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 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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 ëïë 6\VWHPý:HLJKWV 7DEOHýç 8QLWý:HLJKWV &RROLQJý8QLWVóý OEV NJï 00'ëê( 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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. 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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 êïìæ 5XQý'LDJQRVWLFVýõ$YDLODEOHý2Qý5HYýìïííìïíô %\#VHOHFWLQJ#5XQ#'LDJQRVWLFV/#PDLQWHQDQFH#SHUVRQQHO#FDQ#FKHFN#V\VWHP#LQSXWV/#RXWSXWV/#DQG#FRQ0 GXFW#D#WHVW#RI#WKH#PLFURFRQWUROOHU#FLUFXLW#ERDUG#IURP#WKH#ZDOO#ER[#FRQWURO1#D#UHYLHZ#RI#WKH#V\VWHP# 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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. 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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.