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Liebert DS user manual Reassembly Checklist

Models: DS

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6.4Reassembly Checklist

Disassembling the Liebert DS for Transport

6.4Reassembly Checklist

___ 1. Thread-cutting bolts reconnected and torqued to 225 in-lb. (25Nm)

___ 2. Top cover plate attached to coil

___ 3. Filter plate attached

___ 4. High-voltage wires connected to proper contactors:

___ a. Compressor

___ b. Fan motor

___ c. Reheat, if applicable

___ d. Humidifier, if applicable

___ e. Condensate pump, if applicable

___ 5. Low-voltage wires connected

___ a. Actuator

___ b. Terminal strip

___ c. Plug connections

___ d. Smoke detector, if applicable

___ 6. Coil access plates on right and left replaced

___ 7. Water lines brazed

___ 8. Suction and liquid refrigerant lines brazed

___ 9. Unit recharged

___ 10. Filters replaced

___ 11. Panels replaced

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Liebert DS user manual Reassembly Checklist

Contents

For Business-Critical Continuity Liebert DSUser Manual 28-105kW, 8-30 Tons, Upflow and Downflow, 50/60Hz Page TABLE OF CONTENTS 1.0 LIEBERT DS COMPONENTS AND NOMENCLATURE 2.0 COOLING CONFIGURATIONS3.0 PRE-INSTALLATION GUIDELINES SAFETY INFORMATION8.0 PIPING 12.0 MAINTENANCE7.0 ELECTRICAL CONNECTIONS 13.0 HVAC MAINTENANCE CHECKLIST FIGURES compressor models all compressor models TABLES Table 43 Component weights-upflow, air-cooled, 105kW 30 ton, scroll/digital scroll compressor models SAVE THESE INSTRUCTIONS IMPORTANT SAFETY INSTRUCTIONSRisk of leaking water. Can cause equipment and building damage Risk of high-speed moving parts. Can cause injury or deathRisk of contact with hot surfaces. Can cause injury 1.0 LIEBERT DS COMPONENTS AND NOMENCLATURE Figure 1 Downflow model component locationsFigure 2 Upflow model component locations Configuration 5 A U ALiebert DS Components and Nomenclature Air Distribution2.0 COOLING CONFIGURATIONS Cooling ConfigurationsAir-Cooled Glycol-Cooled3.2 Air Distribution-Downflow Units 3.0 PRE-INSTALLATION GUIDELINES3.1 Room Preparation Figure 5 Upflow ducting configurations 3.3 Air Distribution-Upflow Units3.4 Connections and System Setup 3.5 Operating Conditions4.0 LIEBERT DS DIMENSIONS AND WEIGHTS Liebert DS Dimensions and WeightsDownflow Unit Weight, lb Upflow Unit Weight, lbTop View Front ViewTop View Top View Front ViewDPN000924 Rev Air-Cooled2350 2400Figure 10 Cabinet and floor planning dimensions-downflow, air-cooled, 53-77kW 15-22 ton, scroll compressor models Front ViewTOP VIEW FRONT VIEWFront View Weights for downflow, air-Cooled, 105kW 30 ton, all compressor modelsTop View Front View Figure 13 Cabinet and floor planning dimensions-downflow, water/glycol/GLYCOOL, 105kW 30 ton, all compressor modelsTop View Front View Figure 14 Cabinet and floor planning dimensions-upflow, air-cooled 28-42kW 8-12 ton, semi-hermetic compressor modelsTop View Figure 15 Cabinet and floor planning dimensions-upflow, air-cooled 28-42kW 8-12 ton, scroll or digital scroll compressor models FRONT VIEW 838mm Top ViewFront View Front View Figure 18 Cabinet and floor planning dimensions-upflow, air-cooled, 53-77kW 15-22 ton, scroll or digital scroll compressor modelsTop View Front View Table 17 Weights-upflow, air-cooled, 105kW 30 ton, all Liebert DS Dimensions and WeightsDry Weight, Approximate, lb kg TOP VIEWLiebert DS Dimensions and Weights TOP VIEWFRONT VIEW ModelLiebert DS Dimensions and Weights Dimensions, in. mmModel Height, in. mmLiebert DS Dimensions and Weights Dimensions, in. mmModel Height, in. mmFigure 24 Floor stand dimensions-downflow, 105kW 30 ton models Liebert DS Dimensions and WeightsHeight, in. mm D turning vaneFigure 25 Blower outlet and deck dimensions-upflow, 28-42kW 8-12 ton Table 22 Dimensions for upflow, 28-42kW 8-12 tonBlower Outlet Location - Top View Top of UnitBlower outlet and deck dimensions-upflow, 53-77kW 15-22 ton 1-1/2 38mm Figure 27 Blower outlet and deck dimensions-upflow 105kW 30tonTable 24 Blower outlet and deck dimensions-upflow 105kW 30ton DPN001196 Rev Figure 28 Rear return filter box dimensionsTable 25 Rear return filter box dimensions Figure 29 Upflow unit plenum dimensions Table 26 Upflow unit plenum dimensionsCheck One Side View - Unit5.0 EQUIPMENT INSPECTION AND HANDLING SAFETY INFORMATION5.1 Packaging Material Forklift PalletSpreader Bars and Slings Jack5.2.1 Removing the Unit from the Skid With a Forklift Figure 32 Remove the unit from the skid5.2.3 Removing Piano Jacks 5.2.2 Moving the Unit to the Installation Location with Piano JacksFigure 33 Moving the unit to its installation location 5.2.4 Removing Liebert DS from Skid Using Rigging LiftingFigure 35 Using rigging to lift Liebert DS off skid LiftingLifting SlingDETAIL A 5.3 Semi-Hermetic Compressor Spring Isolation System5.4 Placing the Unit on a Floor Stand 6.0 DISASSEMBLING THE LIEBERT DS FOR TRANSPORT 6.2 Disassembly-Downflow Units6.1 Required Equipment 10. Reheat-Optional Component 11. Humidifier-Optional Component12. Condensate Pump-Optional Component 13. GLYCOOL/Dual-Cool-Optional Component6.2.1 Remove the Compressor Assembly 6.2.2 Remove the Filter and Electric Box AssemblyEmerson recommends using piano jacks when moving this section Emerson does not recommend unsweating refrigerant connections6.3 Reassembly-Downflow Units 6.3.1 Reconnecting Piping, Charging and Replacing Panels6.4 Reassembly Checklist Compressor Assembly Filter & Electric Box AssemblyBlower & Coil Assembly 60-3/16Filter & Electric Box Assembly Figure 39 Component dimensions-downflow, water/glycol/GLYCOOL, 28-42kW 8-12 ton, all compressor models 59-7/16 1509mm 1509mm 940mmFigure 42 Component dimensions-downflow water/glycol, GLYCOOL, 53-77kW 15-22 ton, all compressor models Figure 43 Component dimensions-downflow, air-cooled, 105kW 30 ton, semi-hermetic compressor models See disassembly and handling instructions in installation manual Figure 45 Component dimensions-downflow, water/glycol/GLYCOOL, 105kW 30 ton, all compressor models 6.5 Disassembly-Upflow Units Emerson does not recommend unsweating refrigerant connectionsEmerson recommends using piano jacks when moving this section 6.5.1 Remove Compressor Assembly6.5.2 Remove Blower and Electric Box Assembly 6.6 Reassembly-Upflow Unit 6.7 Reassembly ChecklistFigure 46 Component dimensions-upflow, air-cooled, 28-42kW 8-12 ton, semi-hermetic compressor models Figure 47 Component dimensions-upflow, air-cooled, 28-42kW 8-12 ton, scroll/digital scroll compressor models Figure 48 Component dimensions-upflow, water/glycol/GLYCOOL, 28-42kW 8-12 ton, all compressor models 108 2743mm Assembled Length 660mm2083mm Figure 50 Component dimensions-upflow, air-cooled, 53-77kw 15-22 ton, scroll/digital scroll compressor models Figure 51 Component dimensions-upflow water/glycol/GLYCOOL 53-77kw 15-22 ton, all compressor models Figure 52 Component dimensions-upflow, air-cooled, 105kW 30 ton, semi-hermetic compressor models Figure 53 Component dimensions-upflow, air-cooled, 105kW 30 ton, scroll/digital scroll compressor models 31-1/4 794mm 7.0 ELECTRICAL CONNECTIONS Electrical ConnectionsDOWNFLOW LOW VOLT SECTION Electrical ConnectionsA B C D OVERLOAD PROTECTORS12. Factory installed disconnect switch 13. Secondary disconnect switch and earth ground7.1 Electrical Field Connection Descriptions Standard Electrical ConnectionsOptional Low Voltage Terminal Package Connections 8.1.1 Condensate Piping-Field-Installed 8.1 Fluid Connections8.0 PIPING Gravity DrainCORRECT INCORRECTINCORRECT DPN001556 DOWNFLOW DS UNITGeneral Guidelines 8.1.3 Requirements of Systems Using Water or Glycol8.1.2 Humidifier Supply Water-Optional Infrared 8.2 Refrigeration Piping Leak Checking of Unit and Field Piping8.2.1 Piping Guidelines-Air-Cooled Units 11.7 8.3 Dehydration/Leak Test and Charging Procedures for R-407C and R-22 Fan Speed Control Leak Check and Evacuation ProcedureFan Speed Control Piping Fan Speed Control Materials SuppliedTable 49 Fan speed suction pressure transducer settings Fan Speed ChargingLee-Temp Controlled Materials Supplied Lee-Temp Leak Check and Evacuation ProcedureLee-Temp Piping Table 50 Lee-Temp suction pressure transducer settings Lee-Temp ChargingLee-Temp Receiver Refrigerant Level Sight Glass Levels9.0 PIPING SCHEMATICS Valve Liquid ReturnLee-Temp LiquidLiquid Return Lee-TempFan Speed LiquidPiping schematic-water/glycol, semi-hermetic compressor models refer to 12.11.3 - Drycooler SettingsFor systems with drycoolers Liebert DS UnitFigure 60 Piping schematic-water/glycol with scroll compressor models Piping SchematicsFor systems with drycoolers refer to 12.11.3 - Drycooler Settings LIEBERTFigure 61 Piping schematic-GLYCOOL semi-hermetic compressor models Piping SchematicsFor systems with drycoolers refer to 12.11.3 - Drycooler Settings LIEBERTFigure 62 Piping schematic-GLYCOOL with scroll compressor models Piping SchematicsFor systems with drycoolers refer to 12.11.3 - Drycooler Settings LIEBERTPiping Schematics CUSTOMER HEAT REJECTIONLIEBERT HEAT REJECTIONPiping Schematics LIEBERTHEAT REJECTION LIEBERT DS UNIT and associated pipingFigure 65 Optional piping schematic for Econ-O-Coil DPN000805 RevFront View Section A-AFRONT OF UNIT DPN000803Note Drawing not to scale E1 E2 Piping Schematics Connection Size / OpeningPoint DescriptionPiping Schematics Connection Size / OpeningPoint Description408mm DPN00093316-1/16 LV1 LV2 LV3 HUM E1 E2 Front of UnitDPN001014 Rev 14-1/2 Piping Schematics Connection Size / OpeningPoint DescriptionPiping Schematics FRONT SECTION VIEWConnection Size / Opening PointPiping Schematics Left Side Section ViewTop View of Unit Front Section ViewPiping Schematics TOP VIEW OF UNITFRONT SECTION VIEW OF UNIT Left Front Panel Not ShownPiping Schematics Front Section ViewConnection Size / Opening PointPiping Schematics 2. Tolerance on all piping dimensions is ±1/2 13mmTop View Left Side Section ViewPiping Schematics TOP VIEW OF UNITLEFT SIDE SECTION VIEW OF UNIT FRONT SECTION VIEW OF UNITFigure 81 Primary connection locations-upflow, water/glycol/GLYCOOL, 105kW 30 ton, all 10.0 CHECKLIST FOR COMPLETED INSTALLATION 10.1 Moving and Placing Equipment10.2 Electrical 10.3 PipingPage 11.2 Startup Checks Inspection With Panels Removed and Disconnect Off 11.3 Commissioning Procedure With Panels On Return Completed Startup Form to Your Local Emerson Sales Office12.0 MAINTENANCE 12.1 Filters12.1.1 Filter Replacement Procedure-Downflow Units 12.1.2 Filter Replacement Procedure-Upflow Units12.2 Blower Drive System Do Not Use12.2.1 Upflow Motor Access 12.2.3 Belt Installation and TensioningFigure 83 Upflow motor access 12.2.2 Belt RemovalBlower Bearing Maintenance Blower Bearing ReplacementBlower Bearing Inspection Blower MotorCorrect Switch Orientation Incorrect Switch Orientation 12.3.2 Cleaning Humidifier Pan and Float Switch12.3 Humidifier 12.3.1 Infrared Humidifier12.4 Condensate Drain and Condensate Pump Systems 12.3.3 Changing Humidifier Lamps12.4.1 Condensate Drain 12.4.2 Condensate Pump12.5 Air-Cooled Condenser and Drycoolers 12.6 Reheat-Electric Reheat Three-Stage and SCR12.7 Compressor 12.7.1 Compressor Oil12.8 Compressor Replacement 12.9 Facility Fluid and Piping Maintenance12.8.3 Compressor Replacement Procedure 12.8.1 Compressor Motor Burnout12.10.1 Cleaning Instructions Adjustment-Johnson Controls/Penn Johnson Valves12.10 Paradenser-Water-Cooled Condenser 12.11 Water/Glycol Control ValvesTesting Function of Valve AdjustmentLocation 12.11.2Motor Ball Valve-Digital Scroll Compressors12.11.3Drycooler Settings Table 58 Aquastat settings-two-fan through four-fan drycoolersTable 59 Aquastat settings-six-fan drycoolers Table 60 Aquastat settings-eight-fan drycoolers13.0 HVAC MAINTENANCE CHECKLIST FiltersBlower Section ReheatCondensate Pump Refrigeration PipingWater-Cooled Condensers Compressor SectionAir-Cooled Condenser / Drycooler Glycol PumpPage Ensuring The High Availability Of Mission-Critical Data And Applications