Emerson Liebert Prop Fan Condensing Unit Users Manual

2015-01-05

: Emerson Emerson-Liebert-Prop-Fan-Condensing-Unit-Users-Manual-164292 emerson-liebert-prop-fan-condensing-unit-users-manual-164292 emerson pdf

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Page Count: 36

Precision Cooling
For Business-Critical Continuity™
Liebert Prop Fan Condensing Unit™
Installation, Operation and Maintenance Manual - 50 & 60Hz
Figure i Model number nomenclature
Prop Fan Condensing
Unit with Hot-Gas
Bypass
0 = Standard Noise Level
Z =Quiet-Line
Nominal Capacity
1000 BTU/Hr
P = 208/230-1ph-60Hz
Y = 208/230-3ph-60Hz
A = 460-3ph-60Hz
B = 575-3ph-60Hz
S = 220-1ph-50Hz
N = 200/230-3ph-50Hz
M = 380/415-3ph-50Hz
R-407C Refrigerant
— = Standard Coil
C = Coated Coil
PFH 0 37 — P L 7
A = Air Cooled
A
L = 95°F (35°C) Ambient
Liebert Lee-Temp
H = 105°F (41°C) Ambient
Liebert Lee-Temp
Not all options and/or voltage combinations are available.
Example: PFH037A-PL7
i
TABLE OF CONTENTS
1.0 PRODUCT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.1 Prop Fan Condensing Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1.1 Base System 95°F (35°C) Ambient Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1.2 105°F (41°C) Ambient Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1.3 Quiet-Line Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Optional Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2.1 Coated Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2.2 Pre-Charged Refrigeration Line Sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2.3 Refrigerant Line Sweat Adapter Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2.4 277V Step-Down Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2.0 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
2.1 Equipment Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Location Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.3 Dimensional Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.4 Piping and Electrical Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.5 Piping Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.5.1 Piping for Elevation Differences between PFH and Evaporator . . . . . . . . . . . . . . . . . . . . . . . 14
2.5.2 Pre-Charged Line Sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.5.3 Field-Fabricated Line Sets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.5.4 Installation of Piping to Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.5.5 R-407C PFH Installed as a Replacement Condensing Unit in an R-22 System . . . . . . . . . . . 18
2.5.6 General System Charge Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.6 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.6.1 Low-Voltage Control Wire Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.6.2 Low-Voltage Control Wire Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.7 Electrical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.8 Checklist for Completed Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.0 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
3.1 Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.2 High Head Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.3 Liebert Lee-Temp Flood Back Head Pressure Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.4 Hot Gas Bypass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.4.1 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.4.2 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.0 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.2 Compressor Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.2.1 Electrical Failure—Burnout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.2.2 Mechanical Failure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.3 Compressor Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.4 Field Charge Verification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.0 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
ii
FIGURES
Figure i Model number nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inside Front Cover
Figure 1 Dimensions, horizontal air discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Figure 2 Dimensions, top air discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Figure 3 Dimensional data, 277V step-down transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Figure 4 Piping and electrical connections, horizontal discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 5 Piping and electrical connections, top air discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Figure 6 General piping arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Figure 7 Electrical field connections, 1- to 5-ton units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Figure 8 Electrical field connections, 8-ton units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 9 Single-phase, 1-3 ton model schematic, typical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Figure 10 Three-phase, 3-5 ton model schematic, typical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Figure 11 Three-phase, 8 ton model schematic, typical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Figure 12 Refrigerant piping diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Figure 13 Hot gas bypass diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
TABLES
Table 1 Cabinet and floor planning data, horizontal air discharge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Table 2 Electrical and piping connections, top air discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Table 3 Electrical and piping connections, horizontal air discharge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Table 4 Piping and electrical connections, top air discharge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Table 5 Pipe length and condenser elevation relative to evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Table 6 Equivalent lengths for various pipe fittings, ft (m). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Table 7 Refrigerant charge in Liebert pre-charged R-407C line sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Table 8 Liebert PFH unit charge levels and coupling size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Table 9 Recommended line sizes, OD Cu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Table 10 Piping connection sizes and torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Table 11 Line charges - refrigerant per 100 ft. (30m) of Type L copper tube . . . . . . . . . . . . . . . . . . . . . . . . 18
Table 12 Evaporator Charge Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Table 13 Design refrigerant pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Table 14 Application limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Table 15 Recommended minimum wire size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Table 16 Electrical data—Standard sound and ambient models (95°F/35°C) 60Hz . . . . . . . . . . . . . . . . . . 22
Table 17 Electrical data—High ambient models (105°F/41°C) 60Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Table 18 Electrical data—Quiet-Line models (95°F/35°C) 60Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Table 19 Electrical data—Standard sound and ambient models (95°F/35°C) 50Hz . . . . . . . . . . . . . . . . . . 23
Table 20 Electrical data—High ambient models (105°F/41°C) 50Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Table 21 Electrical data - Quiet-Line models (95°F/35°C) 50Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Table 22 Field verification charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Table 23 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Product Description
1
1.0 PRODUCT DESCRIPTION
1.1 Prop Fan Condensing Units
Liebert propeller fan condensing units are available in a range of sizes and configurations to offer
flexibility in designing a precision environmental control system. The appropriate propeller fan con-
densing unit paired with a corresponding Liebert fan coil evaporator model such as Liebert Data-
Mate, Liebert Mini-Mate2 or Liebert Challenger 3000 is an effective solution for your environmental
control application requirements.
Split system condensing units are connected to the evaporator unit by two refrigerant lines (four in
8-ton systems) and a low-voltage control cable. The condensing unit requires a separate power source
and power disconnect switch.
1.1.1 Base System 95°F (35°C) Ambient Models
The heart of the refrigeration system is a quiet, high efficiency scroll compressor with internal vibra-
tion isolation mountings, pressure safety controls and built-in overload protection. Standard features
include crankcase heater, high pressure switch, condenser coil, sight glass, filter drier, hot gas bypass
system with liquid quenching valve, direct drive propeller fan and motor, and Liebert Lee-Temp flood-
back head pressure control. These models are designed to provide catalog capacity of the appropriate
evaporator section up to 95°F (35°C) outside ambient temperature.
1.1.2 105°F (41°C) Ambient Models
These models contain similar components to the base models except the coils and fans are sized to
provide catalog capacity of the appropriate evaporator section up to 105°F (41°C) outside ambient
temperature.
1.1.3 Quiet-Line Models
These models contain similar components to the base models except the coils and fans are sized to
provide catalog capacity of the appropriate evaporator section up to 95°F (35°C) outside ambient tem-
perature with a noise level of less than 58 dBA.
1.2 Optional Equipment
1.2.1 Coated Coil
This option provides a phenolic coating for the condenser coil (extended lead time is required for this
option; consult factory).
1.2.2 Pre-Charged Refrigeration Line Sets
For efficient condenser/evaporator connection, factory pre-charged line sets with quick connect fit-
tings are available in 15-ft. and 30-ft. (4.5m and 9m) lengths. Each set includes an insulated copper
suction line and copper liquid line, both charged with R-407C refrigerant and sealed. Line sets are
only available for 1 to 3.5 Ton Units.
1.2.3 Refrigerant Line Sweat Adapter Kit
This kit includes the compatible fittings required (two for the insulated suction line and two for the liq-
uid line) when using field-supplied interconnecting refrigerant lines instead of the pre-charged line sets.
1.2.4 277V Step-Down Transformer
A 37.5A, 277V step-down transformer is available for 1-to 3-Ton 60Hz condensing units needing
277/1/60 input power. Apply this transformer to a 208/230/1/60 condensing unit. The transformer is
coated with epoxy and contained in an enclosed, non-ventilated electrical box with adaptable mount-
ing brackets.
Installation
2
2.0 INSTALLATION
Read this entire installation section before starting installation. This section details dimensional,
electrical and piping information and specifications that affect the placement of the PFH unit in rela-
tion the connected evaporator unit, other outside units, barriers and walls.
Be particularly mindful of service and airflow clearances and maximum equirvalent piping distances
and in elevation differences between PFH and connected evaporator unit. Consult and confirm appli-
cations with your Emerson Network Power representative when applications exceed any of these
specifications.
2.1 Equipment Inspection
When the unit arrives, inspect all items for any visible or concealed damage. Report any damage to
the carrier immediately and file a damage claim; send a copy of the claim to Emerson Network Power
or your local Emerson sales representative.
If possible, maintain equipment and packaging until it is at the installation location.
2.2 Location Considerations
To ensure an adequate air supply, locate all condensing units in a clean-air area, away from loose dirt
and debris that can clog the coil. Avoid ground-level sites with public access or areas that are exposed
to heavy snow accumulation. Locate unit to allow maximum security and maintenance accessibility.
Do not locate condensing units near steam, hot air or fume exhausts. Do locate units at least 18 in.
(457mm) from walls, obstructions or adjacent units. For multiple unit installations, space unit so that
the hot condenser exhaust air is not directed toward the condenser air inlet of an adjacent unit.
Install a solid base at least 2 in. (51mm) higher than the surrounding grade and 2 in. (51mm) larger
than condensing unit base dimensions and capable of supporting the condenser’s weight.
Installation
3
2.3 Dimensional Data
Figure 1 Dimensions, horizontal air discharge
Table 1 Cabinet and floor planning data, horizontal air discharge
Model Numbers Dimensional Data, in. (mm)
Net Weight
lb. (kg)
60Hz 50Hz A B C
PFH014A-L PFH013A-L
40 (1016) 23-1/2 (597) 18 (457) 200 (91)PFH020A-L PFH019A-L
PFH027A-L PFH026A-L
PFH027A-H PFH026A-H
48 (1219) 31 (787) 18 (457) 241 (109)
PFHZ27A-L PFHZ26A-L
PFH037A-L PFH036A-L
PFH042A-L PFH041A-L
PFH037A-H PFH036A-H
53 (1343) 36-1/4 (918) 18 (457) 351 (159)
PFHZ37A-L PFHZ36A-L
PFH042A-H PFH041A-H
PFHZ42A-L PFHZ41A-L
PFH067A-L PFH066A-L
A
B
C
C
Fan Rotation
CCW
(left side)
Shaded area
indicates a minimum
clearance of 18" (457mm)
for proper air flow.
Shaded area
indicates a minimum
clearance of 18" (457mm)
for proper air flow
Shaded area
indicates a recommended
clearance of 24" (610mm)
for component access and
removal.
DPN000130
Rev. 0
Removable panel for access
to high-voltage and low-voltage
connections and refrigeration
components
Right Air Discharge
Removable (right) panel
for access to
refrigeration component
Left Air Intake
Installation
4
Figure 2 Dimensions, top air discharge
Table 2 Electrical and piping connections, top air discharge
Model Numbers Dimensional Data in. (mm) Module Net
Weight lb.
(kg) .60Hz50HzABCD
PFH067A-H PFH066A-H
53 (1343) 36-1/4 (918) 38-1/2 (978) 5-1/2 (140) 488 (222)
PFHZ67A-L PFHZ66A-L
PFH096A-L PFH095A-L 570 (259)
Guard Height
Fan Rotation
CW
Shaded area
indicates a minimum
clearance of 18" (457mm)
for proper air flow.
Shaded area
indicates a minimum
clearance of 18" (457mm)
for proper air flow
Shaded area
indicates a recommended
clearance of 24" (610mm)
for component access and
removal.
DPN000131
Rev. 0
Removable panel for access
to high-voltage and low-voltage
connections and refrigeration
components
Top A i r
Discharge
Right Air Intake
Left Air
Intake
4-23/32"
(120mm)
36-1/8"
(918mm)
25-3/32"
(637mm)
46-7/32"
(1174mm)
2"
(51mm)
2"
(51mm) typ.
2"
(51mm)
2"
(51mm)
53-3/16"
(1351mm)
4"
(102mm) typ.
32-1/8"
(816mm)
FOOTPRINT DIMENSIONS
1/2" Bolt-Down Holes
(6 places)
Installation
5
Figure 3 Dimensional data, 277V step-down transformer
DPN000647
REV. 0
Notes:
1. 1D18214P1 = Acme catalog no. T-1-37921 for all small systems except 3-ton Liebert DataMate
with integral condenser.
2. 1D18214P2 = Acme catalog no. T-1-37922 for 3-ton Liebert DataMate with integral condenser.
3. Epoxy coated. Suitable for indoor/outdoor service. Horizontal- or vertical-mount.
Totally enclosed, non-ventilated.
4. Both brackets are shipped loose with transformer.
WIRING FOR TRANSFORMER
WALL MOUNTING RIGID MOUNTING
4.92"
(125mm)
5.5"
(140mm)
.281" (7mm) Dia.
For wall mounting
1D18214P1
10.3" (262mm)
1D18214P2
11.68" (297mm)
Remove screws &
attach bracket
Access to electrical
connections from
bottom
.31" (8mm) Dia.
For rigid mounting
and shipping
1/4-20 (2 screws &
lock washers) for
rigid mounting and
shipping
277V line voltage
Jumpers
H4
H3
H2
H1 X4 X3 X1X2
230V to unit
Notes:
1. Jumper as shown.
2. Connect 277V line to H4 and X1
3. Connect 230V load to H1 and H4
Installation
6
2.4 Piping and Electrical Connections
Figure 4 Piping and electrical connections, horizontal discharge
Table 3 Electrical and piping connections, horizontal air discharge
Model Numbers Electrical Connections, in (mm) Piping Connections, in. (mm)
60Hz 50Hz A B C D E F G
PFH014A-L PFH013A-L
2-1/4 (57) 5-1/4 (133) 7-3/4 (197) 8-3/4 (222) — 5 (127) 7-1/4 (184)PFH020A-L PFH019A-L
PFH027A-L PFH026A-L
PFH027A-H PFH026A-H
2 (51) 5-3/4 (146) 8-1/2 (216) 4-3/4 (121) 6-3/4 (171) — 8-1/2 (216)
PFHZ27A-L PFHZ26A-L
PFH037A-L PFH036A-L
PFH042A-L PFH041A-L
PFH037A-H PFH036A-H
2 (51) 6 (152) 8-1/2 (216) 4-3/4 (121) 7-3/4 (197) — 8-1/2 (216)
PFHZ37A-L PFHZ36A-L
PFH042A-H PFH041A-H
PFHZ42A-L PFHZ41A-L
PFH067A-L PFH066A-L
BC
A
F
G
D
E
DPN000132
Rev. 0
Liquid Line
Quick Connect
(Male Coupling)
Suction Line
Quick Connect
(Male Coupling)
Electrical Entrance for
High-Voltage Connection
Electrical Entrance for
Low-Voltage Connection
Installation
7
Figure 5 Piping and electrical connections, top air discharge
Table 4 Piping and electrical connections, top air discharge
Model Numbers
Electrical Connections
in. (mm)
Piping Connections
in. (mm)
60Hz 50Hz A B C D E F G
PFH067A- H PFH066A-H
2
(51)
6
(152)
8-1/2
(216)
4-3/4
(121)
7-3/4
(197)
8-1/2
(216)
—
PFHZ67A- L PFHZ66A-L —
PFH096A- L PFH095A-L 11-1/2 (292)
* System 1 and System 2 on 8 Ton only
Electrical Entrance for
High-Voltage Connection
Electrical Entrance for
Low-Voltage Connection
Liquid Line
Quick Connect
(Male Coupling)
Suction Line
Quick Connect
(Male Coupling)
* System 2 (5 Ton)
DPN000133
Rev. 0
* System 1 (3 Ton)
Installation
8
Figure 6 General piping arrangement
Pressure Balancing
Valve
DPN000129 REV 1
Condenser
Coil
High Pressure
Switch
Compressor *
Hot Gas Bypass
Solenoid Valve
Hot Gas Bypass
Control Valve
3 - Way Head
Pressure
Control Valve
Check Valve
Liquid Injection
Valve Bulb
Pressure Relief Valve
Sight
Glass
Liebert Lee-Temp
Receiver
Liquid Line
Solenoid Valve
Liquid Line Male Quick
Connect Coupling
Liquid Injection
Valve
Suction Line
Male Quick
Connect Coupling
SINGLE CIRCUIT SHOWN
SINGLE CIRCUIT = 1 - 5 Tons
DUAL CIRCUIT = 8 Tons
Receiver Heater
Pressure Limiting
Switch
* Reciprocating compressor 1 Ton, 60Hz
Scroll compressor 1 Ton, 50Hz and 1-1/2 to 8 Tons
Installation
9
Figure 7 Electrical field connections, 1- to 5-ton units
Installation
10
Figure 8 Electrical field connections, 8-ton units
Factory-wired
to components on
electric panel
DPN000135
Rev. 1
Electric service
connection to contactor
or terminal block
Single- or three-phase electric
service not provided by Liebert
High-voltage
electric power
supply entrance
Low-voltage electric
power supply
entrance
Earth ground connection
terminal for field wiring
Field-supplied unit
disconnect switch
Single- or three-phase
electric service not provided
by Liebert
Field-supplied 24V
NEC Class 2 wiring
to evaporator module
Heat rejection connection.
Field-supplied 24V NEC
Class 2 wiring.
Wire connections from evaporator module:
1. 24V GND System 1
2. 24V Supply System 1
3. High Pressure Alarm System 1
4. Hot Gas Bypass Connection System 1
5. 24V GND System 2
6. 24V Supply System 2
7. High Pressure Alarm System 2
8. Hot Gas Bypass Connection System 2
9. 24V GND Condenser Fan
10. 24V SUPPLY Condenser Fan
Refer to tables or unit serial label
for FLA, WSA and OPD values.
Installation
11
Figure 9 Single-phase, 1-3 ton model schematic, typical
3
2
4
1
C1
HG1
BR
W
BL
1
4
2
3
BK
BK
R
R
R
LLSV
BK
BK
R
'FM'
FAN
MOTOR
2C1
1C1
R
BK
RHTR
BK
BK
RRR BK
BR
Y
Optional on
Selected Units
Supplied on
1-Ton PFC
Models Only
BR
CRS
COMP
15
2
PR
BDR
CCSR
AB
Y
Conductors Field-Supplied
(See Note 5)
HGBP Signal
Output
Connection
EVAPORATOR UNIT
Unit Alarm
Input
Connection
24V Ground
Earth Ground
By Others
1-Phase Line
Voltage Supply
By Others
(See Notes 1 & 3)
OUTDOOR CONDENSING MODULE
See Note 6
HG1
CHTR
BK
BK
BK
BR
CAP2
CAP1
CAP3
BR
L1
L2
HP1
HP2
HGSV
24V Power
Supply
From Unit
Min 40 Va
1. All units 208/230V, 1 phase. On 208/230V units installed
in Canada only, CSA requires that L1 and L2 are non-neutral
supply conductors. L1 et L2 pour conducteurs d'alimentation
non-neutres. On other units, L2 is designated neutral. See
unit name plate and installation manual for main supply wiring
information. Use copper conductors onl y.
2. Use copper conductors onl y. See unit nameplate for main supply
wire sizing data. Wire per local codes.
3. A remote disconnect switch is to be field-supplied and mounted
within sight of the condensing unit. See unit nameplate for voltage
and amperage requirements.
4. All motors have internal line break overload protectors.
Three-phase motors protected for primary single-phasing conditions.
25,
27
Factory-Supplied Line Voltage
Field-Installed Line Voltage Wiring
Optional Line Voltage Wiring
Factory-Supplied 24V NEC Class 2 Wiring
Optional 24V Wiring
Factory-Supplied 24V NEC Class 2 Wiring
Factory-Supplied Earth Grounding Wire
Pigtail Leads 24V Wiring
Terminal Strip Connection
OR - Orange
R - Red
BR - Brown
P - Purple
GN - Green
Y - Yellow
BL - Blue
BK - Black
W - White
WIRE COLOR CODE
Insulation Color
GN / Y
Tracer Color
191642
Rev. 0
NOMENCLATURE
Standard Devices
BDR -- Bleed Resistor
C1 -- Condenser Contactor
CAP1 -- Compressor Capacitor
Run
CAP2 -- Fan Motor Capacitor
CAP3 -- Compressor Capacitor
Start
CHTR -- Compressor Heater
COMP -- Compressor
FM -- Fan Motor
HP1 -- High Pressure Switch
(Auto Reset)
HP2 -- Pressure Switch Receiver
(Auto Reset)
LLSV -- Liquid Line Solenoid Valve
PR -- Potential Relay
RHTR -- Receiver Heater
Optional Devices
CSR -- Compressor Start Resistor
HG1 -- Hot Gas Relay
HGSV -- Hot Gas Solenoid Valve
5. Terminals 1,2,3, and 4 are for connection of control circuit from
evaporator unit. Wiring by others to be NEC Class 2 and sized
for 1V maximum drop.
6. Wire '1' is connected to the grounded side of the 24V Class 2 circuit.
Grounding Lug Connection
Installation
12
Figure 10 Three-phase, 3-5 ton model schematic, typical
3
2
4
1
L1
L2
L3
27
27,29,30
HP1 C1
HG1
W
BL
BR
1
4
2
3
BK
CHTR
BR BR
R
BK
HP2 RBK
RHTR1 RHTR2
HG1 HGSV
LLSV1
BR ROR
T3T2T1
COMP
RBK
Y
CAP2
BR
1C1
2C1
3C1
BR
BR
F1
F2
TX1
BK
BK
Conductors Field-Supplied
(See Note 5)
HGBP Signal
Output
Connection
EVAPORATOR UNIT
Unit Alarm
Input
Connection
Earth Ground
By Others
3-Phase Line
Voltage Supply
By Others
(See Note 3)
OUTDOOR CONDENSING MODULE
See Note 7
See Note 1
See Note 6
24V Power
Supply
From Unit
Min 40VA
24V Ground
'FM'
Fan
Motor
1. Transformer 'TX1' provided on units with nameplate voltages greater
than 240V.
2. Use copper conductors onl y. See unit nameplate for main supply wire
sizing data. Wire per local codes.
3. A remote disconnect switch is to be field supplied and mounted
within sight of the condensing unit. See unit nameplate for voltage
and amperage requirements.
4. All motors have internal line break overload protectors. Three-phase
motors protected for primary single-phasing conditions.
5. Terminals 1, 2, 3 and 4 are for connection of control circuit from evaporator
unit. Wiring by others to be NEC Class 2 and sized for 1 volt maximum drop.
6. Wire '1' is connected to the grounded side of the 24V Class 2 circuit.
7. Receiver heater No.2 'RHTR2' supplied on 4- and 5-ton standard models and
3/3.5-ton high ambient and Quiet-Line models.
NOMENCLATURE
Standard Devices
C1 -- Condenser Contactor
CAP2 -- Fan Motor Capacitor
CHTR -- Compressor Heater
COMP -- Compressor
F1 -- Transformer Fuse 1
F2 -- Transformer Fuse 2
FM -- Fan Motor
HP1 -- High Pressure Switch
(Auto Reset)
HP2 -- Pressure Switch Receiver
(Auto Reset)
Optional Devices
HG1 -- Hot Gas Relay
HGSV -- Hot Gas Solenoid Valve
Factory-Supplied Line Voltage
Field-Installed Line Voltage Wiring
Optional Line Voltage Wiring
Factory-Supplied 24V NEC Class 2 Wiring
Optional 24V Wiring
Factory-Supplied 24V NEC Class 2 Wiring
Factory-Supplied Earth Grounding Wire
Pigtail Leads 24V Wiring
Terminal Strip Connection
OR - Orange
R - Red
BR - Brown
P - Purple
GN - Green
Y - Yellow
BL - Blue
BK - Black
W - White
WIRE COLOR CODE
Insulation Color
GN / Y
Tracer Color
191643
Rev. 0
LLSV -- Liquid Line Solenoid Valve
RHTR1 -- Receiver Heater No. 1
RHTR2 -- Receiver Heater No. 2
(3-,4-,and 5-ton only)
TX1 -- Transformer Line
Voltage to230V
Grounding Lug Connection
Installation
13
Figure 11 Three-phase, 8 ton model schematic, typical
3
2
10
9
4
1
7
6
8
5
6
L1
L2
L3
See Note 6
See Note 8
See Note 7
See Note 7
See Note 8
See Note 8
See Note 1
See Note 6
C1 Aux.
C2 Aux.
HP1
MF
C1
C2BK
HP2
W
BL
BR
R
BR
R
W
BL
R
BR
5
8
7
1
4
9
10
2
3
BK
BR BR
R
BK
HP3 RBK
BK
RHTR1
RHTR2
HP4
1C1
2C1
3C1
HG1 HGSV1
LLSV1
BR BR BR
1MF 2MF 3MF
BR ROR
T3T2 T1
COMP1
T3T2 T1
COMP2
BR ROR
1C2
2C2
3C2
HG2 HGSV2
LLSV2
R
F1
F2
TX1
BK
BK
NOTES
1. Transformer TX1 provided on units with nameplate voltages greater than 250V.
2. Use copper conductors only. See unit nameplate for main supply wire sizing data.
Wire per local codes.
3. A remote disconnect switch is to be field-supplied and mounted within sight of the
condensing unit. See unit nameplate for voltage and amperage.
4. All motors have internal line break overload protectors.Three-phase motors
protected for primary single-phasing conditions.
5. Terminals 1 thru 8 are for connection of control circuit from evaporator unit.
(Terminals 4 and 8 are not used by some evaporator models . See Note 7). Wiring by
others to be NEC Class 2 and sized for 1V maximum drop.
6. Connection to Terminals 3 and 7 is used for high head alarm input connection in
evaporator unit.
7. Connection to Terminals 4 and 8 is required only on models with (HGBP) hot gas
bypass control signal output in evaporator unit.
8. Wires 1, 5 and 9 are separately connected to the grounded side of the 24V
Class 2 circuit. Do not connect them together.
STANDARD DEVICES
C1 - Compressor Contactor 1
C2 - Compressor Contactor 2
CHTR1 - Compressor Heater 1
CHTR2 - Compressor Heater 2
COMP1 - Compressor #1
COMP2 - Compressor #2
F1 - Transformer Fuse
F2 - Transformer Fuse
FM - Fan Motor
HP1 - High Pressure Switch 1
(Auto Reset)
HP2 - High Pressure Switch 2
(Auto Reset)
HP3 - Pressure Switch 3
Receiver (Auto Reset)
HP4 - Pressure Switch 4
Receiver (Auto Reset)
LLSV1 - Liquid Line Solenoid Valve 1
LLSV2 - Liquid Line Solenoid Valve 2
MF - Fan Motor Contactor
RHTR1 - Receiver Heater No.1
RHTR2 - Receiver Heater No.2
TX1 - Transformer Line Voltage to 230V
OPTIONAL DEVICES
HG1 - Hot Gas Relay 1
HG2 - Hot Gas Relay 2
HGSV1 - Hot Gas Solenoid 1
HGSV2 - Hot Gas Solenoid 2
WIRING LEGEND
Factory-supplied line voltage
Field-installed line voltage wiring
Optional line voltage wiring
Factory-supplied 24V NEC Class 2 wiring
Optional 24V wiring
Field-supplied 24V NEC Class 2 wiring
Field-supplied earth grounding wire
Pigtail leads
Terminal strip connection
Grounding lug connection
WIRE COLOR CODE
OR - Orange
R - Red
BR - Brown
P - Purple
GN - Green
Y - Yellow
BL - Blue
BK - Black
W - White
Insulation Color
GN / Y
Tracer Color
COMP2
Conductors Field-Supplied
(See Note 5)
Evaporator Unit
HIGH HEAD 1
24V GND
COMP1
HGBP1
HIGH HEAD 2
COOLING 2
COOLING 1
HGBP2
OUTDOOR CONDENSING MODULE
3-Phase Line
Voltage Supply
By Others
(See Notes 2 and 3)
Earth Ground
By Others
CHTR1
CHTR2
FM
Fan
Motor
HG2
HG1
Installation
14
2.5 Piping Considerations
The Liebert Mini-Mate2, Liebert DataMate and the 3-ton Liebert Challenger 3000 split system units
are designed with quick-connect fittings and are factory-charged to proper refrigerant levels. This
permits connecting units without brazing inside critical spaces. These split systems require two
refrigerant lines—an insulated copper suction line and a copper liquid line—between the evaporator
and condensing units. The 8-ton Liebert Mini-Mate2 split system units will require four refrigerant
lines between the evaporator and condensing units. Each refrigeration circuit will need one insulated
copper suction line and one copper liquid line.
Two methods exist for installing the copper suction and liquid lines:
• Using optional pre-charged line sets (for 1- to 3.5-ton R-407C model units only).
• Using optional Sweat Adapter Kit(s) and hard piping between units.
NOTICE
Risk of improper handling of refrigerant. Can cause environmental damage and violation of
environmental regulations.
Refrigerant must handled in accordance with all national, regional and local codes.
2.5.1 Piping for Elevation Differences between PFH and Evaporator
System sizes affect the maximum equivalent piping lengths and maximum relative elevation differ-
ences between evaporator and condensing unit mounting locations. See Table 5 for requirements.
Traps in refrigerant piping are required when elevation differences exist between evaporator and con-
densing unit mounting locations. See Figure 12 for requirements. Table 6 should be used when
traps are required with field-fabricated piping assemblies, to calculate equivalent pipe lengths to
determine if installation will comply with Table 5 requirements.
NOTE
Proper safety equipment and proper refrigeration tools are required in working with R-407C
refrigerant. Check unit serial tag for correct refrigerant type before topping off or recharging a
system.
NOTE
Refrigerant R-407C uses a POE (polyol ester) lubricant. The R-407C refrigerant must be
introduced and charged from the cylinder only as a liquid.
NOTE
When installing field piping, care must be taken to protect all refrigerant lines from the
atmosphere, especially when using refrigerants with POE oils. Do not allow the piping to stand
open to air for more than 15 minutes. Units designed for R-407C have a compressor which
contains POE oil that is very hygroscopic; that is, it quickly absorbs water from the air. The
longer the compressor piping is left open to air, the harder it will be to fully evacuate. If left
open too long, the POE oil may need to be replaced before achieving the required vacuum level.
NOTE
Complete all piping and evacuate lines before connecting quick connects when using an
optional sweat adapter kit and field installed hard piping.
Follow all proper brazing practices including a dry nitrogen purge to maintain system
cleanliness.
Installation
15
Figure 12 Refrigerant piping diagram
Table 5 Pipe length and condenser elevation relative to evaporator
Nominal
System Size
Tons
Max. Equiv.
Pipe Length
ft. (m)
Maximum PFH
Level Above
Evaporator, ft. (m)
Maximum PFH
Level Below
Evaporator, ft. (m)
1 or 1.5 50 (15) 40 (12) 15 (4.6)
2 100 (30) 40 (12) 15 (4.6)
3, 3.5, 5 or 8 150 (45) 50 (15) 15 (4.6)
Table 6 Equivalent lengths for various pipe fittings, ft (m)
Copper Pipe
OD, in.
90 Degree
Elbow Copper
90 Degree
Elbow Cast
45 Degree
Elbow Tee
Gate
Valve
Globe
Valve
Angle
Valve
1/2 0.8 (0.24) 1.3 (0.39) 0.4 (0.12) 2.5 (0.76) 0.26 (0.07) 7.0 (2.13) 4.0 (1.21)
5/8 0.9 (0.27) 1.4 (0.42) 0.5 (0.15) 2.5 (0.76) 0.28 (0.08) 9.5 (2.89) 5.0 (1.52)
3/4 1.0 (0.3) 1.5 (0.45) 0.6 (0.18) 2.5 (0.76) 0.3 (0.09) 12.0 (3.65) 6.5 (1.98)
7/8 1.45 (0.44) 1.8 (0.54) 0.8 (0.24) 3.6 (1.09) 0.36 (0.1) 17.2 (5.24) 9.5 (2.89)
1-1/8 1.85 (0.56) 2.2 (0.67) 1.0 (0.3) 4.6 (1.4) 0.48 (0.14) 22.5 (6.85) 12.0 (3.65)
1-3/8 2.4 (0.73) 2.9 (0.88) 1.3 (0.39) 6.4 (1.95) 0.65 (0.19) 32.0 (9.75) 16.0 (4.87)
1-5/8 2.9 (0.88) 3.5 (1.06) 1.6 (0.48) 7.2 (2.19) 0.72 (0.21) 36.0 (10.97) 19.5 (5.94)
Refrigerant trap = Four times equivalent length of pipe per this table
Evaporator
Evaporator
Condensing
Unit
Condensing
Unit
NOTE
When installing remote condensing units below the
evaporator, the suction gas line should be trapped with
an inverted trap to the height of the evaporator .This
prevents refrigerant migration to the compressors
during off cycles .Maximum recommended vertical
level drop to condensing unit is 15 ft. (4.6m) .
Pitch down 1/2" (13mm) per 10 ft. (3m)
Suction Line Piping
Condensing Unit Above Evaporator
Traps recommended at the base of riser
exceeding 5 ft (1.5m) and every 20 feet
(6m) of vertical rise.
Suction Line Piping
Condensing Unit
Below Evaporator
See Table 5 for maximum
vertical rise recommendation
above evaporator.
NOTE
When installing remote condensing units below the
evaporator, the suction gas line should be trapped
with an inverted trap to the height of the evaporator.
This prevents refrigerant migration to the compres-
sors during off cycles. Maximum recommended verti-
cal level drop to condensing unit is 15 ft. (4.6m).
Installation
16
2.5.2 Pre-Charged Line Sets
Liebert pre-charged line sets are available in 15 ft (4.5m) and 30 ft (9m) lengths (see Table 7).
NOTICE
Risk of improper handling and installation of pre-charged lines. Can cause kinks and similar
damage to lines.
Care must be taken to prevent kinking the pre-charged lines for 1-ton and 3.5-ton units.
Use tube benders and make all bends before making connections to either end of the pre-
charged pipes. Coil any excess tubing in a horizontal plane with the slope of the tubing toward
the condensing unit. Use a soft, flexible material to pack around the tubes when sealing
openings in walls to prevent tube damage and to reduce vibration transmission.
2.5.3 Field-Fabricated Line Sets
All field-fabricated refrigeration piping should be copper piping, brazed using a brazing alloy with a
minimum temperature of 1350°F (732°C), such as Sil-Fos. Use a flow of dry nitrogen through the pip-
ing during brazing to prevent formation of copper oxide scale inside the piping. Avoid soft solders such
as 50/50 or 95/5.
Use the sweat adapter kits to terminate the piping at each unit end. Consult factory representatives
to obtain the proper sweat adapter kit. Table 8 has PFH unit connection sizes. Use Table 9 for rec-
ommended line sizes.
Prevailing good refrigeration practices should be employed for piping supports, leak testing, evacua-
tion, dehydration and charging of the refrigeration circuits. The refrigeration piping should be iso-
lated from the building by the use of vibration-isolating supports. Use a soft, flexible material to pack
around the tubes when sealing openings in walls to prevent tube damage and to reduce vibration
transmission.
Before connecting units together with field-fabricated piping, check for leaks and dehydrate
the field piping as follows:
1. Pressurize the field piping to 150 psig (1034 kPa) using dry nitrogen with a trace of refrigerant.
Check system for leaks with a suitable leak detector.
2. After completion of leak testing, release the test pressure (per local code) and triple evacuate the
field piping to 250 microns or lower, breaking the vacuum between the first two evacuations with
dry nitrogen.
3. After the third evacuation, verify 250 microns is maintained for at least one minute after the
piping is isolated from the vacuum pump by a shutoff valve.
Field piping is now ready to be installed between evaporator and condensing units.
Table 7 Refrigerant charge in Liebert pre-charged R-407C line sets
Line Size,
in.
Length,
ft. (m)
Charge R-407C,
lb-oz (kg)
3/8 liquid 15 (4.5) 0-5 (0.14)
30 (9) 0-10 (0.28)
5/8 or 7/8
suction
15 (4.5) 0-5 (0.14)
30 (9) 0-10 (0.28)
Installation
17
Table 8 Liebert PFH unit charge levels and coupling size
Model Numbers R-407C Charge Coupling Size
60 Hz 50 Hz lb-oz (kg) Liquid Suction
95°F (35°C) Standard Sound
PFH014A-_L7 PFH013A-_L7
8-6 (3.8) #6 #11PFH020A-_L7 PFH019A-_L7
PFH027A-_L7 PFH026A-_L7
PFH037A-_L7 PFH036A-_L7 13-5 (6.04) #6 #11
PFH042A-_L7 PFH041A-_L7
PFH067A-_L7 PFH066A-_L7 26-10 (12.08) #10 #12
PFH096A-_L7 PFH095A-_L7
3-ton Circuit 3-ton Circuit 22-9 (10.23) #6 #11
5-Ton Circuit 5-Ton Circuit 36-5 (16.47) #10 #12
105°F (41°C) High Ambient
PFH027A-_H7 PFH026A-_H7 13-5 (6.04) #6 #11
PFH037A-_H7 PFH036A-_H7 26-10 (12.08) #10 #12
PFH042A-_H7 PFH041A-_H7
PFH067A-_H7 PFH066A-_H7 51-11 (23.45) #10 #12
Quiet-Line
PFHZ27A-_L7 PFHZ26A-_L7 13-5 (6.04) #6 #11
PFHZ37A-_L7 PFHZ36A-_L7 26-10 (12.08) #10 #12
PFHZ42A-_L7 PFHZ41A-_L7
PFHZ67A-_L7 PFHZ66A-_L7 51-11 (23.45) #10 #12
Table 9 Recommended line sizes, OD Cu
Equiv.
ft. (m)
PFH_14A
PFH_13A
PFH_20A
PFH_19A
PFH_27A
PFH_26A
PFH_36A
PFH_37A
3-ton circuit
of 8-ton model
PFH_42A
PFH_41A
PFH_67A
PFH_66A
5-ton circuit
of 8-ton model
Suction Liquid Suction Liquid Suction Liquid Suction Liquid Suction Liquid Suction Liquid
50 (15.2) 5/8" 3/8" 5/8" 3/8" 7/8" 3/8" 7/8" 1/2" 7/8" 1/2" 1-1/8" 1/2"
75 (22.9) * * * * 7/8" 1/2" 7/8" 1/2" 7/8" 1/2" 1-1/8" 5/8"
100 (30.5) * * * * 7/8" 1/2" 1-1/8" 1/2" 1-1/8" 1/2" 1-1/8" 5/8"
125 (38.1) * * * * * * 1-1/8" 1/2" 1-1/8" 5/8" 1-3/8" 5/8"
150 (45.7) * * * * * * 1-1/8" 5/8" 1-1/8" 5/8" 1-3/8" 5/8"
* Exceeds maximum recommended line length
Installation
18
2.5.4 Installation of Piping to Units
Use caution when connecting the quick-connect fittings. Read through the following steps before mak-
ing the connections.
1. Remove protector caps and plugs.
2. Carefully wipe coupling seats and threaded surfaces with a clean cloth.
3. Lubricate the male diaphragm and synthetic rubber seal with refrigeration grade oil.
4. Thread the coupling halves together by hand to ensure that the threads mate properly.
5. Tighten the coupling body hex nut and union nut with the proper sized wrench until the coupling
bodies bottom out or until you feel a definite resistance.
6. Using a marker or pen, make a line lengthwise from the coupling union nut to the bulkhead.
7. Tighten the nuts an additional quarter turn; the misalignment of the lines shows how much the
coupling has been tightened. This final quarter turn is necessary to ensure that the joint will not
leak. Refer to Table 10 for torque requirements.
8. Add liquid refrigerant charge for any field-fabricated piping (refer to Table 11) and the 5-ton
Liebert Challenger evaporator if used (refer to Table 12).
2.5.5 R-407C PFH Installed as a Replacement Condensing Unit in an R-22 System
When replacing the condensing unit of an existing Liebert split system containing R-22 and mineral
oil, the following should be considered.
1. Check for proper operation of the system prior to replacing the outdoor unit. If this is not possible,
at minimum perform a leak check to ensure that the components that remain (line set,
evaporator) are leak tight.
2. Check for acid or contaminants in the mineral oil.
NOTE
When using hard piping, complete all piping and evacuate the lines before connecting
quick-connects.
NOTE
Liebert Challenger 5-ton evaporator includes a nitrogen holding charge only. This holding
charge must be evacuated and unit placed in a 250 micron vacuum prior to connecting piping.
See Table 12 for field charge required.
Table 10 Piping connection sizes and torque
Line Size OD Cu Coupling Size Torque, lb-ft. (N-m)
1/4 or 3/8 #6 10-12 (145-175)
5/8 thru 7/8 #10 or #11 35-45 (510-655)
1-1/8 #12 50-65 (730-950)
Table 11 Line charges - refrigerant per 100 ft. (30m) of Type L copper tube
Line Size,
O.D., in.
R-407C, lb/100 ft. (kg/30m)
Liquid Line Suction Line
3/8 3.7 (1.7) —
1/2 6.9 (3.1) —
5/8 11.0 (5.0 0.4 (0.2)
3/4 15.7 (7.1) 0.6 (0.3)
7/8 23.0 (10.4) 1.0 (0.4)
1-1/8 — 1.7 (0.7)
1-3/8 — 2.7 (1.1)
Installation
19
Remove Existing Condensing Unit
1. Recover refrigerant in system using proper refrigeration practices.
2. Oil removal: The majority of the oil will be in the old condensing unit (compressor, condenser and
receiver), which will be replaced with the new unit.
3. Remove high-voltage and low-voltage wiring.
4. Cut the line set before the Aeroquip fittings entering the condensing unit.
5. Remove the existing filter drier in evaporator unit and discard. The filter drier may contain
contaminants that can be released out of the drier because of the POE oil.
Filter Drier Selection and Installation
Recommended
1. Install a replaceable-core filter drier approved for POE oil. The existing drier must be removed.
The replaceable core drier will not fit in the same location as the existing drier.
2. Ensure there is enough clearance for replacing cores when choosing a location.
3. Replace core a week after startup and inspect the removed replaceable core for contaminants to
determine if another replacement is needed. (If the system experienced a burnout, shorter
interval replacements will be needed.)
Optional
Install a new filter drier approved for POE oil in place of the existing one.
Install the New Condensing Unit
1. Install a stub tube kit on the existing line set connecting to the new condensing unit. This kit is
available from Emerson or your local Emerson representative.
2. Evacuate the evaporator-piping system twice to a minimum 250 microns, breaking the vacuum
with dry nitrogen each time.
3. Evacuate a third time to 250 microns and verify the above levels are maintained for at least one
minute after the unit is isolated from the vacuum pump by a shutoff valve.
4. Connect the condensing unit with the evaporator and piping (see 2.5.4 - Installation of Piping
to Units).
5. Add enough R-407C refrigerant for the evaporator unit and line set. See Table 11 for line set
charges required and Table 12 for standard evaporator units. If a non-standard evaporator was
used, refer to evaporator unit serial tag for charge amounts and use 1 oz. (0.0283kg) R-407C for
every 1 oz. (0.0283kg) R-22 used in old evaporator and piping.
NOTE
Wiring should be removed by a licensed electrician.
Existing low-voltage wiring may have a 3-wire lead. A 4-wire lead is required for hot gas
bypass control on the new condensing unit.
Installation
20
2.5.6 General System Charge Requirements
Liebert split system units are designed with quick-connect fittings and are factory-charged to proper
levels. Due to the wide range of operating ambients and sensitivity of the system components to
charge level, the system charge must be maintained at recommended levels.
If there is any doubt that the system has the correct refrigerant charge level, the correct
procedure is to remove the entire system charge, evacuate the system and weigh in the
recommended factory charge total for both units and any line sets or field piping.
Tables 7,8,11 and 12 are included for field piping allowances, condensing unit charges, line sets and
evaporator charges.
Total refrigerant charge = evaporator + lines + condensing unit
NOTE
All condensing units and most evaporator units are fully charged with refrigerant. Some
evaporator units are shipped from the factory with a nitrogen holding charge only. (Refer to
evaporator serial tags.) If field-supplied refrigerant piping is installed, refrigerant must be
added to the system. Refer to Figure 12 for field-supplied piping guidelines.
Table 12 Evaporator Charge Levels
Indoor Unit
Evaporator
Models
Charge R-407C
oz (kg)
Liebert
Mini-Mate2
MMD11/12E 3 (0.085)
MMD17/18E 4 (0.113)
MMD23/24E 7 (0.198)
MMD35/36E 7 (0.198)
MMD59/60E 4 (0.113)
MMD95/96E 7 (0.198) each circuit
Liebert DataMate
DME020E 4 (0.113)
DME027E 5 (0.141)
DME037E 6.5 (0.184)
Liebert Challenger
3000
BF/BU036E 9 (0.255)
BF/BU060E* 13 (0.368)
* Evaporator is charged with nitrogen at the factory
Installation
21
2.6 Electrical Connections
Each unit is shipped from the factory with all internal wiring completed. All power, control wiring
and ground connections must be made in accordance with the National Electrical Code and local
codes. Refer to equipment nameplate regarding wire size and circuit protection requirements. Refer to
Figures 5,7 and 8 and electrical schematic (reference Figures 9 through 11) when making connec-
tions. A manual electrical disconnect switch should be installed within 5 feet (1.6 m) of the unit in
accordance with codes.
The three-phase scroll compressor requires proper phasing to ensure correct motor rotation. The com-
ponent connections have been phase synchronized at the factory. Power phasing should be changed
only at the line voltage supply to the unit. To change phasing, switch any two power leads to the unit.
Observe system pressures to determine whether the unit is operating properly.
2.6.1 Low-Voltage Control Wire Connections
Field-supplied four-wire control connection (10-wire on 8-ton units) is required between the outdoor
condensing unit and the evaporator. Refer to Figures 5,7 and 8 and to unit electrical schematic and
Figures 9 through 11.
2.6.2 Low-Voltage Control Wire Sizing
Low-voltage wiring should be sized to allow a 1 volt maximum drop due to line resistance between the
evaporator and condensing unit. Use NEC Class 1 or 2 wiring according to wire routing conditions
chosen, local codes and application limits in Tables 14 and 15.
!
WARNING
Use voltmeter to be sure power is turned off before making any electrical connections.
!
CAUTION
Three-phase power must be connected to the unit line voltage terminals in proper sequence so
that scroll compressor rotates in the correct direction.
!
CAUTION
Apply power to condenser 8 hours before operating system. This time is required to allow
liquid refrigerant to be driven out of the compressor. This is especially important at low
ambient temperatures. The compressor crankcase heater is energized as long as power is
supplied to the unit.
Table 13 Design refrigerant pressures
Suction 53 - 95 PSIG
(365 to 655 kPa)
Discharge
(At Design Ambient) 280 psig (1930 kPa)
High Pressure Cutout 400 psig (2760 kPa)
Table 14 Application limits
Input voltage Dry Bulb Air Temperature at Condenser
Minimum Maximum Minimum Maximum
-10%
+10% -30°F (-34°C)
115°F (46°C) Std
Ambient & Quiet-Line
-5% 208/230V
single-phase
125°F (52°C)
High Ambient Models
Table 15 Recommended minimum wire size
Max. Distance*
ft. (m)
Min. Wire Gauge
AWG (mm2)
50 (15) 20 (0.75)
100 (30) 18 (1.0)
150 (45) 16 (1.5)
* One-way control wire run between outdoor condensing unit and evaporator.
Installation
22
2.7 Electrical Data
Table 16 Electrical data—Standard sound and ambient models (95°F/35°C) 60Hz
Model #
Nominal
Capacity
Tons
* Electrical
Characteristic
Input Voltage- Phase
208/230-1 208/230-3 460-3 575-3
14 1
FLA 8.4 — — —
WSA 10.2 — — —
OPD 15 — — —
20 1.5
FLA 12.1 — — —
WSA 14.8 — — —
OPD 25 — — —
27 2
FLA 13.5 — — —
WSA 16.5 — — —
OPD 25 — — —
37 3
FLA 19.3 12.8 6.4 5.9
WSA 23.8 15.7 7.8 7.1
OPD 40 25 15 15
42 3.5
FLA — 15.3 7.1 6.6
WSA — 18.8 8.7 8.0
OPD — 30 15 15
67 5
FLA — 24.1 11.7 9.1
WSA — 29.3 14.2 11.1
OPD — 45 20 15
96 8
FLA — 35.6 17.4 13.5
WSA — 40.8 19.9 15.4
OPD — 60 25 20
*FLA = Full Load Amps
WSA = Wire Size Amps (minimum supply circuit current capacity)
OPD = Overcurrent Protection Device (fuse or circuit breaker)
Table 17 Electrical data—High ambient models (105°F/41°C) 60Hz
Model #
Nominal
Capacity,
Tons
* Electrical
Characteristic
Input Voltage-Phase
208/230-1 208/230-3 460-3 575-3
37 3
FLA 21.3 14.8 7.4 5.9
WSA 25.8 17.7 8.8 7.1
OPD 40 25 15 15
42 3.5
FLA — 17.3 8.1 6.6
WSA — 20.8 9.7 8.0
OPD — 30 15 15
67 5
FLA — 24.2 11.7 9.3
WSA — 29.4 14.2 11.3
OPD — 50 20 15
*FLA = Full Load Amps
WSA = Wire Size Amps (minimum supply circuit current capacity)
OPD = Overcurrent Protection Device (fuse or circuit breaker)
Model # 14, 20 and 96 are not available in high ambient versions.
Installation
23
Table 18 Electrical data—Quiet-Line models (95°F/35°C) 60Hz
Model #
Nominal
Capacity
Tons
* Electrical
Characteristic
Input Voltage-Phase
208/230-1 208/230-3 460-3 575-3
27 2
FLA 13.0 — — —
WSA 16.0 — — —
OPD 25 — — —
37 3
FLA 18.8 12.3 6.4 5.2
WSA 23.3 15.2 7.8 6.4
OPD 40 25 15 15
42 3.5
FLA — 14.8 6.9 5.9
WSA — 18.3 8.5 7.3
OPD — 30 15 15
67 5
FLA — 21.1 10.9 8.8
WSA — 25.9 13.4 10.8
OPD — 45 20 15
*FLA = Full Load Amps
WSA = Wire Size Amps (minimum supply circuit current capacity)
OPD = Overcurrent Protection Device (fuse or circuit breaker)
Model # 14, 20 and 96 are not available in Quiet-Line versions.
Table 19 Electrical data—Standard sound and ambient models (95°F/35°C) 50Hz
Model #
Nominal
Capacity
Tons
* Electrical
Characteristic
Input Voltage-Phase
220-1 200/230-3 380/415-3
13 1 FLA 9.9 — —
19 1.5 FLA 10.9 — —
26 2 FLA 12.7 — 4.9
36 3 FLA 18.4 — 7.0
41 3.5 FLA — 15.3 8.5
66 5 FLA — 24.1 13.2
95 8 FLA — — 20.3
*FLA = Full Load Amps
Table 20 Electrical data—High ambient models (105°F/41°C) 50Hz
Model #
Nominal
Capacity
Tons
* Electrical
Characteristic
Input Voltage-Phase
220-1 200/230-3 380/415-3
13 1 FLA — — —
19 1.5 FLA — — —
26 2 FLA 14.8 — 6.0
36 3 FLA 20.5 — 13.1
41 3.5 FLA — 19.8 9.6
66 5 FLA — 24.2 13.2
95 8 FLA — — —
*FLA = Full Load Amps
Installation
24
2.8 Checklist for Completed Installation
___ 1. All items unpacked and checked.
___ 2. Proper clearances for service access maintained around equipment.
___ 3. Equipment is level and mounting fasteners are tight.
___ 4. Piping completed to refrigerant loop.
___ 5. All piping connections are tight.
___ 6. Piping routed to prevent chafing and rub-through.
___ 7. Piping has been evacuated and refrigerant charge added (if required).
___ 8. Line voltage to power wiring matches equipment nameplate.
___ 9. Power wiring connections completed, including earth ground.
___ 10. Power line circuit breakers or fuses have proper ratings for equipment installed.
___ 11. Control wiring connections completed.
___ 12. All wiring connections are tight.
___ 13. Foreign materials have been removed from area: in and around all equipment installed
(shipping materials, construction materials, tools, etc.).
___ 14. Fans and blowers rotate freely and in the proper direction.
___ 15. Blank startup sheet has been sent with the evaporator unit and is ready to be completed by
the installer.
Table 21 Electrical data - Quiet-Line models (95°F/35°C) 50Hz
Model #
Nominal
Capacity
Tons
* Electrical
Characteristic
Input Voltage-Phase
220-1 200/230-3 380/415-3
13 1 FLA — — —
19 1.5 FLA — — —
26 2 FLA 12.3 — 4.8
36 3 FLA 18.0 — 6.9
41 3.5 FLA — 17.3 8.4
66 5 FLA — 22.5 12.4
95 8 FLA — — —
*FLA = Full Load Amps
Operation
25
3.0 OPERATION
3.1 Compressor
The scroll compressor is equipped with a band type crankcase heater to resist liquid refrigerant
migration into the compressor during the Off cycle. The three-phase scroll compressor requires proper
phasing to ensure correct motor rotation. The component connections have been phase synchronized
at the factory. Refer to 2.6 - Electrical Connections to verify proper compressor wiring.
3.2 High Head Pressure
Compressor high head pressure is monitored with a pressure switch. One SPDT pressure switch is
used for each compressor in the unit. If head pressure exceeds 400 psig (2760 kPa), the switch opens
the compressor contactor and sends an input signal to the evaporator wall-box control. The high head
pressure condition is acknowledged by pressing the alarm silence button, which will clear the alarm if
the high head pressure condition no longer exists.
If the compressor is off for 1 hour, the control goes into a special cold-start mode. In the cold-start
mode on a call for cooling or dehumidification, the liquid line solenoid valve (LLSV) is energized. If
the high pressure switch does NOT trip within 10 seconds, the control returns to normal operation of
monitoring the high head pressure switch for three occurrences in a 12-hour period. It is a rolling
timer and after the third high head alarm occurs and is acknowledged by the user, it will lock off the
compressor. If while in the cold-start mode the high head pressure switch DOES trip within 10 sec-
onds of the activation of the LLSV, the control does not annunciate the alarm. The control will turn off
the LLSV and delay 10 seconds. The control will permit this occurrence two more times, or a total of
three times. If on the fourth try the high head pressure switch trips within 10 seconds, the control will
annunciate the alarm, turn off the LLSV, wait for the user to acknowledge the alarm and hold the
compressor off for 3 minutes, which is the normal short cycle control. The control will permit this
occurrence three times. On the third occurrence, the control will lock the compressor off until the con-
trol power is reset.
Check for these conditions:
• Power shut off to the condensing unit
• Condensing unit fan not working
• Defective head pressure control valves
• Closed services valves
• Dirty condensing coils
•Crimped lines
3.3 Liebert Lee-Temp Flood Back Head Pressure Control
Outdoor condensing unit components for head pressure control include a receiver, heater and
three-way head pressure control valve. The head pressure control valve operates to maintain a mini-
mum condensing pressure. During low ambient temperature operation, the valve meters discharge
gas into the receiver to maintain a discharge pressure operating against the valve dome. This closes
the condenser port, backing liquid refrigerant into the condenser coil, reducing its area available for
condensing. A receiver sized to hold the additional charge required to flood the condenser is provided.
A temperature-compensated heater maintains the liquid refrigerant pressure during Off cycles. A liq-
uid pressure switch is also installed to turn the heater Off during operation, when the receiver pres-
sure is high. The heater pressure switch has a cutout of 150 PSIG (1034 kPa) and a cut-in of 100 PSIG
(690 kPa). The receiver includes a pressure relief valve set for 475 PSIG (3275 kPa).
Operation
26
3.4 Hot Gas Bypass
3.4.1 Operation
When applying hot gas bypass with split system condensing units, bypassing discharge gas to the
compressor suction line offers more flexibility than conventional hot gas bypass to the evaporator
unit.
The hot gas bypass valve is installed between the compressor discharge piping and suction piping,
bypassing the condenser and evaporator coils. The discharge gas mixes with the suction gas, raising
the suction temperature and pressure and decreasing the mass flow through the evaporator. The
higher suction temperatures could cause compressor overheating, therefore a separate liquid quench-
ing valve is provided to mix refrigerant from the system liquid line with the discharge gas before mix-
ing with the suction gas entering the compressor. (Refer to Figure 13).
During normal operation, when the evaporator is under full load the hot gas bypass equalizer pres-
sure will remain high enough to keep the valve port closed. If the evaporator load decreases the evap-
orator temperature and pressure will drop. When the suction pressure reduces below the hot gas
bypass valve setting, the hot gas bypass valve opens, diverting some of the refrigerant flow back to
the compressor suction. The liquid quenching valve bulb senses this increased superheat and opens,
allowing liquid refrigerant to mix with the discharge gas, desuperheating it.
Proper mixing of the three refrigerant paths ensures stable operation and system performance. The
liquid quenching valve bulb must be located downstream of all these connections to control superheat
at the compressor inlet. Superheat settings for the liquid quenching valve are chosen to maintain con-
sistency with the system expansion valve. During hot gas bypass operation higher superheats,
50-60°F (10-15°C), may be observed at the compressor. The liquid-quenching valve is internally
equalized and superheat is not adjustable.
To aid in lubricating the compressor, the hot gas bypass solenoid is delayed for 30 seconds on the ini-
tial call for cooling and de-energized for 30 seconds during every 60 minutes of continuous operation.
3.4.2 Adjustment
Upon deciding what evaporator temperature is desired, the following procedure should be used to
adjust the hot gas bypass valve:
1. Install the suction and discharge pressure gauge.
2. Adjust temperature setpoint to call for cooling so that the refrigeration compressor will run
continuously.
3. Remove the TOP adjusting nut from the valve.
4. Insert an Allen wrench in the brass hole at top of valve in adjusting port and turn clockwise if a
higher evaporator temperature is required. Adjust no more than 1/4 turn at a time. Let the
system stabilize for 15 minutes before determining if additional adjustments are necessary.
5. After obtaining the suction pressure required, reinstall cap tightly making sure there are no
leaks.
6. Let the system operate for approximately 10 to 15 minutes to make sure the suction pressure is
within the range desired.
7. There may be a variation of approximately 3 to 6 PSIG (21 to 41 kPa) on the evaporator due to the
differential on the hot gas bypass.
8. Return temperature setpoint to the desired setting.
Operation
27
Figure 13 Hot gas bypass diagram
Maintenance
28
4.0 MAINTENANCE
4.1 General
Access the condensing unit by removing the unit housing panel. Clean the air cooled condenser coil of
all debris that will inhibit airflow. This can be done with compressed air or with a commercial coil
cleaner. Check for bent or damaged coil fins and repair as necessary. During winter, do not permit
snow to accumulate on or around the condensing unit. Check all refrigerant lines and capillaries for
vibration isolation and support as necessary. Check all refrigerant lines for signs of leaks.
4.2 Compressor Failure
If a compressor motor burns out, the stator wiring insulation decomposes, forming carbon, water and
acid. Not only must the compressor be replaced, but the entire refrigeration circuit must be cleaned of
the harmful contaminants left by the burnout. Successive burnouts of the same system can usually be
attributed to improper system cleaning.
Before proceeding with a suspected burnout, check all electrical components: fuses, contactors and
wiring. Check high-pressure switch operation. If a compressor failure has occurred, determine
whether it is an electrical or mechanical failure. An electrical failure will be indicated by a distinct,
pungent odor. If a severe burnout has occurred, the oil will be black and acidic. In the case of a
mechanical failure, there will be no burn odor and the motor will attempt to run.
4.2.1 Electrical Failure—Burnout
In the event that there is an electrical failure and a complete burnout of the refrigeration compressor
motor, the proper procedures must be performed in order to clean the system to remove any acids that
would cause a future failure.
4.2.2 Mechanical Failure
If a mechanical failure has occurred, the compressor must be replaced.
!
WARNING
Turn Off power to unit at disconnect switch unless you are performing tests that require
power. With power and controls energized, unit could begin operating automatically at any
time.
!
WARNING
Hazardous voltage will still be present at condenser even with power turned Off at the control
panel. To isolate unit for maintenance, turn the unit Off at disconnect switch.
!
CAUTION
If condenser power is disconnected for a long period, do not attempt to start the condensing
unit until 8 hours after restoring power. This allows time for liquid refrigerant to be driven
out of the compressor. This is especially important at low ambient temperatures.
!
WARNING
Damage to a replacement compressor caused by improper system cleaning constitutes abuse
under the terms of the warranty.
NOTE
Failure to properly clean the system after a compressor motor burnout will void the compressor
warranty. Follow the manufacturer’s procedure.
!
CAUTION
Avoid touching or contacting the gas and oils with exposed skin. Severe burns may result. Use
long rubber gloves in handling contaminated parts.
Maintenance
29
4.3 Compressor Replacement
Replacement compressors are available from Emerson. They will be shipped in a permanent crate to
the job site as required by the service contractor.
Upon shipping a replacement compressor, the service contractor will be billed in full for the compres-
sor. Credit for warranty replacement compressors will not be issued until the replacement has been
returned to the factory. The compressor should be returned in the same container used for shipping to
the job. The possible damage causes or conditions that were found must be recorded by marking the
compressor return tag.
1. Disconnect power.
2. Attach suction and discharge gauges to access fittings.
3. Recover refrigerant using approved recovery procedures and equipment. Use a filter drier when
charging the system with recovered refrigerant.
4. Unsweat refrigerant connections and disconnect electrical connections.
5. Remove failed compressor.
6. Install replacement compressor and make all connections.
7. Pressurize and leak test the system.
8. Follow manufacturer’s instructions for cleanout kits.
9. Evacuate the system twice to a minimum 250 microns, breaking the vacuum with dry nitrogen
each time. The third time, evacuate to 250 microns and verify the above levels are maintained for
at least one minute after the unit is isolated by a shutoff valve from the vacuum pump.
10. With the system in a 250 micron or lower vacuum, charge the system with liquid refrigerant
based on requirements of the evaporator, condensing unit and lines. Refer to 2.5.6 - General
System Charge Requirements or unit nameplate for system charge requirements.
11. Apply power and operate system. Check for proper operation. Refer to design pressures in
Table 13.
!
CAUTION
Do not loosen any refrigeration or electrical connections before relieving pressure.
NOTE
Release of refrigerant to the atmosphere is harmful to the environment. Refrigerant must be
recycled or discarded in accordance with federal, state, and local regulations.
Maintenance
30
4.4 Field Charge Verification
An integral sightglass is provided with the receiver to assist in field charge verification. During
charge verification set the control temperature down to keep the system running. If the system is
equipped with hot gas bypass, de-energize it by removing power from the hot gas solenoid valve coil.
To remove power, disconnect the solenoid leads from the unit contactor in the electric box (refer to
specific unit schematic; reference Figures 7 through 10). When charge verification has been com-
pleted, replace and secure all wire connections and covers.
During operation at design ambients (95 or 105°F; 35 or 41°C) the charge level will be above the sight-
glass in the receiver. If levels are below the sightglass an undercharge condition is likely. If levels are
above the sightglass and higher discharge pressures than normal are observed an overcharge condi-
tion may be likely. However, verify that other high discharge pressure causes such as dirty coil and
restricted airflow are not responsible before removing charge.
At temperatures below design ambient, refrigerant backs into the condenser coil and the level in the
receiver will drop below the sightglass. If you are trying to verify charge level at lower ambients, block
the condenser coil to maintain 230 psig (1585 kPa) discharge pressure to ensure the head pressure con-
trol valve is closed. At these conditions the charge level should be above the sightglass in the receiver.
NOTE
The 5-ton high ambient, 5-ton Quiet-Line and 8-ton models consist of two condenser coils and
two receivers. When restricting airflow on these units, the coils should be blocked off
proportionally. If one coil is restricted significantly more than the other, liquid can remain in
the restricted coil causing lower levels in the receivers. The receiver liquid level should be above
the sightglasses in both receivers. There may be some variation in charge level between the two
receiver sightglasses due to piping and assembly variations. When adding charge, determine
which receiver level is lower and use that sightglass to gauge charge level.
NOTE
If no level is visible in the sightglass, add charge until the level is in the middle of the
sightglass. Check the discharge pressure during this procedure and adjust coil restrictions to
maintain 230 psig (1585 kPa). Once the charge is in the middle of the sightglass, add
additional system charge per Table 22. After charging, unblock the coil and allow the unit to
operate normally. After conditions have stabilized, restrict the coil if required to maintain 230
psig (1585 kPa) discharge pressure and verify that the charge level is above the sightglass.
Table 22 Field verification charge
Model Numbers R-407C
60 Hz 50 Hz oz (kg)
PFH014A-_L PFH013A-_L
4 (0.11)PFH020A-_L PFH019A-_L
PFH027A-_L PFH026A-_L
PFH027A-_H PFH026A-_H
18 (0.51)
PFHZ27A-_L PFHZ26A-_L
PFH037A-_L PFH036A-_L
PFH042A-_L PFH041A-_L
PFH037A-_H PFH036A-_H
8 (0.23)
PFHZ37A-_L PFHZ36A-_L
PFH042A-_H PFH041A-_H
PFHZ42A-_L PFHZ41A-_L
PFH067A-_L PFH066A-_L 18 (0.51)
PFH067A-_H PFH066A-_H 50 (1.42)
PFHZ67A-_L PFHZ66A-_L
PFH096A-_L
3-ton circuit
5-ton circuit
PFH095A-_L
3-ton circuit
5-ton circuit
18 (0.51)
18 (0.51)
Troubleshooting
31
5.0 TROUBLESHOOTING
Table 23 Troubleshooting
Problem Cause Remedy
Unit will not start
No power to unit Check voltage at input terminal block.
Compressor contactor not pulling in
Check for 24VAC ±2VAC at control connections 1 & 2. If
no voltage, check control setting requires cooling. If there
is voltage, lockout relay may be energized. Check for
24VAC at control connections 2 & 3. If there is voltage,
see compressor high-discharge pressure/lockout relay.
Control voltage circuit breaker (at
transformer in evaporator module)
open
Locate short and reset circuit breaker.
Short cycle prevention control Control software delays compressor 3 minutes from stop
to start.
Compressor high discharge
pressure/ lockout relay
Check for 24VAC ±2VAC at control connections 2 & 3.
Remove 24VAC signal at Connection 2 by turning indoor
unit control off, then back on, or by raising the setpoint to
remove the cab for cooling, then resetting to re-establish
operation.
High discharge
pressure
Insufficient air flow across
condenser coil
Check fan operation. Remove debris from coil and air
inlets.
High refrigerant charge Check refrigerant charge.
Low discharge pressure
Faulty head pressure control valve Replace if defective.
Compressor rotation in reverse
direction
Check for proper power phase wiring to unit and to
compressor motor.
Low suction pressure /
compressor cycling
Insufficient refrigerant in system Check for leaks; repair and add refrigerant.
Plugged filter drier Replace filter drier.
Improper superheat adjustment Reset expansion valve for 10-15°F (5.6 to 8.4°C)
superheat at evaporator.
Defective liquid line solenoid valve Check valve and coil; replace if necessary.
Low compressor
capacity/ no cooling
Defective liquid line solenoid valve Check valve and coil; replace if necessary.
Plugged filter drier Check pressure drop across filter drier. Replace filter
drier.
Low refrigerant charge
Check for normal system operating pressures. Refer to
abnormal pressure causes if applicable. Check for leaks.
Proper refrigerant charge is very important at low ambient
operation.
Compressor noisy
Loose compressor or piping
support Tighten clamps.
Compressor rotation in reverse
direction
Check for proper power phase wiring to unit and to
compressor motor.
Pipe Rattle Loose pipe connections Check pipe connections.
Compressor running hot Compression ratio too high Check for normal system operating pressures. Refer to
abnormal pressure causes if applicable.
Compressor motor
protectors tripping or
cycling
High discharge pressure Check for blocked condenser fan or coil.
High suction temperature Check expansion valve and hot gas bypass valve setting.
Check liquid quenching valve operation.
Loose power or control circuit
wiring connection Check all power and control circuit connections.
Defective motor Check for motor ground or short. Replace compressor if
either condition is found.
Compressor cycles on
locked rotor
Low line voltage Check line voltage and determine location of voltage drop.
Compressor motor defective Check for motor winding short or ground.
Single phasing Check voltage across all 3 legs at contactor. Correct
source of problem.
Motor burnout
Check control panel for welded
contactor contacts or welded
overload contacts.
Replace defective components.
Ensuring The High Availability
Of Mission-Critical Data And Applications.
Emerson Network Power, the global leader in enabling business-critical
continuity, ensures network resiliency and adaptability through
a family of technologies—including Liebert power and cooling
technologies—that protect and support business-critical systems.
Liebert solutions employ an adaptive architecture that responds
to changes in criticality, density and capacity. Enterprises benefit
from greater IT system availability, operational flexibility and
reduced capital equipment and operating costs.
While every precaution has been taken to ensure the accuracy
and completeness of this literature, Liebert Corporation assumes no
responsibility and disclaims all liability for damages resulting from use of
this information or for any errors or omissions.
© 2008 Liebert Corporation
All rights reserved throughout the world. Specifications subject to change
without notice.
® Liebert is a registered trademark of Liebert Corporation.
All names referred to are trademarks
or registered trademarks of their respective owners.
Technical Support / Service
Web Site
www.liebert.com
Monitoring
liebert.monitoring@emerson.com
800-222-5877
Outside North America: +800 1155 4499
Single-Phase & Three-Phase UPS
liebert.upstech@emerson.com
800-222-5877
Outside North America: +800 1155 4499
Environmental Systems
800-543-2778
Outside the United States: 614-888-0246
Locations
United States
1050 Dearborn Drive
P.O. Box 29186
Columbus, OH 43229
Europe
Via Leonardo Da Vinci 8
Zona Industriale Tognana
35028 Piove Di Sacco (PD) Italy
+39 049 9719 111
Fax: +39 049 5841 257
Asia
29/F, The Orient Square Building
F. Ortigas Jr. Road, Ortigas Center
Pasig City 1605
Philippines
+63 2 687 6615
Fax: +63 2 730 9572
EmersonNetworkPower.com
Emerson Network Power.
The global leader in enabling Business-Critical Continuity.
Business-Critical Continuity, Emerson Network Power and the Emerson Network Power logo are trademarks and service marks of Emerson Electric Co.
©2008 Emerson Electric Co.
Monitoring
AC Power
Connectivity
DC Power
Embedded Computing
Embedded Power Power Switching & Controls
Precision Cooling
Services
Racks & Integrated Cabinets
Outside Plant
Surge Protection
SL-10059_REV02_10-09

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