolant fluid leaks, and substantial building damage. Do not run pumps without fluid in the system. Pump seals require fluid to keep them cool; running them without fluid for any amount of time will damage the seals, which may cause a failure Drycooler quastat Setpoints The fan-off temperature of the aquastat (fluid temperature controls) should be set according to factorysupplied schematic, shipped inside the drycooler s electric panel. Settings might need to be field adjusted based on the indoor unit s glycol regulating valve type, drycooler size and the number of drycoolers on the loop. Typical settings shown in 7.2 above, quastat settings 2-,3- & 4-fan drycoolers on the next page and7.2 above apply to standard drycoolers without customer requested modifications to number of aquastats. pplications with Optional Stat Setting require field piping to be insulated to prevent condensation. quastats must be field adjusted to optional setting for: GLYCOOL/Dual Cool applications Vertiv Liebert Drycooler User Manual 69

74 Single Drycooler loops with motorized ball valve flow controls Motorized ball valve flow controls are used on all Liebert CRV and Liebert PDX units and on all Liebert DS units with digital compressors (see below for unit model numbers containing digital compressors): DS/VSxxxxD DS/VSxxxxG Liebert DS models with seventh characters D or G Drycoolers with DSF or DDF controls should have setpoint temperature adjusted based on Q1 temperatures in 7.2 on the previous page. Table 7.1 Water/glycol system conditions requiring optional settings for aquastats Cooling Glycol GLYCOOL Flow Control Motorized Ball Valve Water Regulating Valve Motorized Ball Valve Water Regulating Valve Drycoolers In Loop 1 Multiple 1 Multiple 1 Multiple 1 Multiple quastat Settings Optional Factory Factory Optional Insulate Field Piping Yes No No Yes Yes Table 7.2 quastat settings 2-,3- & 4-fan drycoolers quastat Fan Motors Factory Setting Non-glycol units Optional Setting (GLYCOOL) Minimum-allowable Settings for CRV Q1 F1 65 F (18.3 C) 35 F (1.7 C) 45 F (7.2 C) Q2 F2 & F3 below 75 F (23.9 C) 45 F (7.2 C) 55 F (12.8 C) Q3 below F4 below 70 F (21.1 C) 40 F (4.4 C) 50 F (10.0 C) F3 fan available only on drycoolers with three or four fans Q3 & F4 applicable only on drycoolers with four fans Dial setting (stat open temp) set for mid differential, 8 F (4.4 C) rise to close Source: DPN001602, Rev. 3 Vertiv Liebert Drycooler User Manual 70

75 Table 7.3 quastat settings 6- and 8-fan drycoolers quastat Fan Motors Stat Location Cabinet Factory Setting (Glycol) Optional Setting (Glycol) 6-Fan Drycoolers Q1 F1 65 F (18.3 C) 35 F (1.7 C) Main Q2 F2 70 F (21.1 C) 40 F (4.4 C) Q3 F3 & F4 73 F (22.8 C) 43 F (6.1 C) ux Q4 F5 & F6 75 F (23.9 C) 45 F (7.2 C) 8-Fan Drycoolers Q1 F1 65 F (18.3 C) 35 F (1.7 C) Main Q2 F2 70 F (21.1 C) 40 F (4.4 C) Q3 F3 & F4 73 F (22.8 C) 43 F (6.1 C) ux Q4 F5 & F6 75 F (23.9 C) 45 F (7.2 C) Q5 F7 & F8 Main 78 F (25.6 C) 48 F (8.9 C) Dial setting (stat open temp) set for mid differential, 8 F (4.4 C) rise to close Source: DPN001602, Rev. 3 Vertiv Liebert Drycooler User Manual 71

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77 8 TROUBLESHOOTING Symptom Possible Cause Check Or Remedy Unit will not operate Unit runs, but motor protector keeps tripping Outlet temperature from unit too high Liquid squirts from surge tank fill cap when pump is turned off No main power Disconnect switch open Blown fuse or circuit breaker tripped Control fuse or circuit breaker tripped Improperly wired No output voltage from transformer Motor protector defective Motor protector too small Fan or pump motor has shorted winding Low or unbalanced voltage Low or no coolant flow mbient air temperature higher than design Heat load higher than design Throttling valve improperly ir in system Check L1, L2 and L3 for rated voltage Close disconnect switch Check fuses or circuit breaker Check for 24VC. If no voltage, check for short. Replace fuse or reset circuit breaker. Check wiring diagram Check for 24VC. If no voltage, check primary voltage Replace protector Check amp. draw Repair motor Determine reason and correct See Pump will not operate or no coolant flow on the next page entry in this table Correct possible hot air discharge to fans from another source Check for misapplication, need larger cooler. Correct possible additional heat load being added to cooling circuit. Reset valve to proper differential pressure Vent all high points, repeat as necessary. Check liquid level in surge tank. Pump suddenly stops pumping Clogged strainer or impeller Clean out debris Pumping suddenly slows Clogged impeller, diffuser or line Clean out debris and use strainer Excessive leakage around the pump shaft while operating Pump performance poor Pump has noisy operation Worn seal or packing Worn impeller or seal Suction lift too high Motor not up to speed; low voltage Worn bearings Worn motor bearings Low discharge head Debris lodged in impeller Replace seal or packing Replace with new impeller or seal Relocate pump closer to supply Larger lead wires may be required. Check for proper line voltage, ±10% Replace pump Replace pump Throttle discharge -- improve conditions Remove cover and clean out Vertiv Liebert Drycooler User Manual 73

78 Symptom Possible Cause Check Or Remedy Pump discharge pressure too high Pump will not operate or no coolant flow Cavitating pumps Throttling valve improperly set Valve closed in circuit Strainer clogged or dirty No power to pump motor Low coolant level Tubes plugged in cooling coil Valve closed downstream of cooling unit Strainer clogged or dirty Pump cavitating (erratic gauge operation) djust system pressures Reset valve to proper differential pressure Open all valves downstream of unit Remove strainer plug and clean See Unit will not operate on the previous page in this table Check coolant level Flush coil with reputable cleaner Open all valves Remove strainer plug and clean Possibility of air in lines. Bleed all components. Check surge tank to pump inlet connection. Check for piping restrictions. Vertiv Liebert Drycooler User Manual 74

79 9 SYSTEM MINTENNCE WRNING! Risk of electric shock. Can cause injury or death. Open all local and remote electric power-supply disconnect switches and verify that power is off before making any electrical connections. Unit contains lethal voltage in some circuits. Only properly trained and qualified personnel may perform repair, maintenance and cleaning operations. The fans may start unexpectedly. Disconnect power supply before working on unit. Line side of factory disconnect remains energized when disconnect is off. Use a voltmeter to make sure power is turned off before checking any electrical connections or functions. 9.1 General Procedures NOTE When ordering replacement parts for equipment, it is necessary to specify unit model number, serial number, and voltage. Please record those numbers in the spaces below. Model Number Serial Number Voltage/Phase/Frequency Periodic attention is necessary for continued satisfactory operation of your unit. Restricted air flow through the drycooler coil, reduced airflow from non-functioning fans and low coolant levels will reduce the operating efficiency of the unit and can result in high fluid temperatures and loss of cooling. In winter, do not permit snow to accumulate around the sides or underneath the drycooler. Monthly and semi-annual inspections and maintenance are recommended for proper system operation. Use copies of Preventive Maintenance Checklist on page 77 for each of these inspections. If performance or operation problems are detected at anytime, refer to Troubleshooting on page 73 for required action Drycooler Coil Cleaning Keeping the outdoor drycooler coils clean is an important factor in maintaining peak efficiency, reliability and long life of the equipment. It is much easier to keep up on frequent cleanings rather than wait until heavy build up has occurred which may create head pressure problems with the evaporator units. When to Clean Normal conditions typically dictate cleaning twice a year, spring and fall. On-site or area conditions such as cottonwood trees, construction, ground level drycooler placement, etc., can increase cleaning frequency. On your standard monthly preventive maintenance schedule, a visual inspection of the coil is recommended to monitor conditions. Vertiv Liebert Drycooler User Manual 75

80 What to Use The best overall drycooler coil cleaner to use is plain water. If the coil has been maintained and cleaned at regular intervals, water is sufficient to remove dirt and debris from the fins. Heavy build up on the exterior of the fins can be removed with a brush. Water pressure from a garden hose and sprayer usually works well. If a pressure washer is used, make sure the equipment is set to a lower pressure setting and that the nozzle is set to the fan spray, not stream. Otherwise, damage to the fins could result. If a cleaner is required, we recommend a non-acidic type cleaner be used. cid-type cleaners can be aggressive to the coil fins as well as surrounding areas. Many sites do not allow the use of acidic cleaners for environmental reasons. How to Clean The absolute best way to clean coils is from the inside out. This requires disconnecting the power supply from the drycooler before working on the unit. The fan guards and fan blades must be removed to gain access to the coil surface. The sprayer can then be worked across the coil using the water/cleaning solution, pushing the dirt and debris out the bottom of the coil. lthough this does extend the time involved, the results are well worth it. This method should be used at least once a year. Spraying the coil from the outside repeatedly can push a majority of the dirt to the inner section of the fins and continue to restrict air flow. Keep in mind you may not have the luxury of shutting the unit(s) down for an extended time. pre-scheduled shutdown with the operator may be in order. If you are using a cleaner along with the spraying process, follow recommended manufacturer instructions and be sure to rinse the coil thoroughly. ny residue left on the coil can act as a magnet to dirt. Reinstall and secure the fan blades and fan guards after the cleaning is finished. Last, reconnect the power supply to the drycooler. Vertiv Liebert Drycooler User Manual 76

81 10 PREVENTIVE MINTENNCE CHECKLIST Source: DPN003119, Rev. 0 Inspection Date Indoor Unit Model # Condenser Drycooler Model # Room Temperature/Humidity Job Name Indoor Unit Serial Number # Condenser Drycooler Serial # % mbient Temperature Good maintenance practices are essential to minimizing operation cost and maximizing product life. Read and follow all applicable maintenance checks listed below. t a minimum, these checks should be performed semi-annually. However, maintenance intervals may need to be more frequent based on site-specific conditions. Review the unit user manual for further information on unit operation. Vertiv recommends the use of trained and authorized service personnel, extended service contracts, and factory-certified replacement parts. Contact your local Vertiv Representative for more details. Check all that apply: Drycooler 1. Coil clean and free of debris 2. Motor mounts tight 3. Piping support/clamps secure 4. Check/Re-torque wire connections 5. Check contactors for pitting (replace if pitted) 6. Check fuses 7. Verify fan operation 8. Check surge-protection device status-indicator lights (if equipped) 9. mbient thermostat settings 10. Refrigerant level (Lee-Temp ) 11. Glycol level 12. Glycol solution ---- % 13. Water/Glycol solution flowing continuously/clean and free of debris 14. Water-treatment plan established and followed for open cooling-tower application 15. Check refrigerant/glycol lines for signs of leaks/repair as found 16. Motor amp draw #1 L1 L2 L3 (L1 and L2 on Fan Speed Control Motor) #2 L1 L2 L3 #3 L1 L2 L3 #4 L1 L2 L3 #5 L1 L2 L3 Vertiv Liebert Drycooler User Manual 77

82 #6 L1 L2 L3 #7 L1 L2 L3 #8 L1 L2 L3 Glycol Pump 1. Check pump rotation 2. Check for glycol leaks 3. Pump pressures #1 Suction Discharge #2 Suction Discharge #3 Suction Discharge 4. mp Draw #1 L1 L2 L3 #2 L1 L2 L3 #3 L1 L2 L3 5. Verify pump changeover (if multiple pumps) Vertiv Liebert Drycooler User Manual 78

83 Maintenance Notes Name Signature Company Make photocopies for your records. Compare readings/information to previous maintenance worksheet. To locate your local Liebert representative for Liebert engineered parts, check or call Liebert. Vertiv Liebert Drycooler User Manual 79

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86 VertivCo.com Vertiv Headquarters, 1050 Dearborn Drive, Columbus, OH, 43085, US 2017 Vertiv Co. ll rights reserved. Vertiv and the Vertiv logo are trademarks or registered trademarks of Vertiv Co. ll other names and logos referred to are trade names, trademarks or registered trademarks of their respective owners. While every precaution has been taken to ensure accuracy and completeness herein, Vertiv Co. assumes no responsibility, and disclaims all liability, for damages resulting from use of this information or for any errors or omissions. Specifications are subject to change without notice. SL-10080_REV4_10-17/