Liebert_Mini-Mate2_User_Manual.pdf

Precision Cooling For Business-Critical Continuity™

Liebert Mini-Mate2™

User Manual - 2 & 3 Tons, 50 & 60Hz i

TABLE OF CONTENTS

IMPORTANT SAFETY INSTRUCTIONS

PRODUCT NUMBER NOMENCLATURE

1.0 INTRODUCTION

1.1 Designed to Match Computer and Electronic Equipment Needs—From Installation to Operation

2.0 STANDARD FEATURES—2 & 3 TON SYSTEMS

2.1 Evaporator Section - Split Systems

2.2 Condensing Unit Section—Split Systems

2.2.1 Indoor Centrifugal Fan Condensing Units

2.2.2 Outdoor Prop Fan Condensing Units

2.2.3 Indoor Water/Glycol Condensing Units

2.3 Chilled Water Units

2.4 System Controls

2.4.1 Other Standard Control Features

3.0 OPTIONAL FACTORY-INSTALLED FEATURES—EVAPORATOR/CHILLED WATER UNITS

3.1 Reheat

3.2 Humidifier

3.3 Sensors

3.4 Switches and Motors

3.5 Free-Cooling

3.6 Optional Configurations—Prop Fan Condensing Units

3.7 Optional Configurations—Water/Glycol Condensing Units

3.8 Optional Configurations—Chilled Water Units

4.0 SHIP-LOOSE ACCESSORIES—FIELD-INSTALLED

4.1 Remote Monitoring, Autochangeover and Leak Detection Equipment

5.0 SITE PREPARATION AND INSTALLATION

5.1 Installation Considerations

5.1.1 System Configurations

5.1.2 Room Preparation

5.1.3 Location Considerations

5.2 Ceiling Unit Weights

5.3 Equipment Inspection—Upon Receipt

5.4 Packaging Material

5.5 Installing the Ceiling Units

5.5.1 Close-Coupled Installations

5.5.2 Evaporator Air Distribution

5.5.3 Piping Connections and Coolant Requirements

5.5.4 Condensate Pump Kit Installation—All Units

5.5.5 Electrical Connections

ii

5.6 Indoor Air-Cooled Centrifugal Fan Condensing Unit Installation

5.6.1 Location Considerations

5.6.2 Electrical Connections

5.6.3 Piping Connections

5.6.4 Ducting

5.7 Outdoor Air Cooled Condensing Unit Installation

5.7.1 Location Considerations

5.7.2 Piping Connections

5.7.3 Electrical Connections

5.8 Water and Glycol Cooled Condensing Unit

5.8.1 Location Considerations

5.8.2 Electrical Connections

5.8.3 Piping Connections

5.9 Optional Equipment Piping

5.9.1 Free-Cooling Coil

5.9.2 Hot Water Reheat Coil

5.10 Checklist for Completed Installation

6.0 MICROPROCESSOR CONTROL

6.1 Feature Overview

6.2 Main Menu <Menu>

6.3 Setpoints

6.4 Status

6.5 Active Alarms

6.6 Time

6.7 Date

6.8 Setback

6.9 Setup Operation

6.9.1 Restart Time Delay

6.9.2 C/F Degrees

6.9.3 Humidity Control Method

6.10 Change Passwords

6.11 Calibrate Sensors

6.12 Alarm Enable

6.13 Alarm Time Delay

6.14 Common Alarm Enable

6.15 Custom Alarms

6.15.1 Standard Custom Alarm Messages

6.16 Custom Text

6.17 Run Diagnostics (Available On Rev 1.001.0 and Higher)

7.0 SYSTEM PERFORMANCE MICROPROCESSOR CONTROLS

7.1 Temperature Control

7.1.1 Cooling/Heating Required

7.1.2 Cooling Operation (Cooling, Compressorized Direct Expansion and Chilled Water)

7.1.3 Heating Operation

iii

7.2 Humidity Control

7.2.1 Dehumidification/Humidification Required

7.2.2 Dehumidification Operation, Compressorized Direct Expansion (DX) Systems

7.2.3 Humidification Operation

7.3 Load Control Features

7.3.1 Communication

8.0 ALARMS

8.1 Standard Alarms: Definitions and Troubleshooting

8.1.1 Custom Alarms

8.1.2 High Head Pressure

8.1.3 Humidity Level

8.1.4 Temperature

8.1.5 Humidifier Problem Alarm

8.1.6 High Water Alarm

8.1.7 Loss of Power

8.1.8 Short Cycle

8.2 Optional/Custom Alarms

8.2.1 Change Filter

8.2.2 High Temperature Sensor

8.2.3 Smoke Detected

9.0 SYSTEM TESTING AND MAINTENANCE

9.1 System Testing

9.1.1 Environmental Control Functions

9.1.2 Cooling

9.1.3 Heating

9.1.4 Humidification

9.1.5 Dehumidification

9.1.6 High Temperature Sensor—Optional

9.1.7 Smoke Detector Sensor

9.1.8 Remote Shutdown

9.2 Maintenance

9.2.1 Electric Panel

9.2.2 Filters

9.2.3 Direct Drive Blower Package

9.2.4 High Static Belt Drive Blower Package (Option)

9.2.5 Refrigeration System

9.2.6 Humidifier Circuit Board Adjustments

9.3 Replacement Procedures

9.3.1 Compressor Replacement

9.3.2 Electrical Failure

9.3.3 Replacing the Humidifier Canister

10.0 MAINTENANCE INSPECTION CHECKLIST

11.0 TROUBLESHOOTING

iv

FIGURES

Figure 1 Model number nomenclature—Evaporator units Figure 2 Model number nomenclature—Air-cooled, indoor condensing units Figure 3 Model number nomenclature—Outdoor air-cooled prop fan condensing units Figure 4 Model number nomenclature—Water/glycol-cooled condensing units Figure 5 Model number nomenclature—Chilled water units Figure 6 Wall-box Figure 7 Free-cooling arrangement Figure 8 Air-cooled systems, 2 and 3 tons Figure 9 Water/glycol-cooled systems, 2 and 3 tons Figure 10 Chilled water systems, 3 tons Figure 11 Threaded rod and hardware kit installation Figure 12 Refrigerant piping diagram Figure 13 Dimensions, evaporator and chilled water units with direct drive blower Figure 14 Dimensions, evaporator units with optional belt drive blower assembly Figure 15 Evaporator and chilled water unit piping data Figure 16 Evaporator and chilled water unit electrical connections Figure 17 Close-coupled installation Figure 18 Indoor air-cooled centrifugal condenser dimensions and pipe connections Figure 19 Centrifugal condenser electrical connections Figure 20 Cabinet and floor planning dimensional data, outdoor condensing unit Figure 21 General arrangement (air- cooled condensing unit) Figure 22 Cabinet dimensions and piping data, water/glycol indoor condensing module Figure 23 General arrangement, water/glycol split systems Figure 24 Optional free-cooling coil (3-way valve) on water/glycol units Figure 25 Optional hot water reheat (two-way valve) Figure 26 Control key locations—all-mounted display box Figure 27 Control menu Figure 28 Control board (inside evaporator) Figure 29 Wall box board Figure 30 Ground current detector Figure 31 Hot gas bypass v

TABLES

Table 1 System configurations - 60Hz Table 2 System configurations - 50Hz Table 3 Application limits, evaporator and chilled water units* Table 4 Application limits, indoor and outdoor air-cooled condensing units Table 5 Application limits, indoor water/glycol-cooled condensing units Table 6 Ceiling unit weights Table 7 Cooling unit air flow at 0.3 IWG (75PA) ESP Table 8 Recommended refrigerant line sizes Table 9 Pipe length and condenser elevation relative to evaporator Table 10 Line charges - refrigerant per 100 ft. (30m) of Type L copper tube Table 11 Refrigerant charge in Liebert pre-charged R-407C line sets Table 12 Equivalent lengths for various pipe fittings, ft (m) Table 13 Refrigerant charge Table 14 Connection sizes and torque Table 15 Net weights—evaporator and chilled water units Table 16 Net weight, high static blower module Table 17 Indoor condensing unit airflow, CFM at 0.5 iwg esp Table 18 Centrifugal condenser dimensions, weights Table 19 Dimensions and net weights—air-cooled outdoor condensing units Table 20 Net weight, indoor water/glycol-cooled condensing unit Table 21 View default setpoints and allowable ranges Table 22 Microprocessor night and weekend setback Table 23 Setup functions, default values and allowable ranges Table 24 Alarm default time delays Table 25 Switch settings (wall box board) Table 26 Equipment switch settings (unit control board) Table 27 Cooling and dehumidification load response of hot gas bypass Table 28 External static pressure available Table 29 Typical discharge pressure Table 30 DIP switch settings for humidifier control board (2- and 3-ton unit Table 31 Troubleshooting vi

Important Safety Instructions

1 Liebert® Mini-Mate2™

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

! WARNING

Arc flash and electric shock hazard. Disconnect all electric power supplies and wear protective equipment per NFPA 70E before working within 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 microprocessor control 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.

The line side of the disconnect switch on the front of the unit 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 and check the internal power supply wires with a voltmeter. Refer to unit electrical schematic. Follow all applicable local and national electric codes.

! WARNING

Risk of explosive discharge from high-pressure refrigerant. Can cause injury or death.

This unit contains fluids and gases under high pressure. Relieve pressure before working with piping.

! WARNING

Risk of refrigerant system rupture or explosion from overpressurization. Can cause equipment damage, injury or death.

If a pressure relief device is not provided with the condenser unit, the system installer must provide and install a discharge pressure relief valve per local and national codes in the high side refrigerant circuit. Do not install a shutoff valve between the compressor and the field installed relief valve. Do not isolate any refrigerant circuits from overpressurization protection.

! WARNING

Risk of high-speed moving parts. Can cause injury or death.

Open all local and remote electrical power disconnect switches before working in the unit and component electrical enclosures.

! CAUTION

Risk of contact with hot surfaces. Can cause injury.

The compressors, refrigerant discharge lines, humidifiers and reheats are extremely hot during unit operation. Allow sufficient time for them to cool before working within the unit cabinet. Use extreme caution and wear protective gloves and arm protection when working on or near hot compressors, discharge lines, humidifiers and reheats.

Important Safety Instructions

Liebert® Mini-Mate2™ 2

NOTICE

Risk of a leaking coil due to freezing and/or corrosion. Can cause equipment and serious building damage.

Cooling coils and piping systems that are connected to open cooling towers or other open water/glycol systems are at high risk for freezing and premature corrosion. Fluids in these systems must contain the proper antifreeze and inhibitors to prevent freezing and premature coil corrosion. The water or water/glycol solution must be analyzed by a competent water treatment specialist before startup to establish the inhibitor requirement. The water or water/glycol solution must be analyzed every six months to determine the pattern of inhibitor depletion. The complexity of water-caused problems and their correction makes it important to obtain the advice of a water treatment specialist and follow a regularly scheduled maintenance program.

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 Liebert Mini-Mate2 upright, indoors and protected from dampness, freezing temperatures and contact damage.

! CAUTION

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

This unit requires a water drain connection. It may also require an external water supply to operate. Improper installation, application and service practice can result in water leakage from the unit. Water leakage can result in severe property damage and loss of critical data center equipment. Do not locate unit directly above any equipment that could sustain water damage. Emerson recommends installing leak detection equipment for 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.

! CAUTION

Risk of sharp edges, splinters and exposed fasteners. Can cause injury.

Only properly trained and qualified personnel wearing appropriate safety headgear, gloves, shoes and glasses should attempt to move the unit, lift it, remove packaging from or prepare the unit for installation.

Product Number Nomenclature

3 Liebert® Mini-Mate2™

PRODUCT NUMBER NOMENCLATURE

Figure 1 Model number nomenclature—Evaporator units

Figure 2 Model number nomenclature—Air-cooled, indoor condensing units

MM

D = Disconnect Switch 0 = No Disconnect Switch

MM = Liebert Mini-Mate2

Refrigerant 7 = R-407C

D 36 7 A H A

Blower Type D = Direct Drive

Internal Blower B = Belt Drive

External Blower

Supply Power P = 208/230V - 1 ph - 60Hz X = 277V - 1 ph - 60Hz S = 220V - 1 ph - 50Hz (3-ton only) A = 460V - 3 ph - 60Hz (3-ton only) Y = 208/230V - 3 ph - 60Hz (3-ton only) M = 380/415V - 3ph - 50Hz (3-ton only)

E

Unit Type E = Split Evaporator K = Split Evaporator with Free-Cooling

E D

Humidification H = Canister Humidifier 0 = No Humidifier R = Remote Humidifier Contact J = Canister Humidifier and Remote

Humidifier Contact

Reheat Type 0 = No Reheat E = Electric Reheat S = SCR Reheat (not available with free-cooling)

Sensor Packages 0 = None A = Filter Clog B = Smoke Sensor C = High-Temperature Sensor D = Filter Clog & Smoke Sensor E = Filter Clog & High-Temperature Sensor F = Smoke Sensor & High-Temperature Sensor G = Filter Clog, Smoke Sensor & High-Temperature Sensor

Nominal Capacity

MC

D = Disconnect Switch 0 = No Disconnect Switch

MC = Liebert Mini-Mate2 indoor condensing units

Refrigerant 7 = R-407C

H = Hot Gas Bypass

D 36 L A H 7 Head Pressure Controls L = Liebert Lee-Temp™ Receiver

Supply Power P = 208/230V - 1 ph - 60Hz X = 277V - 1 ph - 60Hz S = 220V - 1 ph - 50Hz (3-ton only) A = 460V - 3 ph - 60Hz (3-ton only) Y = 208/230V - 3 ph - 60Hz (3-ton only) M = 380/415V - 3ph - 50Hz (3-ton only)

A

Cooling Method A = Air-Cooled

Nominal Capacity 24 = 2-ton, 60Hz 35 = 3-ton, 50Hz 36 = 3-ton, 60Hz

Liebert® Mini-Mate2™ 4

Figure 3 Model number nomenclature—Outdoor air-cooled prop fan condensing units

Figure 4 Model number nomenclature—Water/glycol-cooled condensing units

PFH

Nominal Capacity, kBtuh

PF = Prop Fan Condensing Unit with Hot Gas Bypass

P = 208/230V - 1ph - 60Hz Y = 208/230V - 3ph - 60Hz (3-ton only) A = 460V - 3ph - 60Hz (3-ton only) B = 575V - 3ph - 60Hz (3-ton only) S = 220V - 1ph - 50Hz (3-ton only) M = 380/415V - 3ph - 50Hz (3-ton only)

0 37 A P L 7

L = 95°F Ambient, Liebert Lee-Temp™

H = 105°F High Ambient, Liebert Lee-Temp

0 = Std. Sound Level Z = Quiet-Line

— = Standard Coil C = Coated Coil

Cooling Method A = Air-Cooled

Refrigerant 7 = R-407C

MC

D = Disconnect Switch 0 = No Disconnect Switch

MC = Liebert Mini-Mate2 indoor condensing units

Refrigerant 7 = R-407C

H = Hot Gas Bypass

D 38 2 A H 7 Head Pressure Controls 2 = 2-Way Standard Pressure Water Reg Valve 3 = 3-Way Standard Pressure Water Reg Valve D = 2-Way High-Pressure Water Reg Valve T = 3-Way High-Pressure Water Reg Valve

Supply Power P = 208/230V - 1 ph - 60Hz X = 277V - 1ph - 60Hz S = 220V - 1ph - 50Hz (3-ton only) A = 460V - 3ph - 60Hz (3-ton only) Y = 208/230V - 3ph - 60Hz (3-ton only) M = 380/415V – 3ph-50Hz (3-ton only)

W

Cooling Method W = Water/Glycol

Nominal Capacity 26 = 2-ton, 60Hz 37 = 3-ton, 50Hz 38 = 3-ton, 60Hz

5 Liebert® Mini-Mate2™

Figure 5 Model number nomenclature—Chilled water units

MM

D = Disconnect Switch 0 = No Disconnect Switch

MM = Liebert Mini-Mate2 Blower Type D = Direct Drive Internal Blower B = Belt Drive External Blower

Reheat Type 0 = No Reheat E = Electric Reheat H = Hot Water Reheat

D 40 3 A H EC

Cooling Method C = Chilled Water

Nominal Capacity 39 = 3-ton, 50Hz 40 = 3-ton, 60Hz

AD

Valve Type 2 = 2-Way Chilled Water Valve 3 = 3-Way Chilled Water Valve

Supply Power P = 208/230V - 1 ph - 60Hz X = 277V - 1ph - 60Hz S = 220V - 1ph - 50Hz A = 460V - 3ph - 60Hz Y = 208/230V - 3ph - 60Hz M = 380/415V – 3ph-50Hz

Humidification H = Canister Humidifier 0 = No Humidifier R = Remote Humidifier Contact J = Canister Humidifier and Remote

Humidifier Contact Sensor Packages 0 = None A = Filter Clog B = Smoke Sensor C = High-Temperature Sensor D = Filter Clog & Smoke Sensor E = Filter Clog & High-Temperature

Sensor F = Smoke Sensor & High

Temperature Sensor G = Filter Clog, Smoke Sensor & High-

Temperature Sensor

Introduction

Liebert® Mini-Mate2™ 6

1.0 INTRODUCTION

1.1 Designed to Match Computer and Electronic Equipment Needs—From Installation to Operation Installed above the ceiling, Liebert Mini-Mate2 Precision Cooling systems control the cooling, humidity and air distribution required by sensitive electronic equipment. A range of sizes and configurations is available to meet varying sites’ needs.

The Liebert Mini-Mate2 is also easy to use. Advanced microprocessor technology allows easy, precise control, and menu-driven monitoring keeps you informed of system operation through the LCD readout. These features, combined with Emerson quality construction and reliable components, guarantee satisfaction from installation through operation.

Liebert Precision Cooling Liebert Precision Cooling systems are designed to control the environment required for computers and other sensitive electronic equipment. The Liebert Mini-Mate2 provides complete control on an around-the-clock basis and the high sensible heat ratio required by sensitive electronic equipment.

Easy Installation The Liebert Mini-Mate2 is a split-system evaporator combined with an air-, water- or glycol-cooled condensing unit or is a self-contained, chilled water unit. Each split system has thermostat-type wiring to controls and condensing unit. System components are pre-charged with refrigerant and can be connected together with optional pre-charged line sets or optional sweat adapters for field refrigerant piping.

Easy to Service Low-maintenance components are easily accessed through removable front panels. Spare parts are always in Emerson inventory and available on short notice.

Advanced Control Technology A menu-driven microprocessor control system provides precise temperature and humidity control and accurate alarm setpoints. Using touch-sensitive buttons, the wall-mounted monitor/control panel allows you to select and display temperature and other monitored parameters.

High Efficiency High sensible heat ratio, scroll compressor and precise microprocessor control allow the system to operate efficiently.

Space Saving Design All indoor components are installed above the ceiling, so no floor space is required.

Reliable The Liebert Mini-Mate2 family installed base is a testimony to the system reliability. Components include a rugged scroll compressor, high-efficiency copper tube, aluminum-fin evaporator coil and a double inlet, direct drive fan.

Agency Listed Standard 60Hz 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.

Location When considering installation locations, consider that these units contain water and that water leaks can cause damage to sensitive equipment below. Do not mount these units above sensitive equipment. A field-supplied pan with drain must be supplied beneath cooling units and water/glycol condensers.

Do not mount units in areas where normal unit operating sound might disturb the working environment.

Standard Features—2 & 3 Ton Systems

7 Liebert® Mini-Mate2™

2.0 STANDARD FEATURES—2 & 3 TON SYSTEMS

2.1 Evaporator Section - Split Systems

The evaporator section is designed for ceiling installation. The cabinet and chassis are constructed of heavy gauge galvanized steel. The unit can be serviced using only one side increasing its versatility in mounting locations. Mounting brackets are factory-attached to the cabinet. Internal cabinet insulation meets ASHRAE 62.1 requirements for Mold Growth, Humidity & Erosion, tested per UL 181 and ASTM 1338 standards.

The evaporator section includes the evaporator coil, R-407C unit charge, filter-drier, factory-mounted disconnect switch, two-speed direct-drive blower assembly and microprocessor control with wall-mounted control box. The unit is provided with supply and return air openings for field-supplied ducting or supply/return plenum. Evaporators can be configured with canister humidifier and/or reheat. An indoor or outdoor condensing unit must be selected for each evaporator.

2.2 Condensing Unit Section—Split Systems

2.2.1 Indoor Centrifugal Fan Condensing Units

Indoor Air-Cooled Centrifugal Fan Condensing Units include scroll compressor, factory-mounted disconnect switch, condenser coil, R-407C unit charge, belt-driven centrifugal blower assembly, high-pressure switch, Liebert Lee-Temp™ head pressure control system, hot gas bypass and liquid-line solenoid valve. Unit must be mounted indoors. Condensing unit is designed to use outdoor air with temperatures ranging from -30°F to 95°F (-34°C to 35°C).

2.2.2 Outdoor Prop Fan Condensing Units

Outdoor Prop Fan Condensing Units include scroll compressor, condenser coil, R-407C unit charge, prop fan, liquid-line solenoid valve, high pressure switch, Liebert Lee-Temp head pressure control and hot gas bypass. Condensing unit is designed for outdoor locations with operating ambients ranging from -30°F to 95°F (-34°C to 35°C).

2.2.3 Indoor Water/Glycol Condensing Units

Indoor Water/Glycol Condensing Units includes scroll compressor, R-407C unit charge, factory-mounted disconnect, coaxial condenser, hot gas bypass, high head pressure switch and two-way water regulating valve designed for 150psi (1034.3kPa). Condensing units can be used on either a water or glycol cooling loop.

2.3 Chilled Water Units

Chilled Water Units are designed for ceiling installation. The cabinet and chassis are constructed of heavy gauge galvanized steel. The unit can be serviced using only one side increasing its versatility in mounting locations. Mounting brackets are factory-attached to the cabinet. Internal cabinet insulation meets ASHRAE 62.1 requirements for Mold Growth, Humidity & Erosion, tested per UL 181 and ASTM 1338 standards. Chilled water models are self-contained and include a chilled water coil, two-speed, direct-drive centrifugal blower, factory-mounted disconnect switch and two-way, slow-close motorized valve. Design pressure is 300psi (2068kPa), 60psi (414kPa) close-off differential.

Standard Features—2 & 3 Ton Systems

Liebert® Mini-Mate2™ 8

2.4 System Controls

System controls include a microprocessor control board mounted in the evaporator/chilled water unit and a wall-mounted interface with a two-line, 16-character liquid crystal display. An eight-key, membrane keypad for setpoint/program control, unit On/Off, fan speed and alarm silence is below the LCD screen. It provides temperature setpoint and sensitivity adjustment, humidity setpoint and sensitivity adjustment, digital display of temperature, humidity, setpoints, sensitivities, fan speed and alarm conditions.

The wall-box is field-wired to the microprocessor control using standard four-conductor thermostat wire (field-supplied). The temperature and humidity sensors are in the wall box, which can be installed up to 300 feet (91.4m) from the evaporator unit. The unit-mounted control board also includes common alarm terminals and shutdown terminals. The unit automatically restarts after a power outage.

Figure 6 Wall-box

2.4.1 Other Standard Control Features

• Adjustable auto restart • Calibrate sensors

• 5 day/2 day setback • Predictive humidity control

• Password protection • Common alarm output

• Alarm enable/disable • Remote shutdown terminals

• Self-diagnostics

Optional Factory-Installed Features—Evaporator/Chilled Water Units

9 Liebert® Mini-Mate2™

3.0 OPTIONAL FACTORY-INSTALLED FEATURES—EVAPORATOR/CHILLED WATER

UNITS

3.1 Reheat

Electric Reheat includes 304/304 stainless steel finned tubular reheat elements, with high limit safety switch.

SCR Electric Reheat uses an SCR controller and unit control software to provide full cooling with modulating of the electric reheat elements to control air temperatures. Reheat capacity is up-sized to offset the cooling capacity. (The SCR Electric Reheat is not available on chilled water, free-cooling or 575V units.)

Hot Water Reheat includes hot water coil, 2-way solenoid valve and Y-strainer.

3.2 Humidifier

The Canister Humidifier includes a steam-generating type humidifier with automatic flushing circuit, inlet strainer, drain, 1" (25.4mm) air gap on fill line and solenoid valves. Humidifier problem alarm annunciates at the wall-mounted display panel.

Remote Humidifier Contact allows the unit’s humidity controller to control a humidifier outside the unit. Power to operate the remote humidifier does not come from the Liebert Mini-Mate2.

Available on units with or without internal humidifier.

3.3 Sensors

Smoke Sensor checks return air, shuts down the unit upon sensing smoke and activates visual and audible alarms at the wall-box display. This smoke sensor is not intended to function as or replace any smoke sensor system that may be required by local or national codes.

High-Temperature Sensor senses the return air temperature and shuts down unit if the temperature reaches 125°F (52°C). This device is not meant to replace any fire detection system that may be required by local or national codes.

3.4 Switches and Motors

Filter Clog senses pressure drop across the filters and activates visual and audible alarms at the wall-box display. The wall-box display annunciates the alarm and flashes a notification upon reaching a customer setpoint.

A Factory-Installed Non-Fused Disconnect Switch allows unit to be turned off for maintenance.

A disconnect switch is standard for the evaporators, chilled water units and indoor condensing units, but these units may be specified without the switch.

Direct-Drive blower can be factory-eliminated from the evaporator/chilled water cabinet for high static applications (0.9 to 1.5in. [23 to 38mm] w.g.). See 4.0 - Ship-Loose Accessories—Field- Installed for the optional, externally mounted high static blower assembly.

NOTE

This option is available only on Chilled Water units, but not with other reheat options.

Optional Factory-Installed Features—Evaporator/Chilled Water Units

Liebert® Mini-Mate2™ 10

3.5 Free-Cooling

Free-cooling option includes separate cooling coil, three-way slow-close valve and separate supply and return piping. Free-cooling is activated when the water temperature reaches a field-adjustable temperature, typically 45°F (7°C). The valve is rated for 300psi (2068kPa) working pressure.

Air-cooled condensing units can be matched with evaporators using free-cooling coils with chilled water sources to serve as backup cooling. When matched with a water/glycol condensing unit, a three-way water regulating valve is recommended for the condensing unit to simplify piping to the main supply pipes. The coil is designed for closed-loop applications using properly treated and circulated fluid. Not available with SCR reheat options.

Figure 7 Free-cooling arrangement

3.6 Optional Configurations—Prop Fan Condensing Units

Outdoor Prop Fan Condensing Units are also available in the following optional configurations:

• High ambient models for providing catalog capacities at ambient temperatures up to 105°F (40°C).

• Quiet-Line models for low noise level conditions (below 56 dBA) and for providing catalog capacities at ambient temperatures up to 95°F (35°C).

• Condenser coils can be phenolic-coated for extended coil life in coastal areas.

3.7 Optional Configurations—Water/Glycol Condensing Units

Indoor Water/Glycol Condensing Units are also available with the following piping options:

• Two-way water reg. valve with 350 psi (2413kPa) design pressure.

• Three-way water reg. valve with 150psi (1034kPa) design pressure.

• Three-way water reg. valve with 350psi (2413kPa) design pressure.

3.8 Optional Configurations—Chilled Water Units

Chilled Water Units are also available with the following valve option:

• Three-way, slow-close, motorized chilled water valve rated for 300 psi (2068 kPa) working pressure. Valve is non-spring return.

NOTE

If free-cooling is applied to an open water tower, an optional copper-nickel (CuNi) coil is required to prevent premature corrosion, or a heat exchanger must separate the tower water from the free-cooling loop. The copper-nickel coil requires an extended lead time.

Free - Cooling Coil

Water/Glycol Condenser

Field Piping

Water Temperature Sensor

Liebert Mini-Mate2

Drycooler

Free-cooling option: A second cooling coil allows the system to take advantage of colder outdoor temperatures and bypass compressor operation.

When the water temperature goes below 45°F (7°C), cooling switches over to free-cooling operation. A separate chilled water source can also be used with air-cooled systems.

Ship-Loose Accessories—Field-Installed

11 Liebert® Mini-Mate2™

4.0 SHIP-LOOSE ACCESSORIES—FIELD-INSTALLED

A High Static Blower Assembly can be field-attached to the evaporator to provide up to 2.0" (51mm) of external static pressure on the discharge side of the evaporator. The blower box contains a centrifugal-type double-inlet blower. This blower is equipped with a belt drive and 1.5 hp single speed motor mounted to an adjustable motor base. Note: Unit must be ordered without the internal direct drive motor and the high static blower disables the two-speed fan operation feature.

Filter box kit (for ducted applications) includes filter box with duct flange connection, one MERV 8 (ASHRAE 52.2-2007) filter (20"x20"x4" [508mm x 508mm x 102mm]), and a duct flange for use on the supply air opening of the unit

Air Distribution Plenum includes molded plastic three-way discharge plenum, 16"x25"x4" (406mm x 535mm x 102mm) MERV 8 filter (ASHRAE 52.2-2007), and sheet metal block-off plates for covering the duct openings on the evaporator unit. Plenum mounting requires T-bar ceiling grid.

The Condensate Pump is field-mounted external to the cabinet, wired to the unit power block and is equipped with a check valve. A secondary float can be field-wired to shut down the unit upon high condensate level.

A Remote Temperature and Humidity Sensor package includes sensors in an attractive case with 30 ft. (9 m) of cable. Can be wall or duct mounted. Remote sensors should be used when the wall box is not located in the space to be conditioned.

Field-Installed Kits available for filter clog, smoke sensor, high-temperature sensor, electric reheat and humidifier. The kits include installation instructions and are designed to be added to the evaporator unit before it is installed in the ceiling. Electric reheat kits cannot be installed in units with free-cooling.

277-to-208V step-down transformer (37.5 amps) allows use of 277-1-60 supply power with a 208-1-60 Prop Fan Condensing unit. The transformer is coated with epoxy and contained in an enclosed, non-ventilated electrical box with adaptable mounting brackets.

Single-Point Power Kit contains the necessary electrical components to interconnect the high-voltage sections of a close-coupled evaporator and an MCD condensing unit.

Pre-Charged Refrigerant Line Set (R-407C) contains an insulated copper suction line and a copper liquid line for interconnection of the indoor and outdoor sections. Available in 15-foot (4.5m) and 30-foot (9m) sections.

The Refrigerant-Line Sweat Adapter Kit contains two suction and two liquid line fittings that allow field-supplied refrigerant piping between the evaporator and condensing unit.

Installing the remote sensors disables the sensors included in the wall box.

Ship-Loose Accessories—Field-Installed

Liebert® Mini-Mate2™ 12

4.1 Remote Monitoring, Autochangeover and Leak Detection Equipment

The Liebert RCM4™ is a four-point, normally open, dry contact monitoring panel. One Form-C, dry contact common alarm relay output (rated at 24 VAC, 3 Amp) is provided. Four red LEDs illuminate on the respective alarm and the alarm buzzer is silenced by a front panel switch. The RCM4 requires a 24VAC or 24VDC power source. Power supply is not included.

The Liebert AC4™ Autochangeover Controller provides autochangeover and autosequence control for up to four Liebert Mini-Mate2 units within a room. The Liebert AC4 will enable redundant units in an alarm condition, balance usage and test standby units at programmed intervals. Two common alarm relay outputs are available. A built-in LCD and RS-232 port for direct PC/terminal connection provides two options for configuration and monitoring of the product. The Liebert AC4 requires 24VAC input power.

The Liebert AC8™ is ideal for coordinated control of systems with redundant units. The Liebert AC8 enables redundant devices during an alarm condition, balances usage of devices and tests standby devices at programmable intervals. Supports four zones and can use the 4-20mA temperature sensor (TW420) for temperature staging in each zone. Two programmable output control relays are available for auxiliary control such as humidity lockout. Emergency power operation input provided for device control during an emergency. Two common alarm relay outputs are available. A built-in LCD and RS-232 port for direct PC/terminal connection provides two options for configuration and monitoring of the product.

The Liebert ENV-DO™ interface card provides 16 discrete outputs, corresponding to status and major alarm conditions of Environmental units. The Liebert ENV-DO-ENCL1 packages one Environmental DO interface card in its own steel enclosure and the ENV-DO-ENCL2 packages two Environmental DO interface cards in one enclosure for installation external to the Liebert Mini-Mate2. The self-contained kit includes an external 120VAC-to-24VAC power transformer.

Wiring harnesses are not provided. Power and communication wiring is field-provided.

The Liebert Liqui-tect® 410 Point Leak Detection Sensor detects the presence of conductive liquid using a pair of corrosion-resistant, gold-plated probes mounted in a painted, height-adjustable enclosure. Dual Form-C, dry contact common alarm relays (rated at 24VAC, 3A) signal a leak detected as well as loss of power and cable fault. The Liebert Liqui-tect 410 requires an external 24VAC or 24VDC power source.

Liebert LT460 Zone Leak Detection Kits include one LT460 sensor, a specified length of LT500-xxY cable (maximum length is 100 ft [30.5m]) and a corresponding number of hold-down clips.

The Liebert LT460 requires an external 24VAC, 0.12A power source, such as EXT-XFMR or XFMR24.

Liebert SiteScan® is a monitoring solution that gives you decision-making power to effectively manage the equipment critical to your business.

Liebert SiteScan enables communication from Liebert environmental and power units, as well as many other pieces of analog or digital equipment, to a front-end software package that provides real-time status and alarms so you can react quickly to changing situations.

Liebert SiteScan is designed with flexibility for both small systems and large, complex systems such as those in computer rooms, telecommunications facilities or industrial process control rooms.

Contact your local Emerson representative for assistance with a Liebert SiteScan system.

The NIC-ENCL1 and NIC-ENCL2 package one or two Liebert IntelliSlot® Web/485 Cards with Adapters, respectively, in one steel enclosure for installation external to the Liebert Mini-Mate2. The Liebert IntelliSlot Web/485 Card with Adapter provides communication with the Liebert Mini-Mate2™ via SNMP, HTTP, RTU Modbus 485 and BACnet IP. The self-contained kit includes an external 120VAC-to-24VAC transformer as a power source. Wiring harnesses are not provided. Power and communication wiring are field-provided.

Site Preparation and Installation

13 Liebert® Mini-Mate2™

5.0 SITE PREPARATION AND INSTALLATION

5.1 Installation Considerations

The evaporator unit is usually mounted above the suspended ceiling of the space to be conditioned.

Ducted systems may be installed in a different room.

5.1.1 System Configurations

The typical system configuration has a separate evaporator or cooling unit and a condensing unit.

Chilled water systems are self-contained units. Refer to Tables 1 and 2 and to Figures 8, 9 and 10 for different system combinations and unit configurations that are possible.

NOTE

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

Table 1 System configurations - 60Hz

Nominal Capacity

Cooling Unit

Condensing Unit

Indoor Air-Cooled Centrifugal fan

Outdoor Air-Cooled Propeller Fan

Indoor Water/Glycol

2 Tons MM_24E MC_24A PFH_27A MC_26W

3 Tons

MM_36E MC_36A PFH_37A MC_38W

MM_40C Self-Contained - Chilled Water

Table 2 System configurations - 50Hz

Nominal Capacity

Cooling Unit

Condensing Unit

Indoor Air-Cooled Centrifugal fan

Outdoor Air-Cooled Propeller Fan

Indoor Remote Water/Glycol-Cooled

3 Tons

MM_35E MC_35A PFH_36A MC_37W

MM_39C Self-Contained - Chilled Water

Table 3 Application limits, evaporator and chilled water units*

Input Voltage Range of Return Air Conditions to Unit

Minimum Maximum Dry Bulb Temperature Relative Humidity

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

* Unit will operate at these conditions but will not control to these extremes of conditions.

Table 4 Application limits, indoor and outdoor air-cooled condensing units

Input Voltage Condensing

Units

Entering Dry Bulb Air Temperature

Minimum Maximum Minimum Maximum

-5% +10%

Outdoor Prop Fan Condensing Unit

-30°F (-34°C)

115°F (46°C) standard unit* 125°F (52°C) high ambient unit*

Indoor Air-Cooled Condensing Unit

115°F (46°C)*

* Unit capacity ratings are stated for 95°F (35°C) for standard units and 105°F (41°C) for high ambient PFH units only.

Exceeding these rating points by 20°F (11°C) will result in lower cooling capacities, but will not damage the equipment.

Table 5 Application limits, indoor water/glycol-cooled condensing units

Input Voltage Entering Fluid Temperature

Minimum Maximum Minimum Maximum

-5% +10% 65°F (18.3°C) * 115°F (46°C)

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

Liebert® Mini-Mate2™ 14

5.1.2 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 contain either rubber or plastic.

Outside or fresh air should be kept to a minimum when tight temperature and humidity control is required. Outside air adds to the cooling, heating, dehumidifying and humidifying loads of the site.

Doors should be properly sealed to minimize leaks and should not contain ventilation grilles.

5.1.3 Location Considerations

Install the evaporator unit over an unobstructed floor space if possible. This will allow easy access for routine maintenance or service. Do not attach additional devices (such as smoke detectors, etc.) to the housing, as they could interfere with the maintenance or service.

When using the optional air distribution plenum, avoid locating the evaporator unit in confined areas that affect the air flow pattern. Such locations could cause short cycles, downdrafts and air noise.

Avoid locating the unit in an alcove or at the extreme end of a long, narrow room. Avoid installing multiple units close to each other. This could result in crossing air patterns, uneven loads and competing operating modes.

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.

NOTE

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

! CAUTION

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

Do not mount units over equipment and furniture that can be damaged by leaking water/glycol. Install a watertight drain pan with a drain connection under the cooling unit and water/glycol condenser unit. Route the drain 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.

NOTE

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

NOTE

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

15 Liebert® Mini-Mate2™

Figure 8 Air-cooled systems, 2 and 3 tons

Figure 9 Water/glycol-cooled systems, 2 and 3 tons

Figure 10 Chilled water systems, 3 tons

Split System Evaporator Supply and Return Air Plenum

Indoor Air-cooled Condensing Unit

Split System Evaporator Supply and Return Air Ducted

Indoor Air-cooled Condensing Unit

Split System Evaporator Supply and Return Air Plenum

Outdoor Air-Cooled Condensing Unit

Split System Evaporator Supply and Return Air Ducted

Outdoor Air-Cooled Condensing Unit

Split System Evaporator Supply and Return Air Ducted

Remote Water/Glycol Condensing Unit

Split System Evaporator Supply and Return Air Plenum

Remote Water/Glycol Condensing Unit

Split System Evaporator Supply and Return Air Ducted

Remote Water/Glycol Condensing Unit

Condensing Unit Evaporator

Drycooler

Condensing Unit

Evaporator

Drycooler

Condensing Unit Evaporator

Condensing Unit Evaporator

Cooling Tower

Split System Evaporator Supply and Return Air Plenum

Remote Water/Glycol Condensing Unit

Cooling Tower

Chilled Water Supply and Return Plenum

Chilled Water Ducted

Liebert® Mini-Mate2™ 16

5.2 Ceiling Unit Weights

5.3 Equipment Inspection—Upon Receipt

When the unit arrives, do not uncrate equipment until it is close to its final location. All required assemblies are banded and shipped in corrugated containers. If you discover any damage when you uncrate the unit, report it to the shipper immediately. If you later find any concealed damaged, report it to the shipper and to your Liebert supplier.

5.4 Packaging Material

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

5.5 Installing the Ceiling Units

The evaporator unit and condensing unit are usually mounted above the ceiling and must be securely mounted to the roof structure. The ceiling and ceiling supports of existing buildings may require reinforcements. Be sure to follow all applicable national and local codes. Use field-supplied threaded suspension rods and 3/8-16 factory hardware kit.

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

Install the four field-supplied rods by suspending them from suitable building structural members.

Locate the rods so that they will align with the four mounting holes in the flanges that are part of the unit base.

Table 6 Ceiling unit weights

Model # Weight lb (kg)

Cooling Units *

MMD24E 225 (102)

MMD35E 225 (102)

MMD36E 225 (102)

MMD39C 230 (104)

MMD40C 230 (104)

Indoor Condensing Units

MCD24A 270 (125)

MCD35A 280 (130)

MCD36A 280 (130)

MCD26W 190 (90)

MCD37W 200 (95)

MCD38W 200 (95)

MCD38W 200 (95)

* Add 20 lb. (9kg) to units with free-cooling or hot water reheat coils.

! 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 5.2 - Ceiling Unit Weights.)

Be sure to securely anchor the top ends of the suspension rods. Make sure all nuts are tight.

17 Liebert® Mini-Mate2™

Using a suitable lifting device that is rated for the weight of the unit (see 5.2 - Ceiling Unit Weights), raise the unit and pass the threaded rods through the four mounting holes in the flanges that are part of the unit base.

Attach the threaded rods to the unit flanges using the supplied nuts and grommets. (See Figure 11).

The rubber grommets provide vibration isolation.

1. First, use the plain nuts to hold unit in place. Adjust these nuts so that the weight of the unit is supported evenly by the four rods, does not rest on the ceiling grid, and to ensure the unit is level.

2. Second, use the shake-proof nuts to “jam” the plain nuts.

Figure 11 Threaded rod and hardware kit installation

5.5.1 Close-Coupled Installations

If the evaporator and indoor condensing units are to be mounted back-to-back (close-coupled), hang each unit before connecting them together. Align four bolt holes in the condensing unit with cage nuts in the evaporator. Insert rubber spacers and secure with provided hardware. Align the refrigerant connections and tighten them as described in 5.5.3 - Piping Connections and Coolant Requirements (see Figure 17).

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. Kit should be mounted in evaporator unit before raising unit into ceiling area.

5.5.2 Evaporator Air Distribution

Filter Box

The optional filter box is available for the unit and mounts directly to the return air opening of the evaporator. The 2 and 3 ton filter box is supplied with a MERV 8 filter (per ASHRAE 52.2-2007) measuring 20 in. x 20 in. x 4 in. (508x508x102mm).

NOTE

The units must be level in order to drain condensate properly.

3/8" Threaded Rod (field-supplied)

3/8" Hex Nut 3/8" Washer

Sleeve

Isolator

3/8" Fender Washer

3/8" Hex Nut

3/8" Hex Nut Nylock

Unit Base Pan (ref)

Liebert® Mini-Mate2™ 18

Plenum Installation

The 2- and 3-ton non-ducted evaporators can use the optional ceiling-mounted plenum to provide four-way air distribution. The plenum fastens to the bottom of the evaporator. The plenum includes a 16 in. x 25 in x 4 in (406x635x102mm) MERV 8 filter (per ASHRAE 52.2-2007).

1. The evaporator should be mounted above the bottom of the T-bar supports with at least 30 in.

(762mm) clearance from return air end to wall (for replacing filter).

2. Check the contents of the plenum kit.

3. Follow the installation instructions included with the plenum kit.

Connections for Ducted Systems

In a ducted configuration, the direct drive evaporator has a maximum allowable external static pressure of 0.3" wg (7.6 mm). Use flexible ductwork or non-flammable cloth collars to attach ductwork to the unit and to help control the transmission of vibrations to building structures. 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. Ductwork should be fabricated and installed in accordance with local and national codes.

5.5.3 Piping Connections and Coolant Requirements

The following pipe connections are required:

• A drain line from the evaporator coil drain pan (This line also serves as the drain for the optional humidifier.)

• A drain line from the secondary drain pan beneath the unit.

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

• Refrigerant piping connections between the evaporator unit and the condensing unit (air, water, or glycol). If the evaporator unit is chilled water, connections to the building chilled water source are required.

Drain Line

NOTICE

Risk of water backing up in the evaporator coil drain line. Can cause building and equipment damage from overflowing water.

Do not install an external trap in the drain line. This line already has a factory-installed trap inside the cabinet.

This line may contain boiling water. Use copper or other suitable material for the drain line.

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

NOTE

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

Table 7 Cooling unit air flow at 0.3 IWG (75PA) ESP

Fan Speed 2 Ton

CFM (CMH)

3 Ton

CFM (CMH)

High 885 (1504) 1250 (2124)

Low 800 (1359) 1000 (1699)

19 Liebert® Mini-Mate2™

The optional condensate pump kit is required when the evaporator is installed below the level of the gravity-fed drain line.

Humidifier Water Supply Line

Units supplied with the optional humidifier package have a 1/4 in. (6.4 mm) compression fitting with ferrule at the water supply connection Supply pressure range is 10 PSIG to 150 PSIG. Required flow rate is 1 gpm. A shut-off valve should be installed in this line to isolate the humidifier for maintenance.

Assembly Instructions

1. Cut tube square and remove cutoff burr.

2. Slide nut then sleeve on tube, threaded end on nut facing end of tube.

3. Insert tube into fitting seating it against stop shoulder and thread nut to body “hand-tight.”

4. With proper wrench tighten 1-1/4 to 2-1/4 turns.

NOTICE

Risk of improper tightening of the piping fittings. Can cause fitting damage and leaks that can result in building and equipment damage.

Do not over tighten the piping fittings

Chilled Water Loop

On chilled water units, install manual service shutoff valves at the supply and return lines of each unit. These shutoff valves are used for routine service or emergency isolation of the unit.

Chilled water supply and return lines must be insulated. Insulating them will prevent condensation of the water supply and return lines to the unit.

The minimum recommended water temperature is 42¡F. Design pressure is 300psig (2068 kPag).

Connection sizes are 7/8 in (22.2mm) OD copper for 3 ton units.

Remove any shipping band from the float switch in the evaporator pan before operating unit.

Liebert® Mini-Mate2™ 20

Water/Glycol Loop

Emerson recommends installing manual service shutoff valves at the supply and return line to each unit.