Liebert Mini-Mate2™ - Emerson Network Power

Precision Cooling
For Business-Critical Continuity™
Liebert Mini-Mate2™
Installation, Operation and Maintenance Manual - 2 & 3 Tons, 50 & 60Hz
Table of Contents
PRODUCT MODEL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.0
INTRODUCTION
1.1
Product Description and Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1.1
1.1.2
1.1.3
1.2
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2.1
1.2.2
1.2.3
1.2.4
1.2.5
1.2.6
1.2.7
1.2.8
1.2.9
1.3
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Evaporator System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Condensing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Canister Humidifier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electric Reheat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SCR Electric Reheat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hot Water Reheat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hot Gas Bypass (Condensing Units). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Free-Cooling Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Smoke Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Firestat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filter Clog. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
6
6
6
6
6
6
6
6
Ancillary (Ship Loose Accessories) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3.1
1.3.2
1.3.3
1.3.4
1.3.5
1.3.6
1.3.7
1.3.8
1.3.9
Single Point Power Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refrigerant Line Sweat Adapter Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pre-Charged Refrigerant Line Sets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air Discharge Plenum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Duct Kit with Return Air Filter Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Condensate Pump Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Static Blow Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Monitoring and Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
6
6
7
7
7
7
7
7
2.0
SITE PREPARATION AND INSTALLATION
2.1
Installation Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1.1
2.1.2
Room Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Location Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.2
System Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.3
Equipment Inspection (upon receipt) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.4
Installing the Ceiling Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.4.1
2.4.2
2.4.3
2.4.4
2.4.5
2.5
Close Coupled Installations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Evaporator Air Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piping Connections and Coolant Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Condensate Pump Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
12
13
18
19
Centrifugal Fan Condensing Unit Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.5.1
2.5.2
2.5.3
2.5.4
Location Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Piping Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ducting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
i
21
21
22
22
2.6
Outdoor Air Cooled Condensing Unit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.6.1
2.6.2
2.6.3
2.7
Location Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Piping Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Water and Glycol Cooled Condensing Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.7.1
2.7.2
2.7.3
Location Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Piping Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.8
Checklist for Completed Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.0
MICROPROCESSOR CONTROL
3.1
Feature Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.2
Main Menu <Menu>. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.3
Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.4
Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.5
Active Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.6
Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.7
Date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.8
Setback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.9
Setup Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.9.1
3.9.2
3.9.3
Restart Time Delay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
C/F Degrees. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Humidity Control Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.10
Change Passwords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.11
Calibrate Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.12
Alarm Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.13
Alarm Time Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.14
Common Alarm Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.15
Custom Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.16
Custom Text . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.17
Run Diagnostics (Available On Rev 1.001.0) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.0
SYSTEM PERFORMANCE MICROPROCESSOR CONTROLS
4.1
Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.1.1
4.1.2
4.1.3
4.2
Humidity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.2.1
4.2.2
4.2.3
4.3
Cooling/Heating Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Cooling Operation (Cooling, Compressorized Direct Expansion and Chilled Water). . . . 41
Heating Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Dehumidification/Humidification Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Dehumidification Operation, Compressorized Direct Expansion (DX) Systems . . . . . . . 42
Humidification Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Load Control Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.3.1
Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
ii
5.0
ALARMS
5.1
Alarms: Definitions and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.1.1
5.1.2
5.1.3
5.1.4
5.1.5
5.1.6
5.1.7
5.1.8
5.2
Custom Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Head Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Humidity Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Humidifier Problem Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Water Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loss of Power:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Short Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
43
43
44
44
44
44
44
44
Optional/Custom Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.2.1
5.2.2
Loss of Water Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Smoke Detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.0
SYSTEM TESTING AND MAINTENANCE
6.1
System Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
6.1.1
6.1.2
6.1.3
6.1.4
6.1.5
6.1.6
6.1.7
6.1.8
6.2
Environmental Control Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Humidification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dehumidification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Firestat (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Smoke Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
46
46
46
46
46
46
46
46
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.2.1
6.2.2
6.2.3
6.2.4
6.2.5
6.2.6
6.2.7
Electric Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Direct Drive Blower Package. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Static Belt Drive Blower Package (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steam Generating Humidifier-Operation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Board Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.0
MAINTENANCE INSPECTION CHECKLIST
8.0
TROUBLESHOOTING
iii
47
47
47
47
48
51
53
Figures
Figure i
Figure ii
Figure 1
Figure 2
Figure 3
Figure 4
Figure 5
Figure 6
Figure 7
Figure 8
Figure 9
Figure 10
Figure 11
Figure 12
Figure 13
Figure 14
Figure 15
Figure 16
Figure 17
Evaporators and Chilled Water Units Model Number Designation . . . . . . . . . . . . . . . . . . . . . 1
Condensing Unit Model Number Designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Air Cooled Systems, 2 and 3 Tons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Water/Glycol Cooled Systems, 2 and 3 Tons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Chilled Water Systems, 3 Tons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Unit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Piping Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Condensate Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Unit Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Close Coupled Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Centrifugal Condenser Dimensions and Pipe Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Centrifugal Condenser Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
General Arrangements (Air Cooled Condensing Unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
General Arrangements (Water/Glycol Cooled Condensing Unit). . . . . . . . . . . . . . . . . . . . . . . 28
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Control Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Control Board (Inside Evaporator). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Wallbox Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Hot Gas Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Tables
Table 1
Table 2
Table 3
Table 4
Table 5
Table 6
Table 7
Table 8
Table 9
Table 10
Table 11
Table 12
Table 13
Table 14
Table 15
Table 16
Table 17
Table 18
Table 19
Table 20
Table 21
Table 22
Table 23
Table 24
Table 25
Table 26
System Configurations - 60 Hz. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
System Configurations- 50 Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Application Limits, Evaporator and Chilled Water Units* . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Application Limits, Indoor and Outdoor Air Cooled Condensers. . . . . . . . . . . . . . . . . . . . . . . . 8
Application Limits, Indoor Water/Glycol Cooled Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Unit Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Cooling Unit Air. Flow (CFM) at 0.3 iwg esp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Recommended Line Sizes O.D. Cu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Connection Sizes and Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Unit Piping Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Indoor Condensing Unit Air Flow (CFM) at 0.5 iwg esp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Centrifugal Condenser Dimensions in. (mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Unit Dimensions - in. (mm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2 and 3 Ton Unit Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Line Sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
View Default Setpoints and Allowable Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Microprocessor Night and Weekend Setback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Set-Up Functions, Default Values and Allowable Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Alarm Default Time Delays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Equipment Switch Settings (Unit Control Board) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Switch Settings (Wallbox Board) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Cooling and Dehumidification Load Response of Hot Bypass . . . . . . . . . . . . . . . . . . . . . . . . . 41
External Static Pressure Available . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Typical Discharge Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
DIP switch Settings for Humidifier Control Board (2 and 3-ton Unit) . . . . . . . . . . . . . . . . . . 53
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
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Outside or fresh air should be kept to a minimum when tight temperature and humidity control is
required. Outside air adds to the cooling, heating, dehumidifying and humidifying loads of the
site. Doors should be properly sealed to minimize leaks and should not contain ventilation grilles.
2.1.2
Location Considerations
!
CAUTION
Units contain water. Water leaks can cause damage to sensitive
equipment below. DO NOT MOUNT UNITS OVER SENSITIVE
EQUIPMENT. A field supplied pan with drain must be installed
beneath cooling units and water/glycol cooled condensers.
NOTE
Do Not mount units in areas where normal unit operating sound may
disturb the working environment.
NOTE
Temperature and humidity sensors are located in the wall box. Carefully select a
position for the box where discharge air DOES NOT directly blow on the sensors.
Locate the evaporator unit over an unobstructed floor space if possible. This will allow easy access
for routine maintenance or service. Do not attach additional devices (such as smoke detectors,
etc.) to the housing, as they could interfere with the maintenance or service.
When using the optional air distribution plenum, avoid locating the evaporator unit in confined
areas that affect the air flow pattern. Such locations could cause short cycles, down drafts and air
noise. Avoid locating the unit in an alcove or at the extreme end of a long, narrow room. Avoid
installing multiple units close to each other. This could result in crossing air patterns, uneven
loads and competing modes.
Figure 1
Air Cooled Systems, 2 and 3 Tons
Split System Evaporator
Supply & Return Air Plenum
Split System Evaporator
Supply & Return Air Ducted
Indoor Air Cooled Condensing Unit
Site Preparation and Installation
9
Figure 2
Water/Glycol Cooled Systems, 2 and 3 Tons
Drycooler
Drycooler
Condensing Unit
Condensing Unit
Evaporator
Evaporator
Split System Evaporator
Supply & Return Air Plenum
Remote Water/Glycol Condensing Unit
Cooling Tower
Split System Evaporator
Supply & Return Air Ducted
Remote Water/Glycol Condensing Unit
Cooling Tower
Condensing Unit
Condensing Unit
Evaporator
Evaporator
Split System Evaporator
Supply & Return Air Plenum
Remote Water/Glycol Condensing Unit
Figure 3
Split System Evaporator
Supply & Return Air Ducted
Remote Water/Glycol Condensing Unit
Chilled Water Systems, 3 Tons
Evaporator
Evaporator
Chilled Water Supply and Return Plenum
10
Site Preparation and Installation
Chilled Water Ducted
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3.0
MICROPROCESSOR CONTROL
The Microprocessor Control for the Liebert Mini-Mate2 unit features an easy to use menu-driven
LCD display. The menus, control features, and circuit board details are described in this section.
Detailed information concerning controls (4.0 - System Performance Microprocessor Controls) and alarms (5.0 - Alarms) are provided.
3.1
Feature Overview
To turn the unit ON, press the ON/OFF (I/O) key after power is applied. To turn the unit OFF,
press the ON/OFF (I/O) key before power is disconnected.
The following control keys may be used to move through the menus, as prompted on the LCD display:
• ON/OFF (I/O) – turns unit on or off (top far left).
• Menu – Enables user to access the program menu to change control parameters, alarms, setback schedule, etc. (top near left).
• Increase (UP) – Raises the value of displayed parameter while in a set mode (setpoints, time,
etc.) (Arrow-top near right).
• Escape (ESC) – Allows user to move back to a previous menu (top far right).
• Alarm Silence/Help – If an alarm is present, pressing this keypad will silence he alarm. If this
key is pressed when no alarms are present, help text will appear (bottom near left).
• Decrease (DOWN) Arrow – Lowers the value of displayed parameter while in a set mode (bottom near right).
• Enter – After setting a control point, press “Enter” to store the information in the microprocessor (bottom far right).
Figure 16 Wallbox
Active alarms are displayed on the LCD screen and sound an audible beeper. To silence an alarm,
press the Alarm Silence/Help key as prompted on the display.
Setpoints, DIP switch settings, and other selections were made during factory testing of your unit
and are based upon typical operating experience. (Other default selections were made according
to options included with your unit). MAKE ADJUSTMENTS TO THE FACTORY DEFAULT
SELECTIONS ONLY IF THEY DO NOT MEET YOUR SPECIFICATIONS.
Allowable ranges are displayed by pressing the help key. A password will be required (if enabled)
to change setpoints, time delays, etc.
The display normally shown includes the present room temperature, humidity, active status functions (cooling, heating, dehumidifying, humidifying), and active alarms. The Status Display may
also be selected from the Main Menu.
31
Microprocessor Control
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3.16
Custom Text
To modify the two custom alarm messages select “CUSTOM TXT”. Then select “CUS TXT #1” or
“CUS TXT #2”. Text can be up to 20 characters in length and can be either a blank space or any of
the following alphanumeric characters and symbols:
• A,B,C,D,E,F,G,H,I,J,K,L,M,N,O,P,Q,R,S,T,U,V,W,X,Y,Z
• #,%,*,• 0,1,2,3,4,5,6,7,8 or 9
Use the Up/Down Arrows to select a character, then press Enter. The cursor will move to the
next space where you may once again use the Up/Down Arrows to select another character, etc.
LCD Contrast
The level of contrast due to the viewing angle of the Liquid Crystal Display (LCD) can be adjusted
using a potentiometer screw, inside the wall box next to the display.
Nonvolatile Memory
All critical information is stored in nonvolatile memory. Setpoints, setup parameters, and component run hours are kept inside the microcontroller in EEPROM.
Equipment Options Switches
Equipment options are selected and enabled using DIP switches 1 through 7. These are located on
the control board near TB1. These switches are factory set and should not require any user
changes. The setting and function of the switches can be individually read on the LCD.
NOTE
In order to update the DIP switch settings, power must be cycled off, then
on, from the unit disconnect switch.
Table 20
Switch
Equipment Switch Settings (Unit Control Board)
OFF Position
ON Position
1
Compressor
Chill Water
2
Staged Reheat
SCR Reheat
3
Not Used—Must remain in OFF position
4
Not Used—Must remain in OFF position
5
Enable Reheat
6
Enable Humidifier
Disable Humidifier
7
Enable Dehumidifier
Disable Dehumidifier
8
Electric Reheat
Gas Reheat
Table 21
Switch
Disable Reheat
Switch Settings (Wallbox Board)
OFF Position
ON Position
1
Disable Beeper
2
Not Used—Must remain in OFF position
Enable Beeper
3
Not Used—Must remain in OFF position
4
Not Used—Must remain in OFF position
5
Not Used—Must remain in OFF position
6
Not Used—Must remain in OFF position
7
Disable Setback
Enable Setback
8
Enable Password
Disable Password
Microprocessor Control
37
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4.0
SYSTEM PERFORMANCE MICROPROCESSOR CONTROLS
This section provides a detailed description of how the Mini-Mate2 responds to operator inputs
and room conditions.
4.1
Temperature Control
4.1.1
Cooling/Heating Required
The temperature control program for the microprocessor is based on a calculated percentage
requirement for cooling/heating.
4.1.2
Cooling Operation (Cooling, Compressorized Direct Expansion and Chilled Water)
Cooling is ACTIVATED when the temperature control calculates a requirement for cooling of
100%. It is DEACTIVATED when the cooling requirement drops below 50%. The optional hot gas
bypass is energized when a call for cooling occurs, unless there is also a call for dehumidification.
Table 22 Cooling and Dehumidification Load Response of Hot Gas Bypass
Situation
4.1.3
Response
Cooling only
ON
Dehumidification only
OFF
Cooling with Dehumidification
OFF
Heating Operation
Electric Heat or Hot Water
The reheat stage is ACTIVATED when the temperature control calculates a requirement of 100%.
Conversely, the reheat is DEACTIVATED when the heat requirement is 50% less than the activation point.
Ground Current Detector (GCD)
A Ground Current Detector is factory-installed on all 1-ton through 3-ton Mini-Mate2 units with
reheat. The GCD detects reheat leakage current and shuts down operation of the reheat. A steady
green LED indicates that the reheat is operating properly. A red LED indicates that the reheat
has failed and both the reheat element and GCD need to be replaced.
!
WARNING
DO NOT REMOVE OR DISABLE THE GROUND CURRENT DETECTOR.
FAILURE TO LEAVE THE GCD IN PLACE COULD RESULT IN SMOKE OR
FIRE.
System Performance Microprocessor Controls
41
SCR Electric Reheat
The SCR (Silicon Controlled Rectifier) controller proportionally controls the stainless steel reheat
feature to maintain the selected room temperature. The rapid cycling made possible by the SCR
controller provides precise temperature control, while the constant element temperature improves
heater life. During operation of the SCR control, THE COMPRESSOR OPERATES CONTINUOUSLY. The heaters are modulated to provide temperature control. The display status will show
when the unit is cooling and heating. The control will automatically lock the compressor cooling to
“ON” position, except when the temperature falls below the low temperature alarm setpoint. Cooling will then be disabled until the room temperature reaches this minimum temperature setpoint.
4.2
Humidity Control
4.2.1
Dehumidification/Humidification Required
The humidity control is based on a calculated percentage requirement for dehumidification or
humidification (i.e., the difference between the return air humidity and the humidity setpoint). As
the return air humidity rises above the humidity setpoint, the percent dehumidification required
increases proportionally from 0% to 100% over a humidity band equal to the humidity sensitivity
setting. The converse is true for percent humidification requirement.
4.2.2
Dehumidification Operation, Compressorized Direct Expansion (DX) Systems
Dehumidification with the standard configuration is accomplished by operating the compressor
without the hot gas bypass active. The fan will operate at low speed unless the cooling requirement reaches 100%. At that point, the low speed fan is disabled (unless manually overridden by
the user) until the cooling requirement decreases to 0%. Dehumidification will also be disabled if
the heating requirement exceeds 125%. It will be re-enabled when the heating requirement
reaches 50%.
4.2.3
Humidification Operation
The canister humidifier is activated when the humidity control calculates a requirement of 100%
humidification, and it is deactivated when the humidification requirement falls below 50%.
4.3
Load Control Features
The control system monitors the compressor and prevents it from turning on within a 3-minute
period of being off. If this on-off-on cycle occurs too often (e.g., 10 times in a one-hour period), a
Short Cycle Alarm will occur.
4.3.1
Communications
The control system uses a two-wire, RS-422 channel to communicate with Liebert Site Products
via a proprietary protocol. A converter board (ECA2) is available to allow communications with a
“dumb” terminal or a computer using RS-232 channel. More details are provided in the Site Products and ECA2 user manual.
The communications channel provides both monitoring and control options, including:
•
•
•
•
TEMPERATURE/HUMIDITY: Current temperature and humidity readings.
STATUS (%): Cooling/heating and humidify/dehumidify operating status.
PRESENT ALARMS: Alarms currently activated.
SETPOINTS:
• Temperature Setpoint
• Temperature Sensitivity
• Humidity Setpoint
• Humidity Sensitivity
• High Temperature Alarm
• Low Temperature Alarm
• High Humidity Alarm
• Low Humidity Alarm
• ON/OFF STATUS
• SILENCE ALARM
42
System Performance Microprocessor Controls
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Ensuring The High Availability
0f Mission-Critical Data And Applications.
Emerson Network Power, the global leader in enabling business-critical
continuity, ensures network resiliency and adaptability through
a family of technologies—including Liebert power and cooling
technologies—that protect and support business-critical systems.
Liebert solutions employ an adaptive architecture that responds
to changes in criticality, density and capacity. Enterprises benefit
from greater IT system availability, operational flexibility and
reduced capital equipment and operating costs.
Technical Support / Service
Web Site
www.liebert.com
Monitoring
800-222-5877
[email protected]
Outside the US: 614-841-6755
Single-Phase UPS
800-222-5877
[email protected]
Outside the US: 614-841-6755
Three-Phase UPS
800-543-2378
[email protected]
Environmental Systems
800-543-2778
Outside the United States
614-888-0246
Locations
United States
1050 Dearborn Drive
P.O. Box 29186
Columbus, OH 43229
Europe
Via Leonardo Da Vinci 8
Zona Industriale Tognana
35028 Piove Di Sacco (PD) Italy
+39 049 9719 111
Fax: +39 049 5841 257
Asia
7/F, Dah Sing Financial Centre
108 Gloucester Road, Wanchai
Hong Kong
852 2572220
Fax: 852 28029250
While every precaution has been taken to ensure the accuracy
and completeness of this literature, Liebert Corporation assumes no
responsibility and disclaims all liability for damages resulting from use of
this information or for any errors or omissions.
© 2007 Liebert Corporation
All rights reserved throughout the world. Specifications subject to change
without notice.
® Liebert and the Liebert logo are registered trademarks of Liebert
Corporation. All names referred to are trademarks
or registered trademarks of their respective owners.
SL-10531_REV02_02-07
Emerson Network Power.
The global leader in enabling Business-Critical Continuity.
Embedded Computing
AC Power
Embedded Power
Connectivity
DC Power
Monitoring
Outside Plant
Power Switching & Controls
Precision Cooling
EmersonNetworkPower.com
Racks & Integrated Cabinets
Services
Surge Protection
Business-Critical Continuity, Emerson Network Power and the Emerson Network Power logo are trademarks and service marks of Emerson Electric Co.
©2007 Emerson Electric Co.