A04_liebert-mini-mate2--5-tons-user-manual.pdf

Liebert® Mini-Mate2™ Thermal Management System

Installer/User Guide 5-ton Capacity, 50 and 60 Hz

Vertiv | Liebert® Mini-Mate2™ Installer/User Guide

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TABLE OF CONTENTS

1 Important Safety Instructions 1

1.1 Agency Listed 7

2 Nomenclature 9

2.1 Nomenclature for Evaporator and Chilled-water Units 9

2.2 Nomenclature for Split-system Condensing units 11

2.2.1 Indoor Condensing Units for Air-cooled Split Systems 11

2.2.2 Outdoor Prop-fan Condensing Units for Air-cooled Split Systems 12

2.2.3 Water/Glycol-cooled Condensing Units 13

2.3 System Configurations 14

3 Site Preparation and Equipment Handling 17

3.1 Planning Dimensions 17

3.2 Room Preparation 17

3.2.1 Duct work Considerations for the Indoor Air-cooled Condensing-unit 17

3.3 Application Limits 18

3.4 Location Considerations 18

3.4.1 Location Considerations for Evaporator, Indoor-condensing and Chilled-water Units 19

3.4.2 Location Considerations for an Outdoor Condensing Unit 20

3.5 Indoor Unit Weights 20

3.6 Equipment Inspection and Handling 21

3.7 Packaging Material 21

4 Installation 23

4.1 Installing Ceiling-mounted Evaporators and Condensing Units 23

4.1.1 Installing Suspension Rods and Mounting Ceiling Units 23

4.1.2 Close-coupled Installations for Indoor Condensing Units 25

4.2 Installing Air-distribution Components for Evaporators 25

4.2.1 Installing a Filter Box 26

4.2.2 Guidelines for Ducted Systems 27

5 Piping and Refrigerant Requirements 29

5.1 Fluid Piping Required 30

5.1.1 Drain Line Installation Requirements 30

5.1.2 Condensate-drain Pump Kit 32

5.1.3 Water-supply line to the Humidifier 33

5.1.4 Chilled-water Loop Piping 33

5.1.5 Water/Glycol Loop Piping 34

5.1.6 Free-cooling Coil Piping 35

5.1.7 Hot-water Reheat Coil Piping 35

5.2 Refrigerant Piping 36

5.2.1 Piping when Condensing Unit is Above or Below Evaporator 37 i

5.2.2 Refrigerant-line Sizes and Equivalent Lengths 38

5.2.3 Refrigerant Charge Requirements 39

5.2.4 Field-fabricated Refrigeration Piping 40

5.2.5 Evacuation and Leak-testing Air-cooled Systems 40

5.2.6 Charging Air-cooled Systems 42

5.2.7 Field Charge Verification for Air-cooled Systems 43

5.2.8 Documenting Refrigerant Charge on Air-cooled Units 44

5.2.9 Evacuation and Leak-testing Water/Glycol-cooled Systems 44

5.2.10 Charging Water/Glycol-cooled Systems 46

5.2.11 Optimizing Refrigerant Charge on Water/Glycol Units 47

5.2.12 Documenting Refrigerant Charge on Water/Glycol-cooled Units 47

6 Electrical Connection Requirements 49

6.1 Input-power Connection Requirements 50

6.2 Control-wiring Connection Requirements 51

6.2.1 Wall-box Controller Control Connections 51

6.2.2 Split-system Condensing-unit Control Connections 51

6.2.3 Water/Glycol-cooled Unit Control Connections 51

6.2.4 Additional Control Connections 51

7 Checklist for Completed Installation 53

8 Initial Start-up Checks and Commissioning Procedure for Warranty Inspection 55

9 Microprocessor Control 57

9.1 Controller Operation 57

9.1.1 Powering On/Off with Wall-mounted Display 58

9.1.2 Silencing an Audible Alarm 58

9.2 Main Menu <MENU> 59

9.2.1 Editing Setpoints 62

9.2.2 Viewing Unit Status 62

9.2.3 Viewing Active Alarms 63

9.2.4 Viewing Alarm History 63

9.2.5 Setting Controller Time 63

9.2.6 Setting Controller Date 63

9.2.7 Programming Setback 64

9.2.8 Editing Setup Operation 64

9.2.9 Changing Setpoint and Setup Passwords 66

9.2.10 Calibrating Sensors and Setting Sensor-response Delay 67

9.2.11 Enabling/Disabling Alarms 68

9.2.12 Setting Alarm Delays 68

9.2.13 Activating the Common Alarm Relay 69

9.2.14 Configuring Custom Alarms 70

9.2.15 Customizing Alarm-message Text 70

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9.2.16 LCD Display Contrast 70

9.2.17 Non-volatile Memory 71

9.2.18 Equipment Options DIP Switches 71

9.3 Running Diagnostics 72

9.3.1 Showing Test Inputs 72

9.3.2 Testing Outputs 72

9.3.3 Testing the Microcontroller 73

9.4 System Control and Performance 76

9.4.1 Temperature Control 76

9.4.2 Reheat 76

9.4.3 Humidity Control 78

9.4.4 Load Control 78

9.4.5 Monitoring 78

9.5 Alarm Notification, Acknowledgment and Descriptions 79

9.5.1 Custom Alarms 80

9.5.2 High Head-Pressure Alarm 80

9.5.3 Humidity-level Alarms 81

9.5.4 Temperature-level Alarms 81

9.5.5 Humidifier-problem Alarm 81

9.5.6 High-water Alarm 81

9.5.7 Loss-of-Power Alarm 82

9.5.8 Short Cycle Alarm 82

9.5.9 Loss of Water Flow Alarm 82

9.5.10 Change-filter Alarm 82

9.5.11 High-temperature Alarm 82

9.5.12 Smoke Alarm 82

10 Maintenance 83

10.1 System Testing 84

10.1.1 Environmental-control Function Tests 84

10.1.2 Cooling Test 84

10.1.3 Heating Test 84

10.1.4 Humidification Test 84

10.1.5 Dehumidification Test 84

10.1.6 Smoke Sensor Test 84

10.1.7 Remote Shutdown Test 85

10.2 Filter Maintenance 85

10.3 Electric Panel Maintenance 85

10.4 Belt-drive Blower Package Maintenance 85

10.4.1 Fan Impeller and Motor Bearing Maintenance 85

10.4.2 Air Distribution Inspection 85

iii

10.4.3 Motor Replacement 85

10.4.4 Removing the Blower from the Evaporator 86

10.5 Electric Reheat Maintenance 86

10.6 Refrigeration System Maintenance 86

10.6.1 Refrigeration Suction Pressure 86

10.6.2 Refrigeration Discharge Pressure 86

10.6.3 Thermostatic Expansion Valve (TXV) Maintenance 87

10.6.4 Air-Cooled Condensing Unit Maintenance 87

10.6.5 Hot Gas Bypass Operation and Maintenance 87

10.6.6 Coaxial Condenser Maintenance (Water/Glycol-cooled Condensers Only) 89

10.6.7 Regulating Valve Maintenance (Water/Glycol-cooled Condensers Only) 89

10.6.8 Glycol Solution Maintenance 89

10.7 Compressor Maintenance 90

10.7.1 Mechanical Failure of the Compressor 90

10.7.2 Electrical Failure of the Compressor 91

10.7.3 Replacement Compressors 91

10.7.4 Replacing a Failed Compressor 91

10.8 Steam-generating Humidifier Maintenance 92

10.8.1 Operating the Humidifier 93

10.8.2 Replacing the Canister 93

10.8.3 Circuit Board Adjustments 94

11 Preventive Maintenance Checklist 97

12 Troubleshooting 103

Appendices 107

Appendix A: Technical Support and Contacts 107

Appendix B: Submittal Drawings 109

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1 IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS

This manual contains important safety instructions that should be followed during the installation and maintenance of the Liebert® Mini-Mate2. Read this manual thoroughly before attempting to install or operate this unit.

Only qualified personnel should move, install or service this equipment.

Adhere to all warnings, cautions, notices and installation, operating and safety instructions on the unit and in this manual. Follow all installation, operation and maintenance instructions and all applicable national and local building, electrical and plumbing codes.

WARNING! Arc flash and electric shock hazard. Open all local and remote electric power-supply disconnect switches, verify with a voltmeter that power is Off and wear appropriate, OSHA-approved personal protective equipment (PPE) per NFPA 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 Liebert® controller does not isolate power from the unit, even in the “Unit Off” mode. Some internal components require and receive power even during the “Unit Off” mode of the controller. 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.

WARNING! Risk of electric shock. Can cause equipment damage, injury or death. Open all local and remote electric power supply disconnect switches and verify with a voltmeter that power is off before working within any electric connection enclosures. Service and maintenance work must be performed only by properly trained and qualified personnel and in accordance with applicable regulations and manufacturers’ specifications. Opening or removing the covers to any equipment may expose personnel to lethal voltages within the unit even when it is apparently not operating and the input wiring is disconnected from the electrical source.

1 Important Safety Instructions 1

WARNING! Risk of over-pressurization of the refrigeration system. Can cause piping rupture, explosive discharge of high-pressure refrigerant, loss of refrigerant, environmental pollution, equipment damage, injury, or death. This unit contains fluids and gases under high pressure.

Use extreme caution when charging the refrigerant system. Do not pressurize the system higher than the design pressure marked on the unit's nameplate. Relieve pressure before cutting into or making connections/disconnections to the piping system. Local building or plumbing codes may require installing a pressure-relief device in the system.

Consult local building and plumbing codes for installation requirements of additional pressure-relief devices when isolation valves are field installed. Do not isolate any refrigerant circuits from over pressurization protection. The PFH condensing units include a factory-installed pressure-relief valve mounted on top of the receiver. The valve is rated for a maximum working pressure of 475 psig.

WARNING! Risk of contact with high-speed, rotating fan blades. Can cause injury or death.

Open all local and remote electric power-supply disconnect switches, verify with a voltmeter that power is off, and verify that all fan blades have stopped rotating before working in the unit cabinet.

WARNING! Risk of electric shock. Can cause serious injury or death. The microprocessor does not isolate power from the unit, even in the "Unit Off" mode. Some internal components require and receive power even during the "unit off" mode of the control. Open all local and remote electric power disconnect switches and verify with a voltmeter that power is Off before working on any component of the system.

WARNING! Risk of improper wiring, piping, moving, lifting and handling. Can cause equipment damage, serious injury or death. Installation and service of this equipment should be done only by qualified personnel, wearing appropriate, OSHA-approved PPE, who have been specially-trained in the installation of air-conditioning equipment.

WARNING! Risk of improper wire and loose electrical connections. Can cause overheated wire and electrical connection terminals resulting in smoke, fire, equipment and building damage, injury or death. Use correctly sized copper wire only and verify that all electrical connections are tight before turning power On. Check all electrical connections periodically and tighten as necessary.

WARNING! Risk of ceiling collapse and heavy unit falling. Can cause building and equipment damage, serious injury or death. Verify that the supporting roof structure is capable of supporting the weight of the unit(s) and the accessories. See Indoor unit weights on page 20, for the unit weights. Securely anchor the top ends of the suspension rods and verify that all nuts are tight.

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WARNING! Risk of smoke and fire. Can cause activation of fire suppression systems, building evacuation, dispatching of fire/rescue equipment and personnel and catastrophic canister failure resulting in water leaks, equipment damage, injury or death. Using a humidifier canister that has reached the end of it’s service life can be extremely hazardous. If the canister cannot be replaced immediately at the end of life condition, turn Off the power and water supply to the humidifier and remove the canister until a replacement canister can be installed. Do not ignore humidifier problem alarms. Resetting humidifier without addressing cause may result in fire or damage due to leaking water.

CAUTION: Risk of excessive refrigerant line pressure. Can cause tubing and component rupture resulting in equipment damage and personal injury. Do not close off any field-installed refrigerant-line isolation valve for repairs unless a pressure-relief valve is field- installed in the line between the isolation valve and the check valve. The pressure-relief valve must be rated 5% to 10% higher than the system-design pressure. An increase in ambient temperature can cause the pressure of the isolated refrigerant to rise and exceed the system-design pressure rating (marked on the unit nameplate).

CAUTION: Risk of contact with sharp edges, splinters, and exposed fasteners. Can cause injury. Only properly trained and qualified personnel wearing appropriate, OSHA-approved PPE should attempt to move, lift, remove packaging from or prepare the unit for installation.

CAUTION: Risk of contact with hot surfaces. Can cause injury. The compressor, refrigerant discharge lines, fan motor, and some electrical components are extremely hot during unit operation. Allow sufficient time for them to cool to a touch-safe temperature before working within the unit cabinet. Use extreme caution and wear appropriate, OSHA-approved PPE when working on or near hot components.

CAUTION: Risk of contact with hot surfaces. Can cause burn injury. The humidifier canister and steam discharge lines are extremely hot during operation. Allow sufficient time for them to cool to a touch-safe temperature before handling. Use extreme caution and wear appropriate, OSHA-approved PPE when performing maintenance on the humidifier.

CAUTION: Risk of contacting caustic substances. Can cause injury. Avoid touching or contacting the gas and oils with exposed skin. Severe burns will result. Wear appropriate, OSHA-approved PPE when handling contaminated parts.

1 Important Safety Instructions 3

NOTICE

Risk of oil contamination with water. Can cause equipment damage.

Liebert® Mini-Mate2 DX systems require the use of POE (polyolester) oil. POE oil absorbs water at a much faster rate when exposed to air than previously used oils. Because water is the enemy of a reliable refrigeration system, extreme care must be used when opening systems during installation or service. If water is absorbed into the POE oil, it will not be easily removed and will not be removed through the normal evacuation process. If the oil is too wet, it may require an oil change. POE oils also have a property that makes them act as a solvent in a refrigeration system. Maintaining system cleanliness is extremely important because the oil will tend to bring any foreign matter back to the compressor.

NOTICE

Risk of clogged or leaking drain lines and leaking water-supply lines. Can cause equipment and building damage.

This unit requires a water drain connection. Drain lines must be inspected at start-up and periodically, and maintenance must be performed to ensure that drain water runs freely through the drain system and that lines are clear and free of obstructions and in good condition with no visible sign of damage or leaks. This unit may also require an external water supply to operate.

Improper installation, application and service practices can result in water leakage from the unit. Water leakage can result in catastrophic and expensive building and equipment damage and loss of critical data center equipment.

Do not locate unit directly above any equipment that could sustain water damage.

We recommend installing a monitored fluid-detection system to immediately discover and report coolant-fluid system and condensate drain-line leaks.

NOTICE

Risk of leaking water/glycol. Can cause equipment and building damage.

Improper installation, application, and service practices can result in water leakage from the unit. Do not mount this unit over equipment and furniture that can be damaged by leaking water. Install a water-tight drain pan with a drain connection under the cooling unit and the ceiling mounted water/glycol condensing unit. Route the drain line to a frequently-used maintenance sink so that running water can be observed and reported in a timely manner.

Post a sign to alert people to report water flowing from the secondary drain pan. We recommend installing monitored leak detection equipment for the unit and supply lines and in the secondary drain pan. Check drain lines periodically for leaks, sediment buildup, obstructions, kinks and/or damage and verify that they are free running.

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Risk of piping-system corrosion and freezing fluids. Can cause leaks resulting in equipment and very expensive building damage. Cooling coils and piping systems are at high risk of freezing and premature corrosion. Fluids in these systems must contain the proper antifreeze and inhibitors to prevent freezing and premature coil and piping corrosion. The water or water/glycol solution must be analyzed by a competent local water treatment specialist before start up to establish the inhibitor and antifreeze solution requirement and at regularly scheduled intervals throughout the life of the system to determine the pattern of inhibitor depletion.

The complexity of water/glycol solution condition problems and the variations of required treatment programs make it extremely important to obtain the advice of a competent and experienced water treatment specialist and follow a regularly scheduled coolant fluid system maintenance program.

Water chemistry varies greatly by location, as do the required additives, called inhibitors, that reduce the corrosive effect of the fluids on the piping systems and components. The chemistry of the water used must be considered, because water from some sources may contain corrosive elements that reduce the effectiveness of the inhibited formulation. Sediment deposits prevent the formation of a protective oxide layer on the inside of the coolant system components and piping. The water/coolant fluid must be treated and circulating through the system continuously to prevent the buildup of sediment deposits and or growth of sulfate reducing bacteria.

Proper inhibitor maintenance must be performed in order to prevent corrosion of the system.

Consult glycol manufacturer for testing and maintenance of inhibitors.

Commercial ethylene glycol, when pure, is generally less corrosive to the common metals of construction than water itself. It will, however, assume the corrosivity of the water from which it is prepared and may become increasingly corrosive with use if not properly inhibited.

We recommend installing a monitored fluid-detection system that is wired to activate the automatic-closure of field-installed coolant-fluid supply and return shut-off valves to reduce the amount of coolant-fluid leakage and consequential equipment and building damage. The shut-off valves must be sized to close-off against the maximum coolant-fluid system pressure in case of a catastrophic fluid leak.

NOTICE

Risk of frozen pipes and corrosion from improper coolant mixture. Can cause water leaks resulting in equipment and building damage.

When piping or the cooling unit may be exposed to freezing temperatures, charge the system with the proper percentage of glycol and water for the coldest design ambient temperature.

Automotive antifreeze is unacceptable and must NOT be used in any glycol fluid system. Use only HVAC glycol solution that meets the requirements of recommended industry practices.

1 Important Safety Instructions 5

Risk of no-flow condition. Can cause equipment damage. Do not leave the water/coolant fluid-supply circuit in a no-flow condition. Idle fluid allows the collection of sediment that prevents the formation of a protective oxide layer on the inside of tubes. Keep unit switched On and water/coolant fluid-supply circuit system operating continuously.

NOTICE

Risk of improper water supply. Can reduce humidifier efficiency or obstruct humidifier plumbing.

Do not use completely demineralized water with this unit. The water must contain minerals for the electrode principle to work.

Do not use a hot water source. It will cause deposits that will eventually block the fill-valve opening.

NOTICE

Risk of water backing up in the drain line. Leaking and overflowing water can cause equipment and building damage.

Do not install an external trap in the drain line. This line already has a factory-installed trap inside the cabinet. Installation of a second trap will prevent drain-water flow and will cause the water to overflow the drain pan.

This line may contain boiling water. Use copper or other material that is rated for handling boiling water for the drain line. Sagging condensate drain lines may inadvertently create an external trap.

NOTICE

Risk of doorway/hallway interference. Can cause unit and/or structure damage. The unit may be too large to fit through a doorway or hallway while on the skid. Measure the unit and passageway dimensions, and refer to the installation plans prior to moving the unit to verify clearances.

NOTICE

Risk of damage from forklift. Can cause unit damage. Keep tines of the forklift level and at a height suitable to fit below the skid and/or unit to prevent exterior and/or underside damage.

NOTICE

Risk of improper storage. Can cause unit damage.

Keep the unit upright, indoors and protected from dampness, freezing temperatures and contact damage.

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1.1 Agency Listed

Standard 60-Hz units are CSA Certified to the harmonized U.S. and Canadian product safety standard CSA C22.2 No 236/UL 1995 for “Heating and Cooling Equipment” and are marked with the CSA c-us logo.

1 Important Safety Instructions 7

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2 NOMENCLATURE

This section describes the model-number configuration for Liebert® Mini-Mate2 units and components.

2.1 Nomenclature for Evaporator and Chilled-water Units

Table 2.2 below describes each digit of the model number.

1 2 3 4 5 6 7 8 9 10 11 12

M M D 6 0 E N C R E L 5

Table 2.1 Nomenclature Example

Digit Description

Digits 1 and 2 = the base unit

MM= Mini-Mate2

Digit 3 = Disconnect

D = Disconnect switch

Digit 4 and 5 = NominalCapacity

60 = 60 kBtuh, 60 Hz evaporator

59= 59 kBtuh, 50 Hz evaporator

91 = 91 kBtuh, 50 Hz chilledwater

92 = 92 kBtuh, 60 Hz chilledwater

Digit 6 = Cooling type

C= Chilled-water cooled

E= Split-system evaporator (See Nomenclature for Split-system Condensing units on page 11.)

K = Split-system evaporator with free-cooling (See Nomenclature for Split-system Condensing units on page 11.)

Digit 7= Refrigerant/Valve type

N = R-407C field-charged, DX evaporator

2 = 2-way standard-pressure chilled-water valve

3 = 3-way standard-pressure chilled-water valve

D = 2-wayhigh-pressure chilled-water valve

T = 3-wayhigh-pressure chilled-water valve

Digit 8 = Supplypower

A= 460 V / 3 ph / 60 Hz

B = 575 V / 3 ph / 60 Hz

C= 208 V / 3 ph / 60 Hz

D = 230 V / 3 ph / 60 Hz

M= 380/415 V / 3 ph / 50 Hz

Table 2.2 Nomenclature Digit Definitions for Evaporator and Chilled-water units

2 Nomenclature 9

Digit Description

Digit 9 = Humidification

R = Remote Humidifier Contact (without canister humidifier)

J = Canister Humidifier andRemote Humidifier Contact

Digit 10 = Reheat

0 = No reheat

E= Electric reheat

S= SCR reheat (for DX evaporator without free-cooling option)

H= Hot-water reheat (chilled-water systems only)

Digit 11 = Blower type

L= Low-static blower, 1.5-hpmotor

H= High-static blower, 2-hpmotor

Digit 12 = Sensor packages

N = Base package of filter-clog and high-temperature sensor

1 = iCOMCMS (Mobile Cloud) +Base package

2 = Smoke sensor +Base package

3 = iCOM CMS (Mobile Cloud) +smoke sensor +Base package

4= IS-UNITY-DP (BMS) +Base Package

5 = IS-UNITY-DP (BMS) +Smoke sensor +Base package

Table 2.2 Nomenclature Digit Definitions for Evaporator and Chilled-water units (continued)

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2.2 Nomenclature for Split-system Condensing units

This section describes the model-number configuration for Mini-Mate2 split-system condensing units.

2.2.1 Indoor Condensing Units for Air-cooled Split Systems

Table 2.4 below describes each digit of the model number.

1 2 3 4 5 6 7 8 9 10

M C D 6 5 A L A H N

Table 2.3 Indoor, Air-cooled Condensing Unit Nomenclature Example

Digit Description

Digits 1 to 2 = the base unit

MC= Mini-Mate2 condensing unit

Digit 3 = Disconnect

D = Disconnect switch

Digit 4 and 5 = NominalCapacity

65 = 65 kBtuh, 60 Hz

64= 64kBtuh, 50 Hz

Digit 6 = Cooling type

A= Air-cooled

Digit 7= Head-pressure control

L= Liebert® Lee-Temp™Receiver

Digit 8 = Supplypower

A= 460 V / 3 ph / 60 Hz

B = 575 V / 3 ph / 60 Hz

M= 380/415 V / 3 ph / 50 Hz

Y = 208/230 V / 3 ph / 60 Hz

Digit 9 = Hot-gas bypass

H= Hot-gas bypass

Digit 10 = Refrigerant

N = R-407C field-charged

Table 2.4 Nomenclature Digit Definitions for Indoor, Air-cooled Condensing Units

2 Nomenclature 11

2.2.2 Outdoor Prop-fan Condensing Units for Air-cooled Split Systems

Table 2.6 below describes each digit of the model number.

1 2 3 4 5 6 7 8 9 10 11

P F H 0 6 7 A — A L N

Table 2.5 Prop-fan Condensing Unit Nomenclature Example

Digit Description

Digits 1 to 3 = the base unit

PFH= Prop-fan condensing unit with hot-gas bypass

Digit 4 = Sound level

0 = Standard

Z= Quiet-Line

Digit 5 and 6= NominalCapacity

66= 66 kBtuh, 50 Hz

67= 67kBtuh, 60 Hz

Digit 7= Cooling type

A= Air-cooled

Digit 8 = Coil type

— = Standard coil

C = Coated coil (epoxywith UV topcoat)

Digit 9 = Supplypower

A= 460 V / 3 ph / 60 Hz

B = 575 V / 3 ph / 60 Hz

M= 380/415 V / 3 ph / 50 Hz

Y = 208/230 V / 3 ph / 60 Hz

Digit 10 = Ambient rating/Control

L= 95°F Ambient, Liebert® Lee-Temp™

H= 105°F Ambient, Liebert® Lee-Temp™

Digit 11 = Refrigerant

N = R-407C field-charged

Table 2.6 Nomenclature Digit Definitions for Outdoor, Prop-fan Condensing Units

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2.2.3 Water/Glycol-cooled Condensing Units

Table 2.8 below describes each digit of the model number.

1 2 3 4 5 6 7 8 9 10

M C D 6 9 W 2 A H N

Table 2.7 Remote, IndoorWater/Glycol Condensing Unit Nomenclature Example

Digit Description

Digits 1 to 2 = the base unit

MC= Mini-Mate2 condensing unit

Digit 3 = Disconnect

D = Disconnect switch

Digit 4 and 5 = NominalCapacity

69= 69 kBtuh, 60 Hz

68 = 68 kBtuh, 50 Hz

Digit 6 = Cooling type

W= Water/Glycol-cooled

Digit 7= Head-pressure control

2 = 2-way standard-pressure fluid-regulating valve

3 = 3-way standard-pressure fluid-regulating valve

D = 2-wayhigh-pressure fluid-regulating valve

T = 3-wayhigh-pressure fluid-regulating valve

Digit 8 = Supplypower

A= 460 V / 3 ph / 60 Hz

B = 575 V / 3 ph / 60 Hz

M= 380/415 V / 3 ph / 50 Hz

Y = 208/230 V / 3 ph / 60 Hz

Digit 9 = Hot-gas bypass

H= Hot-gas bypass

Digit 10 = Refrigerant

N = R-407C field-charged

Table 2.8 Nomenclature Digit Definitions for Indoor, Water/Glycol-cooled Condensing Units

2 Nomenclature 13

2.3 System Configurations

The following figures show the available capacity and cooling options for the Liebert® Mini-Mate2.

Figure 2.1 Air-cooled Units

Item Description

1 Split-system (indoor condensing unit) with ducted supply/return air

2 Split-system (outdoor condensing unit) with ducted supply/return air

3 Evaporator

4 Indoor condensing unit

5 Outdoor condensing unit

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Figure 2.2 Water/Glycol-cooled Units

Item Description

1 Split-system water-cooledwith ducted supply/return air

2 Split-system glycol-cooledwith ducted supply/return air

3 Evaporator

4 Water/Glycol condensing unit

5 Cooling tower

6 Pump

7 Drycooler

Figure 2.3 Chilled-water Units

Item Description

1 Chilled-water unit with ducted supply/return air

2 Nomenclature 15

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3 SITE PREPARATION AND EQUIPMENT HANDLING

NOTE: Before installing unit, determine whether any building alterations are required to run piping, wiring and ductwork. Follow all unit dimensional drawings and refer to the submittal engineering dimensional drawings of individual units for proper clearances.

3.1 Planning Dimensions

The unit dimensions are described in the submittal documents included in the Submittal Drawings on page 109.

The following table lists the relevant documents by number and title.

Document Number Title

Split-system Evaporators/Chilled-water Units

DPN000218 Evaporator/Chilled-water Unit and Filter BoxOption Dimensions

Indoor CondensingUnits

DPN004422 Cabinet Dimensions, Air-cooled units

DPN004423 Cabinet Dimensions, Water/Glycol-cooled units

Table 3.1 Dimension Planning Drawings

3.2 Room Preparation

The room should be well insulated and must have a sealed vapor barrier. The vapor barrier in the ceiling and walls can be a polyethylene film. Paint on concrete walls and floors should be vapor resistant.

NOTE: The vapor barrier is the single most important requirement for maintaining environmental control in the conditioned area.

Outside or fresh air should be kept to a minimum when tight temperature and humidity control is required. Outside air adds to the site’s cooling, heating, dehumidifying and humidifying loads. Doors should be properly sealed to minimize leaks and should not contain ventilation grilles.

NOTE: Temperature and humidity sensors are located in the wall box. Proper and efficient cooling requires placing the wall box where discharge air does not directly blow on the sensors.

3.2.1 Duct work Considerations for the Indoor Air-cooled Condensing-unit

Observe the following when planning the installation of the indoor air-cooled condensing unit:

Ensure a satisfactory source of clean air for the condensing unit supply and a means to discharge the hot air without allowing the supply and discharge air to mix. Consider duct work to outdoor air. Duct work for outdoor air to and from the condensing unit is optional.

The total external static pressure for the inlet and outlet ducts, including grille, must not exceed 0.5 in. of water. Hood intake and duct-work cross-sectional area dimensions should be equal-to or greater-than the area of the condensing unit intake flange.

For all duct-work installation, see Guidelines for Ducted Systems on page 27

3 Site Preparation and Equipment Handling 17

3.3 Application Limits

Input voltage Range of return-air conditions to the unit*

Minimum Maximum Dry-bulb temperature Relative humidity

–5% +10% 65 to 85°F (18 to 29°C) 20 to 80%

*The unit will operate at these conditions, but it will not control to these condition extremes.

Table 3.2 Application Limits for Evaporator and Chilled-water Units

Input voltage

Condensing-unit type

Entering dry-bulb air temperature

Minimum Maximum Minimum Maximum

–5% +10% Outdoor Prop-fan condensing unit –30°F (–34°C) 120°F (49°C)

–5% +10% Indoor air-cooled condensing unit –20°F (–29°C) 115°F (46°C)

Table 3.3 Application Limits for Indoor and Outdoor Air-cooled Condensing Unit

Input voltage Entering fluid temperature

Minimum Maximum Minimum Maximum

–5% +10% 65°F (18°C)* 115°F (46°C)

*Operation below 65°F (18°C)may result in fluid noise and reduced valve life.

Table 3.4 Application Limits for IndoorWater/Glycol-cooled Condensing Unit

3.4 Location Considerations

When determining installation locations, consider that these units contain water and that water leaks can cause damage to sensitive equipment and furniture below.

NOTICE

Risk of leaking water/glycol. Can cause equipment and building damage.

Improper installation, application, and service practices can result in water leakage from the unit. Do not mount this unit over equipment and furniture that can be damaged by leaking water. Install a water-tight drain pan with a drain connection under the cooling unit and the ceiling mounted water/glycol condensing unit. Route the drain line to a frequently-used maintenance sink so that running water can be observed and reported in a timely manner.

Post a sign to alert people to report water flowing from the secondary drain pan. We recommend installing monitored leak detection equipment for the unit and supply lines and in the secondary drain pan. Check drain lines periodically for leaks, sediment buildup, obstructions, kinks and/or damage and verify that they are free running.

Vertiv | Liebert® Mini-Mate2™ Installer/User Guide18

3.4.1 Location Considerations for Evaporator, Indoor-condensing and Chilled-water Units

The evaporator or chilled-water unit is usually mounted above the suspended ceiling and must be securely mounted to the roof structure. For ducted systems, the evaporator may be located in a different room from the heat-producing equipment.

For a split system with an indoor condensing unit, the condensing unit may be:

• Installed above the suspended ceiling near the evaporator or closely-coupled with the evaporator.

• In any remote indoor area, subject to the requirements detailed in Pipe length and condensing unit elevation relative to evaporator on page 37.

Refer to Refrigerant-line Sizes and Equivalent Lengths on page 38 for maximum refrigerant line lengths.

The ceiling and ceiling supports of existing buildings may require reinforcement. Be sure to follow all applicable national and local codes.

Install the ceiling-mounting 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.

NOTE: Temperature and humidity sensors are in the wall box. Install the wall box where discharge air DOES NOT blow directly on the sensors.

Do not install units in areas where normal unit operating sound may disturb the working environment.

When installing an air-cooled or water/glycol-cooled unit inside a space, ensure that national and local codes are met for refrigerant concentration limits that might vary with building type and use.

3 Site Preparation and Equipment Handling 19

3.4.2 Location Considerations for an Outdoor Condensing Unit

For a split system with an air-cooled, outdoor condensing unit, the condensing unit may be mounted on the roof or remotely in any outdoor area.

Observe the following when planning the installation of the outdoor unit:

• To ensure a satisfactory air supply, locate air-cooled condensing units in an environment with clear air, away from loose dirt and foreign matter that may clog the coil.

• Condensing units must not be located in the vicinity of steam, hot air or fume exhausts or closer than 18 inches from a wall, obstruction or adjacent unit.

• Avoid areas where heavy snow will accumulate at air inlet and discharge locations.

• The condensing unit should be located for maximum security and maintenance accessibility.

Avoid ground-level sites with public access. Install a solid base, capable of supporting the weight of the condensing unit.

• The base should be at least 2 in. (51 mm) higher than the surrounding grade and 2 in. (51 mm) larger than the dimensions of the condensing-unit base. For snowy areas, a base of sufficient height to clear snow accumulation must be installed.

• Securely attach the unit to the base using the holes provided in the unit mounting rails to prevent unit movement that might stress refrigerant piping and electrical wiring.

Before beginning, refer to Piping and Refrigerant Requirements on page 29 for unit placement, piping guidelines, and refrigerant-charge requirements for your system.

The condensing unit must be located within the maximum distance from evaporator guidelines listed in Table 5.6 on page 37.

3.5 Indoor Unit Weights

Model# Weight, lb (kg)

CoolingUnits*

MMD60E 498 (226)

MMD59E 498 (226)

MMD92C 498 (226)

MMD91C 498 (226)

CondensingUnits

MCD65A 449 (204)

MCD64A 449 (204)

MCD69W 282 (128)

MCD68W 282 (128)

*Add 32 lb. (14 kg.) to units with free cooling or hot water reheat coils.

Table 3.5 Indoor unit weights

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3.6 Equipment Inspection and Handling

CAUTION: Risk of contact with sharp edges, splinters, and exposed fasteners. Can cause injury. Only properly trained and qualified personnel wearing appropriate, OSHA-approved PPE should attempt to move, lift, remove packaging from or prepare the unit for installation.

Do not un-crate the equipment until it is close to its final location. All required assemblies are banded and shipped in corrugated containers. If any damage is discovered when the unit is un-crated, report it to the shipper immediately. If any concealed damage is later discovered, report it to the shipper and to your Vertiv representative.

3.7 Packaging Material

All material used to package this unit is recyclable. Save it for future use or dispose of the material appropriately.

3 Site Preparation and Equipment Handling 21

Vertiv | Liebert® Mini-Mate2™ Installer/User Guide22

4 INSTALLATION

Refer to the appropriate installation procedures depending the configuration and options of your Liebert® Mini-Mate2 Thermal Management System.

4.1 Installing Ceiling-mounted Evaporators and Condensing Units

WARNING! Risk of ceiling collapse and heavy unit falling. Can cause building and equipment damage, serious injury or death. Verify that the supporting roof structure is capable of supporting the weight of the unit(s) and the accessories. See Indoor unit weights on page 20, for the unit weights. Securely anchor the top ends of the suspension rods and verify that all nuts are tight.

NOTICE

Risk of leaking water/glycol. Can cause equipment and building damage.

Improper installation, application, and service practices can result in water leakage from the unit. Do not mount this unit over equipment and furniture that can be damaged by leaking water. Install a water-tight drain pan with a drain connection under the cooling unit and the ceiling mounted water/glycol condensing unit. Route the drain line to a frequently-used maintenance sink so that running water can be observed and reported in a timely manner.

Post a sign to alert people to report water flowing from the secondary drain pan. We recommend installing monitored leak detection equipment for the unit and supply lines and in the secondary drain pan. Check drain lines periodically for leaks, sediment buildup, obstructions, kinks and/or damage and verify that they are free running.

4.1.1 Installing Suspension Rods and Mounting Ceiling Units

Refer to the Location Considerations on page 18 before beginning installation. These instructions apply to evaporators, indoor air-cooled condensing units, and indoor water/glycol-cooled condensing units.

NOTE: Follow all national and local building, electrical and plumbing codes.

• The ceiling and ceiling supports of existing buildings may require reinforcements.

• Four 3/8-in.-16 TPI threaded suspension rods are required and field supplied.

• The factory-supplied 3/8-in.-16 TPI hardware kit includes the remaining installation hardware.

• Recommended clearance between ceiling grids and building structural members is the unit’s height plus 3 in. (76 mm).

To install the suspension rods:

1. Install the 4 field-supplied 3/8-in.-16 TPI threaded rods by suspending them from suitable building structural members so that they will align with the 4 mounting locations on the unit base.

2. Securely anchor the top ends of the suspension rods with field-supplied nuts.

3. Make sure all nuts are tight and locked.

4 Installation 23

To lift and install the unit on the rods:

1. Using a suitable lifting device that is rated for the weight of the unit (see Indoor Unit Weights on page 20), raise the unit and pass the threaded rods through the 4 mounting locations in the unit base.

2. Attach the threaded rods to the flanges using the plain nuts to hold the unit in place as shown in Figure 4.1 below.

3. Slowly lower the lifting device, making sure that the rods securely hold the weight of the unit.

4. Adjust the plain nuts to distribute the weight of the unit evenly by the rods, making sure that the unit does not rest on the ceiling grid and that the unit is level.

NOTE: Evaporator units must be level to properly drain condensate. This does not apply to condensing units.

5. Use the Nylock nuts to "jam" the plain nuts in place as shown in Figure 4.1 below.

Figure 4.1 Installing threaded rods and hardware of ceiling-mounted units

Item Description Item Description

1 3/8-in. threaded rod, field-supplied 7 3/8-in. fender washer

2 3/8-in. hexnut 8 3/8-in. hexnut

3 3/8-in. washer 9 3/8-in. Nylock locking nut

4 Sleeve 10 Unit base pan (reference)

5 Bracket on unit

6 Isolator

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4.1.2 Close-coupled Installations for Indoor Condensing Units

You can mount the evaporator and indoor condensing units directly-next to each other, "close-coupled."

Close-coupled installations may take advantage of a single-point power kit to allow one power feed to provide input for both evaporator and condensing units.

To install close-coupled indoor units:

1. If you are using a single-point power kit:

• Install the single-point power box into the condensing unit before assembling the condensing unit to the evaporator and before raising the unit to the ceiling.

• Route power-wire flex conduit into condensing unit when raising units to ceiling.

• Refer to the instructions supplied with kit for details

2. Raise the units to the ceiling before connecting them. See Installing Suspension Rods and Mounting Ceiling Units on page 23.

3. Align the 4 bolt holes in the condensing unit with cage nuts provided on the evaporator.

4. Insert rubber spacers and secure with hardware (field-provided).

5. Align the refrigerant connections as shown in Figure 4.2 below.

6. Braze the refrigerant connections together as detailed in Refrigerant Piping on page 36.

Figure 4.2 Evaporator/Condensing-unit close-coupling connections

Item Description

1 Close-coupled connections

2 Spacer between evaporator and condensing unit in close-coupled installations

4.2 Installing Air-distribution Components for Evaporators

Your indoor units may include a filter box and ducting. Refer to the appropriate installation procedures for each.

4 Installation 25

4.2.1 Installing a Filter Box

The optional filter box attaches directly to the return-air opening of the evaporator.

The following is included:

• For the return-air opening, the filter box includes a 1-in. (25.4-mm) duct flange connection with two MERV 8 filters (per ASHRAE 52.2-2007), 20 in. x 20 in. x 4 in. (508 mm x 508 mm x 102 mm).

• For the supply-air opening, a 1-in. (25.4 mm) duct flange is included.

NOTE: Do not operate the unit without filters installed in return air system.

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4.2.2 Guidelines for Ducted Systems

Observe the following for all ductwork:

• Duct work should be fabricated and installed in accordance with local and national codes

• Use flexible ductwork or nonflammable cloth collars to attach ductwork to the unit and to control vibration transmission to the building.

• Attach the ductwork to the unit using the flanges provided.

• Locate the unit and ductwork so that the discharge air does not short-circuit to the return-air inlet.

• Duct work that runs through a conditioned space or is exposed to areas where condensation may occur must be insulated. Insulation of ductwork is vital to prevent condensation during the cooling cycle.

• The use of a vapor barrier is required to prevent absorption of moisture from the surrounding air into the insulation.

• If the return-air duct is short or if noise is likely to be a problem, sound-absorbing insulation should be used inside the duct.

• Duct work should be suspended using flexible hangers. Duct work should not be fastened directly to the building structure.

• For multiple-unit installations, space the units so that the hot condensing unit exhaust air is not directed toward the air inlet of an adjacent unit.

Consider the following in specific applications of ductwork to evaporator or chilled-water units:

• The evaporator unit is designed for 2500 CFM. Use Table 4.1 below, to adjust the blower speed for ESP created by ductwork to maintain 2500 CFM (4248 CMH).

Turns Open

1.5 hp Motor (60 Hz) 2.0 hp Motor (60 Hz)

Blower rpm External Static, in. Blower rpm External Static, in.

1 N/A N/A 1329 N/A

1.5 N/A N/A 1296 N/A

2 1037 0.9 1264 N/A

2.5 1005 0.7 1231 1.5

3 972 0.6 1199 1.4

3.5 940 0.5 1164 1.3

4 907 0.4 1134 1.2

4.5 875 0.3 1102 1.1

5 843 0.2 1069 1.0

5.5 810 0.1 1037 0.9

6 778 0.0 1005 0.7

Table 4.1 Evaporator external static pressure

NOTE: Additional components such as a free-cooling coil, hot water reheat coil or high efficiency filters will reduce available static pressure.

4 Installation 27

Consider the following in specific applications of ductwork to condensing units:

• In applications where the ceiling plenum is used as the heat rejection domain, the discharge air must be directed away from the condensing unit air inlet and a screen must be added to the end of the discharge duct to protect service personnel. Locate the air discharge a minimum of 4 ft from an adjacent wall. Failure to do so may result in reduced air flow and poor system performance.

• If the condensing unit draws air from the outside of the building, rain hoods must be installed.

Hood intake and duct-work cross-sectional area dimensions should be equal-to or greater-than the area of the condensing unit intake flange. In addition, install a triple-layer bird screen over rain hood openings to eliminate the possibility of insects, birds, water, or debris entering the unit. Avoid directing the hot exhaust air toward adjacent doors or windows.

• Condensing-unit fan operation is designed for 3500 CFM (5947 CMH).

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5 PIPING AND REFRIGERANT REQUIREMENTS

All field-supplied refrigeration piping to the unit must be sweat copper. Use prevailing good piping practices for all connections which include brazing copper pipes using a brazing alloy of minimum temperature of 1350 °F (732 °C) and adhering to all local codes. All other fluid connections to units, with the exception of the condensate drain, are sweat copper. Factory-installed piping brackets must not be removed. Field-installed piping must be installed in accordance with local codes and must be properly assembled, supported, isolated and insulated. Avoid piping runs through noise-sensitive areas, such as office walls and conference rooms.

The following pipe connections are required:

• A drain line from the evaporator coil drain pan.

• A drain line from the secondary drain pan (if applicable).

• A water-supply line to the optional humidifier (if applicable).

• On split-systems systems: refrigerant piping connections between the evaporator unit and the condensing unit.

• On chilled-water systems: connections to the building chilled-water source. See Chilled-water Loop Piping on page 33, for additional requirements.

• On water/glycol systems: connections to a water or glycol loop. See Water/Glycol Loop Piping on page 34, for additional requirements.

Refer to specific text and detailed diagrams in this manual for other unit-specific piping requirements.

The pipe connection locations, piping general arrangement and schematics are described in the submittal documents included in the Submittal Drawings on page 109.

The following tables list the relevant documents by number and title.

Document Number Title

DPN004412 GeneralArrangement, Water/Glycol-cooled

DPN004413 GeneralArrangement, Air-cooled andChilled-water

DPN000219 GeneralArrangement, Freecooling andHot-water reheat options

Table 5.1 Piping General-arrangement Drawings

Document Number Title

Evaporator andChilled-water Units

DPN004304 PipingConnections

Split-system Indoor CondensingUnits

DPN004422 PipingConnections, Air-cooled units

DPN004423 PipingConnections, Water/Glycol-cooled units

Table 5.2 Piping Connection Drawings

5 Piping andRefrigerant Requirements 29

5.1 Fluid Piping Required

5.1.1 Drain Line Installation Requirements

NOTICE

Risk of water backing up in the drain line. Leaking and overflowing water can cause equipment and building damage.

Do not install an external trap in the drain line. This line already has a factory-installed trap inside the cabinet. Installation of a second trap will prevent drain-water flow and will cause the water to overflow the drain pan.

This line may contain boiling water. Use copper or other material that is rated for handling boiling water for the drain line. Sagging condensate drain lines may inadvertently create an external trap.

A 3/4 in. (19.1 mm) NPT-female connection is provided for the evaporator-unit condensate drain. This connection also drains the humidifier if applicable. The evaporator drain pan includes a float switch to prevent unit operation if the drain becomes blocked.

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Observe the following requirements and refer to Figure 5.1 below, when installing and routing the drain line:

• The drain line must be sized for 2 gpm (7.6 l/m) flow.

• The drain line must be located so it will not be exposed to freezing temperatures.

• The drain should be the full size of the drain connection.

• The drain line must slope continuously away from the unit.

• Do not externally-trap the drain line.

• The drain line must be rigid enough that it does not sag between supports, which unintentionally creates…