A04_liebert-pdx-pcw-thermal-management-system-user-manual.pdf

Liebert® PDX™ and PCW™ Thermal Management Systems

Installer/User Guide 3 to 8 Ton (11 to 29 kW) Capacity, Upflow and Downflow, 60 Hz

Vertiv | Liebert® PDX™ andPCW™ Installer/User Guide

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If you encounter any installation or operational issues with your product, check the pertinent section of this manual to see if the issue can be resolved by following outlined procedures.

Visit https://www.Vertiv.com/en-us/support/ for additional assistance.

The information contained in this document is subject to change without notice and may not be suitable for all applications. While every precaution has been taken to ensure the accuracy and completeness of this document, Vertiv assumes no responsibility and disclaims all liability for damages resulting from use of this information or for any errors or omissions. Refer to other local practices or building codes as applicable for the correct methods, tools, and materials to be used in performing procedures not specifically described in this document.

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TABLE OF CONTENTS

Important Safety Instructions 1

1 Nomenclature and Components 11

1.1 Liebert® PDX Model-number Nomenclature 12

1.2 Liebert® PCW Model-number Nomenclature 13

1.3 Component Location 13

2 Pre-installation Preparation and Guidelines 15

2.1 Planning Dimensions 16

2.2 Considerations for Air Distribution 16

2.3 Connections and System Setup 17

2.4 Operating Conditions 17

2.4.1 Cooling, Humidification and Dehumidification 17

2.4.2 Heating 18

2.5 Shipping Dimensions and Unit Weights 18

3 Equipment Inspection and Handling 21

3.1 Packaging Material 22

3.2 Handling the Unit while Packaged 22

3.3 Unpacking the Unit 23

3.3.1 Removing the Unit from the Skid with a Forklift 24

3.3.2 Removing the Unit from the Skid Using Rigging 25

3.3.3 Moving the Unit with Piano Jacks 27

3.4 Placing the Unit on a Floor Stand 28

4 Piping and Refrigerant Requirements 29

4.1 Fluid Piping for Air-cooled, Water/Glycol-cooled and Chilled-water Piping Applications 30

4.1.1 Field-installed, Gravity-fed Drain Line Requirements 31

4.1.2 Water Supply-line Requirements for the Optional Humidifier 33

4.2 Refrigerant Piping and Charging 34

4.2.1 Refrigerant Piping Guidelines for Air-cooled Systems 35

4.2.2 Refrigerant Line Sizes and Equivalent Lengths 36

4.2.3 Refrigerant Charge Requirements for Air-cooled Systems 36

4.2.4 Evacuation, Leak-testing, and Charging Air-cooled Systems with TXV and without Receivers 39

4.2.5 Evacuation, Leak-testing, and Charging Air-cooled Systems with Liebert Lee-Temp™ “Flooded-condenser” Head-pressure Control System 44

4.2.6 Evacuation, Leak-testing and Charging Air-cooled Systems with EEV and Unheated Receivers 46

4.2.7 Superheat and Refrigerant Charge Optimization 48

4.3 Water/Glycol and Chilled-water Loop Piping Guidelines 50

4.3.1 Leak Checking for Unit and Field-installed Piping 51

i

5 Electrical Connections 53

5.1 Wye- and Delta-connected Power Supply for PDX and PCW 55

5.2 Supply Temperature Sensor 56

5.3 Return Air Sensor 56

5.3.1 Internal Temperature/Humidity Sensor 56

5.3.2 Remote Temperature/Humidity Sensor 56

5.4 2T Wired Remote Sensors 56

6 Checklist for Completed Installation 59

6.1 Moving and Placing Equipment 59

6.2 Electrical Installation Checks 59

6.3 Piping Installation Checks 59

6.4 Other Installation Checks 60

7 Initial Start-up Checks and Commissioning Procedure for Warranty Inspection 61

8 Maintenance 63

8.1 Filters 64

8.1.1 Filter-replacement for Downflow Units 64

8.1.2 Filter-replacement for Upflow Units 65

8.1.3 Filter-replacement for Upflow Units with Rear Return 65

8.2 Blower Drive System—EC Fans 66

8.2.1 Fan Impellers and Bearings Maintenance 67

8.2.2 Protective Features 67

8.2.3 Fan Assembly Troubleshooting 67

8.2.4 Replacing EC Fans in Downflow Models 71

8.2.5 Replacing EC Fans in Upflow Models 74

8.3 Infrared Humidifier Maintenance 78

8.3.1 Cleaning Humidifier Pan and Float Switch 78

8.3.2 Changing Humidifier Lamps 79

8.4 Steam-generating Humidifier Maintenance 80

8.4.1 Removing the Old Canister 82

8.4.2 Mandatory Cleaning of the Drain Valve 82

8.4.3 Installing the New Canister 83

8.4.4 Humidifier Troubleshooting 84

8.5 Condensate-drain and Condensate-pump System Maintenance 88

8.5.1 Condensate Drain 88

8.5.2 Condensate Pump 88

8.6 Air-Cooled Condenser and Drycooler Maintenance 88

8.7 Electric Reheat Maintenance 88

8.8 Thermostatic Expansion Valve (TXV) Maintenance 89

8.8.1 Determining Suction Superheat 89

8.8.2 Adjusting Superheat Setting with the TXV 89

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8.9 Electronic Expansion Valve (EEV) Maintenance 89

8.10 Compressor Maintenance 90

8.10.1 Compressor Oil 90

8.10.2 Scroll and Digital-scroll Compressor Maintenance 90

8.10.3 Replacement Compressors 90

8.10.4 Rotalock Valve on Scroll and Digital-Scroll Compressors 91

8.10.5 Unloading Solenoid(s) on a Digital-scroll Compressor 91

8.10.6 Compressor Electrical Failure (Motor Burnout) 92

8.10.7 Replacing a Compressor with Electrical Failure (Motor Burnout) 92

8.10.8 Compressor Mechanical Failure 93

8.10.9 Replacing a Compressor with Mechanical Failure 93

8.11 Facility Fluid and Piping Maintenance for Water and Glycol Systems 94

8.12 Glycol Solution Maintenance 94

8.13 Motorized Ball Valve (MBV) Maintenance (Digital-scroll Compressors) 94

8.13.1 MBV Control 95

8.13.2 MBV Control Method 95

8.13.3 MBV Adjustment 95

8.13.4 MBV Start-up 95

8.13.5 MBV Location 95

8.13.6 MBV Manual Control 95

8.14 Drycooler Aquastat Settings 96

9 Preventive Maintenance Checklist 97

Appendices 103

Appendix A: Technical Support and Contacts 103

Appendix B: Liebert PDX Model-number Detail 105

Appendix C: Liebert PCW Model-number Detail 108

Appendix D: Submittal Drawings 111 iii

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IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS

This manual contains important safety instructions that should be followed during the installation and maintenance of the Liebert® PDX/PCW. 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 factory-supplied disconnect switch is inside the unit. The line side of this switch contains live high-voltage. The only way to ensure that there is NO voltage inside the unit is to install and open a remote disconnect switch. Refer to unit electrical schematic. Follow all local codes.

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.

WARNING! Risk of electric shock. Can cause serious injury or death. The Liebert® iCOM 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 Liebert® iCOM 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.

Important Safety Instructions 1

WARNING! Risk of electric shock. Can cause serious 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 the fan-motor electric-connection enclosures. Fan-motor controls can maintain an electric charge for 10minutes after power is disconnected. Wait 10minutes after power is verified as off before working within the electric control/connection enclosures. Use only fully-trained and qualified HVAC technicians to perform maintenance on the fans.

WARNING! Risk of electric shock. Can cause injury or death. Open all local and remote electric power-supply disconnect switches and verify that power is Off with a voltmeter before working within the condensate pump electrical connection enclosure. The Liebert® iCOM™ 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 Liebert® iCOM.

WARNING! Risk of electric shock. Can cause serious injury or death. The Liebert® iCOM 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 Liebert® iCOM 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 over-pressurization of the refrigeration system. Can cause 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 fusible plug or other type of pressure-relief device in the system.

WARNING! Risk of contact with high-speed rotating fan blades. Can cause serious 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 or on the fan assembly. If control voltage is applied, the fan motor can restart without warning after a power failure. Do not operate the unit with any or all cabinet panels removed. Do not operate upflow units without installing a plenum, duct work or guard over the blower opening(s) on the top surface of the unit cabinet. Ductwork must be connected to the blower(s), or a plenum must be installed on the blower deck for protection from rotating blower wheel(s) on upflow units.

WARNING! Risk of top-heavy unit falling over. Improper handling can cause equipment damage, injury or death. Read all of the following instructions and verify that all lifting and moving equipment is rated for the weight of the unit before attempting to move, lift, remove packaging from or prepare the unit for installation. Unit weights are specified in Table 2.3 on page 19.

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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 who have been specially-trained in the installation of air-conditioning equipment and who are wearing appropriate, OSHA-approved PPE.

WARNING! Risk of improper wire sizing/rating 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 very heavy fan module dropping downward suddenly. Can cause injury or death. Only properly trained and qualified personnel should work on this equipment. The fan module weighs approximately 100 lb. (45.4 kg).

WARNING! Risk of improper humidifier-canister maintenance. Can cause smoke and fire, 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. See Table 8.4 on page 85, for alarm corrective actions.

WARNING! Risk of humidifier canister meltdown, smoke and fire. Can cause fire suppression system activation, fire and smoke alarm activation, building evacuation, dispatching of fire and rescue equipment and personnel and water leaks resulting in expensive equipment or building damage, injury or death. Check steam generating humidifier electrode plugs to ensure that they are pressed firmly onto pins. Loose connections will cause overheating of cylinder and plugs.

WARNING! Risk of explosive discharge of high-pressure refrigerant. Can cause serious injury.

Neutral and service ports on the rotalock valve do not have a valve core. Front-seat the service valves and relieve pressure from the compressor before loosening a part or a component attached to the service valve. Follow local codes to properly reclaim refrigerant.

Important Safety Instructions 3

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 improper moving, lifting and handling. Can cause equipment damage or injury. Only properly trained and qualified personnel should work on this equipment.

Evaporator fan modules weigh approximately 100 lb (45.4 kg). Use proper lifting techniques and wear appropriate, OSHA-approved PPE to avoid injury and dropping the fan module during removal. Equipment used in handling/lifting, and/or installing the fan assemblymust meet OSHA requirements. Use handling/lifting equipment rated for the weight of the fan assembly.

Use ladders rated for the weight of the fan assembly and technicians if used during installation.

Refer to handling/lifting, and/or installation equipment operating manual for manufacturer's safety requirements and operating procedures.

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 electronics housing, humidifier components, 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 extremely hot water and part surfaces. Can cause burn injury.

The infrared humidifier bulbs, metal enclosure, humidifier water, water reservoir pan and drain tubing are very hot during and shortly after operation. Allow sufficient time for these parts to cool to a touch-safe temperature before handling. Use extreme caution, and wear appropriate, OSHA-approved PPE when performing maintenance on the infrared humidifier.

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.

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CAUTION: Risk of handling heavy and lengthy parts. Can cause personal injury and equipment damage. Cabinet panels can exceed 5 ft. (1.5 m) in length and weigh more than 35 lb. (15.9 kg).

Follow relevant OSHA lifting recommendations and consider using a two-person lift for safe and comfortable removal and installation of cabinet panels. Only properly trained and qualified personnel wearing appropriate, OSHA-approved PPE should attempt to remove or install cabinet panels.

CAUTION: Risk of smoke generation. Can cause fire suppression and alarm system activation, resulting in injury during building evacuation and mobilization of emergency fire and rescue services. Start-up operation of optional electric reheat elements can create smoke or fumes that can activate the facility alarm and fire suppression system. Prepare and take appropriate steps to manage this possibility. Activating reheat during initial start-up may burn off particulates from electric reheat elements. Check the steam generating humidifier electrode plugs to ensure that they are pressed firmly onto the pins. Loose connections will cause the cylinder and plugs to overheat. Before beginning initial start-up checks, make certain that unit was installed according to the instructions in this manual. All exterior panels must be in place.

CAUTION: Risk of exposure to harmful noise levels. Can cause hearing injury or loss.

Depending on the installation and operating conditions, a sound pressure level greater than 70 dB(A) may arise. Take appropriate technical safetymeasures. Operating personnel must wear appropriate, OSHA-approved PPE and observe all appropriate hearing-protection safety requirements.

NOTICE

Risk of improper power-supply connection. Can cause equipment damage and loss of warranty coverage.

Prior to connecting any equipment to a main or alternate power source (for example: back-up generator systems) for start-up, commissioning, testing, or normal operation, ensure that these sources are correctly adjusted to the nameplate voltage and frequency of all equipment to be connected. In general, power-source voltages should be stabilized and regulated to within ±10% of the load nameplate nominal voltage. Also, ensure that no three-phase sources are single-phased at any time.

NOTICE

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

Liebert® PDX 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.

Important Safety Instructions 5

NOTICE

Risk of improper refrigerant charging. Can cause equipment damage.

Refrigerant charge must be weighed into air-cooled compressorized systems before they are started. Starting scroll and digital scroll compressors without proper refrigerant charging can cause the compressors to operate at less than 5°F (–15°C) evaporator temperature and at less than 20 psig (138 kPa). Operation for extended periods at less than 20 psig (138 kPa) can cause premature compressor failure.

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.

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Risk of piping-system corrosion and freezing fluids. Can cause leaks resulting in equipment and expensive building damage. Cooling coils, heat exchangers and piping systems are at high risk of freezing and premature corrosion. Fluids in these systems must contain an inhibitor to prevent premature corrosion.

The system coolant fluid must be analyzed by a competent fluid-treatment specialist before start up to establish the inhibitor level and evaluated at regularly scheduled intervals throughout the life of the system to determine the pattern of inhibitor depletion. The fluid complexity and variations of required treatment programs make it extremely important to obtain the advice of a competent and experienced fluid-treatment specialist and follow a regularly scheduled coolant-fluid system-maintenance program.

Fluid chemistry varies greatly 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 coolant fluid used must be considered, because 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 coolant fluid must be treated and circulating through the system continuously to prevent the buildup of deposits and/or growth of bacteria.

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

Consult fluid manufacturer for testing and maintenance of inhibitors.

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

Vertiv recommends 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 the cooling unit or piping 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.

Do not use galvanized pipe.

NOTICE

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.

Important Safety Instructions 7

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.

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.

NOTE: The Liebert® indoor cooling unit has a factory-installed high-pressure safety switch in the high-side refrigerant circuit. Consult local building codes to determine whether the Liebert® MCCondensers without receivers will require field-provided pressure-relief devices such as a fusible plug. A pressure-relief valve is provided with Liebert® Lee-Temp™ receivers and an integral, fusible plug is provided on PDX-EEV unheated receivers.

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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.

Important Safety Instructions 9

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1 NOMENCLATURE AND COMPONENTS

This section describes the model number for Liebert® PDX/PCW units and components.

Figure 1.1 Liebert PDX/PCW Views

Item Description

1 Top-discharge, front-return unit

2 Raised-floor discharge unit

3 3-way floor-level discharge unit

1 Nomenclature andComponents 11

1.1 Liebert® PDX Model-number Nomenclature

The tables below describe each digit of the 25-digit configuration number. The 14-digit model number consists of the first 10 digits and last 4 digits of the configuration number.

For the full description of configuration and model number refer to Liebert PDX Model-number Detail on page 105.

ModelNumber Digits 1 to 10 ModelDetails Model Number Digits 11 to 14

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

P X 0 2 9 D A 1 A D H 2 2 8 0 1 P L B F P A # # #

Table 1.1 PDX 25-digit Configuration Number

Digits 1 and 2 = Unit Family Digit 15 Coil, Valve Type & Pressure Rating1

Digit 3, 4, 5 = NominalCooling Capacity, kW Digit 16 = Enclosure Options

Digit 6 = Air Direction andDischarge Digit 17= High-voltage Options

Digit 7= System Type Digit 18 = Low-voltage Option Packages

Digit 8 = Fan Type Digit 19 = Monitoring

Digit 9 = Power Supply Digit 20 = Sensors

Digit 10 = Compressor & Valve (R-410A) Digit 21 = Packaging

Digit 11 = Humidifier Digit 22 = FactoryConfiguration code

Digit 12 = Display Digit 23-25 = FactoryConfigurationNumber

Digit 13 = Reheat N/A

Digit 14 = Air filter N/A

1. High-pressure MBValso results in high-pressure Econ-O-Coil valve.

Table 1.2 PDX Model-number Digit Summary

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1.2 Liebert® PCW Model-number Nomenclature

The tables below describe each digit of the 25-digit configuration number. The 14-digit model number consists of the first 10 digits and last 4 digits of the configuration number.

For the full description of configuration and model number refer to Liebert PCW Model-number Detail on page 108.

ModelNumber Digits 1 to 10 ModelDetails Model Number Digits 11 to 14

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

P W 0 2 9 D C 1 A D H 2 2 8 H 1 P L B F P A # # #

Table 1.3 PCW 25-digit Configuration Number

Digits 1 and 2 = Unit Family Digit 15 = Coil

Digit 3, 4, 5 = NominalCooling Capacity, kW Digit 16 = Enclosure Options

Digit 6 = Air Discharge Digit 17= High-voltage Options

Digit 7= System Type Digit 18 = Low-voltage Option Packages

Digit 8 = Fan Type Digit 19 = Monitoring

Digit 9 = Power Supply Digit 20 = Sensors

Digit 10 = ChilledWater Valve andPressure Digit 21 = Packaging

Digit 11 = Humidifier Digit 22 = FactoryConfiguration code

Digit 12 = Display Digit 23-25 = FactoryConfigurationNumber

Digit 13 = Reheat N/A

Digit 14 = Air filter N/A

Table 1.4 PCW Model-number Digit Summary

1.3 Component Location

The unit component locations are described in the submittal documents included in the Submittal Drawings on page 111.

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

Document Number Title

DPN003004 PDX Component Location Diagram, Downflow Models

DPN003005 PDX Component Location Diagram, Upflow Models

DPN003020 PCWComponent Location Diagram, Downflow Models

DPN003021 PCWComponent Location Diagram, Upflow Models

Table 1.5 Component-location Drawings

1 Nomenclature andComponents 13

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2 PRE-INSTALLATION PREPARATION AND GUIDELINES

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

Refer to Table B.2 on page 105, or Table B.4 on page 108, and submittal drawings to determine the type of system being installed and anticipate building alterations, piping and duct work needed.

The unit dimensions, pipe-connection locations, and piping schematics are described in the submittal documents included in the Submittal Drawings on page 111.

• Verify that the floor is level, solid and sufficient to support the unit. See Table 2.3 on page 19 for unit weights.

• Confirm that the room is properly insulated and has a sealed vapor barrier.

• For proper humidity control, keep outside or fresh air to an absolute minimum (less than 5% of total air circulated in the room).

• Do not install a Liebert® PDX/PCW in an alcove or at the end of a long, narrow room.

• Install the units as close as possible to the largest heat load.

• Allow at least the minimum recommended clearances for maintenance and service. See the appropriate submittal drawings for dimensions.

• We recommend installing an under-floor water detection system. Contact your Vertiv representative for information.

2 Pre-installation Preparation and Guidelines 15

2.1 Planning Dimensions

The unit, floor stand, and plenum dimensions are described in the submittal documents included in the Submittal Drawings on page 111.

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

Document Number Title

Downflow Units

DPN002936 Cabinet DimensionalData, Downflow Models

DPN002944 Cabinet DimensionalData, Downflow Floor LevelDischarge Models

Upflow Units

DPN002937 Cabinet DimensionalData, Upflow Models

DPN002971, pg. 1 Cabinet DimensionalData, Upflow Rear ReturnModels

Floor Stands

DPN002970 Floorstand& Floor PlanningDimensionalData, Downflow Models

DPN002971, pg. 2 FloorstandDimensionalData, Upflow Rear ReturnModels

Plenums

DPN002981 Plenum DimensionalData, Upflow Discharge Grille

DPN003697 Plenum DimensionalData, Upflow Discharge w/ Duct Collar

DPN003447 Plenum DimensionalData, TopDischarge Upflow Units

DPN003610 Downflow Plenum DimensionalData

DPN003757 Duct-flange Dimensions, Downflow models, Field-supplied duct work

Table 2.1 Dimension Planning Drawings

2.2 Considerations for Air Distribution

Depending on the intake/discharge configuration of the unit, consider the following when preparing for installation:

When installing a downflow unit with raised-floor discharge:

• Verify that the raised floor is properly sized for the unit’s airflow and the room is free of airflow restrictions.

• Perforated floor tiles in the raised floor should ensure minimal pressure loss.

• The raised floor must provide a minimum of 7-1/2 in. (191 mm) of clearance.

• Ensure that there is adequate clearance above the unit for return air.

• Provide clearance for service access, see DPN002936 in the Submittal Drawings on page 111.

When installing a downflow units with floor-level discharge:

• Provide several feet of clearance for air discharge of the unit.

• Ensure that there is adequate clearance above the unit for return air.

• Provide clearance for service access, see DPN002944 in the Submittal Drawings on page 111.

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When installing upflow units

• Provide several feet of clearance for intake and discharge of the unit or for supply and return ducting.

• Provide clearance for service access. See DPN002937 in the Submittal Drawings on page 111.

2.3 Connections and System Setup

• The unit requires a drain, which must comply with all applicable codes. This drain line may contain boiling water. See Field-installed, Gravity-fed Drain Line Requirements on page 31, for details.

• Three-phase electrical service is required for all models. Electrical service must conform to national and local electrical codes. See equipment nameplate for details.

• Plan the routing of wiring, piping and duct work to the unit. Refer to the appropriate piping connection location drawings, piping schematics, and electrical-connection drawings for your system in Submittal Drawings on page 111.

• Water/glycol and GLYCOOL units utilizing a drycooler may require an optional aquastat setting. See Table 8.7 on page 96 and Table 8.8 on page 96 for drycooler aquastat setting guidelines. Applications with the optional stat setting require field piping to be insulated to prevent condensation.

NOTE: Seal openings around piping and electrical connection to prevent air leakage. Failure to do so could reduce the unit’s cooling performance.

2.4 Operating Conditions

The Liebert® PDX/PCW must be operated in a conditioned space within the operating envelope that ASHRAE recommends for data centers. Operating the PDX/PCW outside of this envelope can decrease equipment reliability. Refer to ASHRAE’s publication, “Thermal Guidelines for Data Processing Environments.”

2.4.1 Cooling, Humidification and Dehumidification

For operation in the Cooling, Humidification or Dehumidification modes, the Liebert® PDX/PCW unit’s return-air requirements for proper unit operation are:

• Maximum dew point of 59°F (15°C).

• Minimum 68°F (20°C) DB.

• Maximum 85° (29.4°C) DB for humidification mode and maximum 100˚F (37.7°C) DB for cooling and dehumidification modes.

NOTE: Operating some PDX units equipped with Thermal Expansion Valves (TXVs) above 80 to 85°F (27 to 29.4°C) return air can cause the TXV to run out of stroke and result in an increase in superheat (above 20˚F) thus limiting the unit’s capacity.

2 Pre-installation Preparation and Guidelines 17

2.4.2 Heating

For operation in the Heating mode, the Liebert® PDX/PCW unit’s return-air requirements for proper unit operation are:

• Maximum dew point of 59°F (15°C).

• Maximum dry bulb of 80°F (27°C).

NOTE: Heating operation is not available when unit iCOM is set for Supply Air Control.

2.5 Shipping Dimensions and Unit Weights

ModelNumber

L x Wx H, in. (mm)

Domestic Export

PX011, PX018

PX023, PX029

PW011, PW017, PW029

44 x60 x85.5

(1118 x1524 x2172)

45 x60 x86

(1143 x1524 x2184)

Table 2.2 Shipping dimensions for Liebert PDX/PCW

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Model

Cooling Type Dry Unit Weight, lb

(kg) Shipping Weight Domestic, lb

(kg) Shipping Weight Export, lb

(kg)

PX011

Air 600 (272) 750 (340) 885 (401)

Air with Econ-O-Coil 700 (318) 850 (386) 985 (447)

Water/Glycol 620 (281) 770 (349) 905 (410)

Water/Glycolwith Econ-O- Coil 720 (327) 870 (395) 1005 (456)

GLYCOOL™

PX018

PX023

Air 670 (304) 820 (372) 955 (433)

Air with Econ-O-Coil 750 (340) 900 (408) 1035 (469)

Water/Glycol 690 (313) 840 (381) 975 (442)

Water/Glycolwith Econ-O- Coil 770 (349) 920 (417) 1055 (478)

GLYCOOL

PX029

Air 700 (317) 850 (385) 985 (446)

Air with Econ-O-Coil 790 (358) 940 (426) 1075 (487)

Water/Glycol 720 (327) 870 (395) 1005 (456)

Water/Glycolwith Econ-O- Coil 810 (367) 960 (435) 1095 (496)

GLYCOOL

PW011

ChilledWater

575 (261) 725 (379) 860 (390)

PW017 600 (272) 750 (340) 885 (401)

PW029 650 (294) 800 (362) 935 (423)

Table 2.3 Unit Weights—approximate

NOTE: See capacity tables for unit liquid volume. Consult your factory sales rep for additional component weight information.

2 Pre-installation Preparation and Guidelines 19

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3 EQUIPMENT INSPECTION AND HANDLING

SAFETY INFORMATION

WARNING! Risk of top-heavy unit falling over. Improper handling can cause equipment damage, injury or death. Read all of the following instructions and verify that all lifting and moving equipment is rated for the weight of the unit before attempting to move, lift, remove packaging from or prepare the unit for installation. Unit weights are specified in Table 2.3 on page 19.

WARNING! Risk of improper moving. Can cause equipment damage, injury or death. Use only lifting equipment that is rated for the unit weight by an OSHA-certified rating organization. The center of gravity varies depending on the unit size and selected options. The slings must be equally spaced on either side of the center of gravity indicator.

Shipping weights and unit weights are listed in the tables in Table 2.3 on page 19. Use the center of gravity indicators on the unit to determine the position of the slings.

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.

NOTICE

Risk of passageway interference. Can cause unit and/or structure damage. The unit may be too large to fit through a passageway while on or off 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. Keep the unit upright, indoors and protected from dampness, freezing temperatures and contact damage.

Upon arrival of the unit and before unpacking:

• Verify that the labeled equipment matches the bill of lading.

• Carefully inspect all items for visible or concealed damage.

• Report damage immediately to the carrier and file a damage claim with a copy sent to Vertiv or to your sales representative.

3 Equipment Inspection andHandling 21

Equipment Recommended for Handling the Unit:

• Forklift

• Pallet jack

• Piano jacks

• Slings

• Spreader bars

3.1 Packaging Material

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

3.2 Handling the Unit while Packaged

If possible, transport the unit with a forklift or pallet jack. If that is not possible, use a crane with slings and spreader bars that are rated for the weight of the unit.

When using a forklift or pallet jack:

• Ensure that the fork length is suitable for the unit length and, if adjustable, spread to the widest allowable distance that will fit under the skid.

• When moving the packaged unit, do not lift the unit any higher than 3 in. (76 mm). All personnel except those moving the unit must be kept 20 ft (5 m) or more from the unit while it is being moved.

• If the unit must be lifted higher than 3 in. (76 mm), all personnel not directly involved in moving the unit must be 20 ft (5 m) or farther from the unit.

• Always refer to the location of the center-of-gravity indicators when lifting the unit from any other side, see Figure 3.1 below.

Figure 3.1 Center-of-gravity indicator

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3.3 Unpacking the Unit

1. Ship-loose items, if ordered, are secured to the unit package with stretch wrap. Remove the stretch wrap and place the ship-loose box(es) to the side.

2. Remove the exterior stretch wrap packaging from around the unit and protective corner and side packaging, as shown in Figure 3.2 below.

3. Remove the protective top and side package pads from the unit, exposing the bag over the unit, see Figure 3.2 below.

NOTE: The bag may remain in place to protect from dust and to protect the unit panels, or it may be removed for immediate installation.

4. Remove the bag from the unit when ready to remove the skid and install the unit.

Figure 3.2 Unpacking the Unit

Item Description

1 Ship-loose items location, and removing exterior wrap from unit

2 Remove corner and side packaging planks

3 Leave the bag on the unit until ready to install.

3 Equipment Inspection andHandling 23

3.3.1 Removing the Unit from the Skid with a Forklift

1. Remove the panels from the unit, and remove the 4 bolts attaching the unit to the skid. They are inside unit base as shown in Figure 3.3 below.

Figure 3.3 Remove unit panels and bolts to skid

2. Align a forklift so the tines can be inserted under the unit.

3. Referring to Figure 3.4 below:

• Insert the tines of the forklift completely under the base and beyond the opposite side of the unit making sure they are level, not angled upward.

• Lift the unit off the skid to where the skid is not supporting the weight of the unit, and remove the skid.

4. To move the unit with piano jacks, keep the unit elevated, and refer to Moving the Unit with Piano Jacks on page 27.

Figure 3.4 Remove the unit from the skid with a forklift

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Item Description

1 Insert tines completely under base of unit.

2 Lift unit and remove skid.

3.3.2 Removing the Unit from the Skid Using Rigging

1. Remove the panels from the unit, and remove the 4 bolts attaching the unit to the skid. They are inside unit base as shown in Figure 3.3 on the previous page.

2. Place slings under the unit using the spaces provided between the skid deck boards. Use the center of gravity indicators on the unit to determine the position of the slings as shown in Figure 3.5 below.

NOTE: The unit is shown without packaging. You may refer to these steps to move the unit with rigging while the outer packaging is in place.

Figure 3.5 Center-of-gravity indicator and example sling placement

Item Description

1 Center-of-gravitymarker

2 Equal distance between sling andmarker.

3 Equipment Inspection andHandling 25

3. Referring to Figure 3.6 below:

• Use spreader bars or an equivalent device to protect the unit from crushing when it is lifted with the slings. Ensure that the unit’s panels, if the bag is removed, are protected from the slings.

NOTE: If rigging will be used to move the unit closer to the site for installation, place one or two horizontal straps around the unit at mid-height.

• Lift the unit off the skid to a point where the weight of the unit is not resting on the skid, and remove the skid from under the unit.

4. To move the unit with piano jacks, keep the unit elevated, and refer to Moving the Unit with Piano Jacks on the facing page.

Figure 3.6 Remove the unit from the skid with rigging

Item Description

1 Use spreader bars and protect unit from slings.

2 Lift unit so that weight is not on skid, and remove the skid.

3 Horizontal strap location, at mid-height of unit.

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3.3.3 Moving the Unit with Piano Jacks

1. With the unit raised by a forklift, pallet jack or rigging according to the previous instructions, position a piano jack on either side of the elevated unit, see Figure 3.7 below, then lower the unit to a height suitable for the piano jacks.

Figure 3.7 Lower unit to piano jacks

2. Place protective padding between the unit and the piano jacks and straps, then secure the unit to the piano jacks with the straps as shown in Figure 3.8 below.

Figure 3.8 Unit strapped to piano jacks

Item Description

2 Protective padding between piano jacks and straps.

3 Second piano jack on opposite side.

3 Equipment Inspection andHandling 27

3. Depending on the method used, lower the forklift tines and move the forklift away or remove the straps and move the rigging away.

4. Use the piano jacks to move the unit to the installation site.

• At least 2 properly-trained and qualified personnel are required to move the unit with piano jacks.

5. Once the unit is in the installation location, remove the unit from the piano jacks:

• Lower the unit as far as the piano jacks will allow.

• Undo all straps holding the unit to the piano jacks.

• Use a pry bar or similar device to lift one end of the unit enough to remove one piano jack.

• Repeat the previous step to remove the piano jack on the opposite end.

• Remove the padding used to protect the unit from the piano jacks and strapping.

3.4 Placing the Unit on a Floor Stand

Liebert® Floor Stand—Refer to the floor stand installation sheet shipped inside the floor stand package.

Lower the unit onto the floor stand.

NOTE: The floor stand for a Liebert® PDX/PCW is not symmetrical. Its orientation to the unit is critical for installation of the unit.

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4 PIPING AND REFRIGERANT REQUIREMENTS

All fluid and refrigeration connections to the unit, 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.

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

All piping below the elevated floor must be located so that it offers the least resistance to air flow. Careful planning of the piping layout under the raised floor is required to prevent the air flow from being blocked.

When installing piping on the subfloor, we recommend that the pipes be mounted in a horizontal plane rather than stacked one above the other. Whenever possible, the pipes should be run parallel to the air flow.

The pipe connection locations, piping general arrangement and schematics are described in the submittal documents included in the Submittal Drawings on page 111.

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

Document Number Title

Liebert® PDX Piping Schematics

DPN002929 Air CooledModels with TXV

DPN003954 Liebert®MCCondenser PositioningAbove/Same Level/Below Indoor Unit with TXV

DPN003843 Air CooledModels with EEV

DPN003993 Liebert®MCCondenser PositioningAbove/Same Level Indoor Unit with EEV

DPN002931 Water/GlycolModels

DPN002932 GLYCOOL™Models

DPN002972 Econ-O-CoilModels

Liebert® PCWPiping Schematics

DPN002930 ChilledWater Models

DPN003737 Hot Water Reheat

Table 4.1 Piping General-arrangment Drawings

Document Number Title

Downflow ModelPrimaryConnection Locations

DPN002938 Air Cooled, Raised Floor Models

DPN002945 Air Cooled, Front Discharge Models

DPN002942 Water/Glycol, Raised Floor Models

DPN002947 Water/Glycol, Front Discharge Models

Table 4.2 Piping Connection Drawings

4Piping andRefrigerant Requirements 29

Document Number Title

DPN003520 GLYCOOL™Raised Floor Models

DPN003522 GLYCOOL™Front Discharge Models

DPN002940 ChilledWater, Raised Floor Models

DPN002946 ChilledWater, Front Discharge Models

Upflow ModelPrimaryConnection Locations

DPN002939 Air CooledModels

DPN002943 Water/GlycolModels

DPN003521 GLYCOOL™Models

DPN002941 ChilledWater Models

Table 4.2 Piping Connection Drawings (continued)

4.1 Fluid Piping for Air-cooled, Water/Glycol-cooled and Chilled-water Piping Applications

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 air-cooled systems: refrigerant piping connections between the Liebert® PDX and the condenser. See Refrigerant Piping and Charging on page 34.

• On chilled-water systems: connections to the building chilled-water source.

• On water-glycol systems: connections to a water or glycol loop.

Vertiv | Liebert® PDX™…