liebert® mini-mate™ installer/user guide...tableofcontents 1importantsafetyinstructions 1...

Liebert®

Mini-Mate™ Variable CapacityThermal Management Systems

Installer/User Guide3, 4 and 5 Ton (10.5, 14 and 17.5 kW) Capacity, Ceiling Mounted, 60 Hz

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

Technical Support Site

If you encounter any installation or operational issues with your product, check the pertinent section of thismanual to see if the issue can be resolved by following outlined procedures.Visit https://www.Vertiv.com/en-us/support/ for additional assistance.

The information contained in this document is subject to change without noticeand may not be suitable for all applications. While every precaution has beentaken to ensure the accuracy and completeness of this document, Vertivassumes no responsibility and disclaims all liability for damages resulting fromuse of this information or for any errors or omissions. Refer to other localpractices or building codes as applicable for the correct methods, tools, andmaterials to be used in performing procedures not specifically described in thisdocument.

The products covered by this instruction manual are manufactured and/or soldby Vertiv. This document is the property of Vertiv and contains confidentialand proprietary information owned by Vertiv. Any copying, use or disclosure ofit without the written permission of Vertiv is strictly prohibited.

Names of companies and products are trademarks or registered trademarks ofthe respective companies. Any questions regarding usage of trademark namesshould be directed to the original manufacturer.

https://www.vertiv.com/en-us/support/

TABLE OF CONTENTS

1 Important Safety Instructions 1

2 Nomenclature and Components 7

2.1 Mini-Mate Model Number Nomenclature 7

2.2 Component Location 9

3 Pre-installation Preparation and Guidelines 11

3.1 Planning Dimensions 11

3.2 Location Considerations 11

3.2.1 Location Considerations for Outdoor Condensing Unit 12

3.3 Connections and System Setup 12

3.4 Operating Conditions 12

3.4.1 Cooling, Humidification, and Dehumidification 13

3.4.2 Heating 13

3.5 Mini-Mate Unit Weights 13

3.6 Equipment Inspection and Handling 13

4 Piping and Refrigerant Requirements 15

4.1 Refrigerant Piping and Charging 15

4.1.1 Refrigerant Piping Guidelines for Air Cooled Systems 16

4.1.2 Piping when Condensing Unit is Above or Below Evaporator 17

4.2 Refrigerant Line Sizes and Equivalent Lengths 18

4.2.1 Refrigerant Charge Requirements for Air Cooled Systems 19

4.2.2 Additional Oil Requirements for Digital Scroll Compressors 20

4.3 Water/Glycol Loop Piping Guidelines 21

4.3.1 Refrigerant Charge Requirements for Water/Glycol Cooled Systems 22

4.3.2 Evacuation and Leak Testing Water/Glycol Cooled Systems 23

4.3.3 Charging Water/Glycol Cooled Systems 26

4.3.4 Optimizing Refrigerant Charge on Water/Glycol Units 27

4.3.5 Documenting Refrigerant Charge on Water/Glycol Cooled Units 27

4.4 Drain and Humidifier Piping 27

4.4.1 Water Supply Line to the Humidifier 28

4.4.2 Drain Line Installation Requirements 28

4.4.3 Condensate Drain Pump Kit 30

5 Electrical Connection Requirements 31

5.1 Low Voltage Electrical Field Connections 32

6 Installation 35

6.1 Installing Ceiling Mounted Units 35

6.1.1 Installing Suspension Rods and Mounting Ceiling Units 35

6.2 Installing Air Distribution Components for Evaporators 36

6.2.1 Installing a Filter Box for 3 Ton Models 36

i

6.2.2 Installing an Air Distribution Plenum for 3 Ton Models 37

6.2.3 Installing a Filter Box for 4 Ton and 5 Ton Models 37

6.2.4 Installing a Bottom Discharge Grille for 4 Ton and 5 Ton Models 37

6.2.5 Guidelines for Ducted Systems 37

7 Checklist for Completed Installation 39

7.1 Moving and Placing Equipment 39

7.2 Electrical Installation Checks 39

7.3 Piping Installation Checks 39

7.4 Other Installation Checks 39

8 Initial Start-up Checks and Commissioning Procedure for Warranty Inspection 41

9 Maintenance 43

9.1 Filters 44

9.1.1 Filter Replacement 44

9.2 Blower Drive System—EC Fans 45

9.2.1 Fan Impellers and Bearings Maintenance 45

9.2.2 Protective Features 46

9.2.3 Fan Assembly Troubleshooting 46

9.3 Direct Drive Blower System 50

9.3.1 Fan Impellers and Motor Bearings Maintenance 50

9.4 Steam Generating Humidifier Maintenance 50

9.4.1 Operating the Humidifier 51

9.4.2 Replacing the Canister 52

9.4.3 Circuit Board Adjustments 52

9.4.4 Humidifier Troubleshooting 53

9.5 Condensate Drain and Condensate Pump System Maintenance 54

9.5.1 Condensate Drain 54

9.5.2 Condensate Pump 54

9.6 Electric Reheat Maintenance 54

9.7 Thermostatic Expansion Valve (TXV) Maintenance 54

9.7.1 Determining Suction Superheat 54

9.7.2 Adjusting Superheat Setting with the TXV 55

9.7.3 Coaxial Condenser Maintenance (Water/Glycol Cooled Condensers Only) 55

9.7.4 Regulating Valve Maintenance (Water Glycol Cooled Condensers Only) 55

9.7.5 Glycol Solution Maintenance 55

10 Preventive Maintenance Checklist 57

Appendices 61

Appendix A: Technical Support and Contacts 61

Appendix B: Submittal Drawings 63

Vertiv | Liebert® Mini-Mate™ Installer/User Guideii

1 IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS

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

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

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

WARNING! Arc flash and electric shock hazard. Open all local and remote electric power supply disconnectswitches, verify with a voltmeter that power is Off and wear appropriate, OSHA-approved personal protectiveequipment (PPE) per NFPA 70E before working within the electric control enclosure. Failure to comply cancause serious injury or death. Customer must provide earth ground to unit, per NEC, CEC and local codes, asapplicable. Before proceeding with installation, read all instructions, verify that all the parts are included andcheck the nameplate to be sure the voltage matches available utility power. The Liebert® controller does notisolate power from the unit, even in the “Unit Off” mode. Some internal components require and receivepower even during the “Unit Off” mode of the controller. The only way to ensure that there is NO voltageinside the unit is to install and open a remote disconnect switch. Refer to unit electrical schematic. Follow alllocal codes.

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

WARNING! Risk of electric shock. Can cause serious injury or death. The Liebert® iCOM microprocessor doesnot isolate power from the unit, even in the "Unit Off" mode. Some internal components require and receivepower even during the "unit off" mode of the Liebert® iCOM control. Open all local and remote electric powerdisconnect switches and verify with a voltmeter that power is Off before working on any component of thesystem.

WARNING! Risk of electric shock. Can cause injury or death. Open all local and remote electric power-supplydisconnect switches and verify that power is Off with a voltmeter before working within the condensatepump electrical connection enclosure. The Liebert® iCOM™ does not isolate power from the unit, even in the“Unit Off” mode. Some internal components require and receive power even during the “Unit Off” mode of theLiebert® iCOM.


WARNING! Risk of over-pressurization of the refrigeration system. Can cause explosive discharge of high-pressure refrigerant, loss of refrigerant, environmental pollution, equipment damage, injury, or death. Thisunit contains fluids and gases under high pressure. Use extreme caution when charging the refrigerantsystem. Do not pressurize the system higher than the design pressure marked on the unit's nameplate.Relieve pressure before cutting into or making connections/disconnections to the piping system. Localbuilding or plumbing codes may require installing a pressure-relief device in the system. Consult localbuilding and plumbing codes for installation requirements of additional pressure-relief devices whenisolation valves are field installed. Do not isolate any refrigerant circuit from over-pressurization protection.Do not close off any field-installed, refrigerant-line isolation valves for repairs unless a pressure-relief valve isfield- installed in the line between the isolation valve and the check valve. The pressure-relief valve must berated 5% to 10% higher than the system-design pressure. An increase in ambient temperature can cause thepressure of the isolated refrigerant to rise and exceed the system-design pressure rating (marked on theunit nameplate).

WARNING! Risk of improper moving. Can cause equipment damage, injury or death. Use only liftingequipment that is rated for the unit weight by an OSHA-certified rating organization. The center of gravityvaries depending on the unit size and selected options. The slings must be equally spaced on either side ofthe center of gravity indicator. Unit weights are listed in Table 3.2 on page 13.

WARNING! Risk of contact with high-speed rotating fan blades. Can cause serious injury or death. Open alllocal and remote electric power-supply disconnect switches, verify with a voltmeter that power is off, andverify that all fan blades have stopped rotating before working in the unit cabinet or on the fan assembly. Ifcontrol voltage is applied, the fan motor can restart without warning after a power failure. Do not operate theunit with any or all cabinet panels removed.

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

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

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

Vertiv | Liebert® Mini-Mate™ Installer/User Guide2

CAUTION: Risk of improper moving, lifting and handling. Can cause equipment damage or injury. Onlyproperly trained and qualified personnel should work on this equipment. Evaporator fan modules weigh inexcess of 37 lb (17 kg). Use proper lifting techniques and wear appropriate, OSHA-approved PPE to avoidinjury and dropping the fan module during removal. Equipment used in handling/lifting, and/or installing thefan assembly must meet OSHA requirements. Use handling/lifting equipment rated for the weight of the fanassembly. Use ladders rated for the weight of the fan assembly and technicians if used during installation.Refer to handling/lifting, and/or installation equipment operating manual for manufacturer's safetyrequirements and operating procedures.

CAUTION: Risk of improper moving, lifting and handling. Can cause equipment damage or injury. Onlyproperly trained and qualified personnel should work on this equipment. Condenser fan modules weigh inexcess of 37 lb (17 kg). Use proper lifting techniques and wear appropriate, OSHA-approved PPE to avoidinjury and dropping the fan module during removal. Equipment used in handling/lifting, and/or installing thefan assembly must meet OSHA requirements. Use handling/lifting equipment rated for the weight of the fanassembly. Use ladders rated for the weight of the fan assembly and technicians if used during installation.Refer to handling/lifting, and/or installation equipment operating manual for manufacturer's safetyrequirements and operating procedures.

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

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

CAUTION: Risk of exposure to harmful noise levels. Can cause hearing injury or loss. Depending on theinstallation and operating conditions, a sound pressure level greater than 70 dB(A) may arise. Takeappropriate technical safety measures. Operating personnel must wear appropriate, OSHA-approved PPEand observe all appropriate hearing-protection safety requirements.

NOTICE

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

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


NOTICE

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

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

NOTICE

Risk of improper refrigerant charging. Can cause equipment damage.

Refrigerant charge must be weighed into air-cooled compressorized systems before they are started. Startingdigital scroll compressors without proper refrigerant charging can cause the compressors to operate at lessthan 5°F (–15°C) evaporator temperature and at less than 55 psig (379 kPa). Operation for extended periods atless than 55 psig (379 kPa) can cause premature compressor failure.

NOTICE

Risk of clogged or leaking drain lines and leaking water supply lines. Can cause equipment and buildingdamage.

This unit requires a water drain connection. Drain lines must be inspected at start-up and periodically, andmaintenance must be performed to ensure that drain water runs freely through the drain system and that linesare clear and free of obstructions and in good condition with no visible sign of damage or leaks.

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

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

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


NOTICE

Risk of leaking water/glycol. Can cause equipment and building damage. Improper installation, application,and service practices can result in water leakage from the unit. Do not mount this unit over equipment andfurniture that can be damaged by leaking water. Install a water-tight drain pan with a drain connection underthe cooling unit and the ceiling mounted water/glycol condensing unit. Route the drain line to a frequently-usedmaintenance sink so that running water can be observed and reported in a timely manner. Post a sign to alertpeople to report water flowing from the secondary drain pan. We recommend installing monitored leakdetection equipment for the unit and supply lines and in the secondary drain pan. Check drain linesperiodically for leaks, sediment buildup, obstructions, kinks and/or damage and verify that they are freerunning.

NOTICE

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

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

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

Proper inhibitor maintenance must be performed in order to prevent corrosion of the system. Consult glycolmanufacturer for testing and maintenance of inhibitors. Commercial ethylene glycol, when pure, is generallyless corrosive to the common metals of construction than water itself. It will, however, assume the corrosivity ofthe water from which it is prepared and may become increasingly corrosive with use if not properly inhibited.We recommend installing a monitored fluid-detection system that is wired to activate the automatic-closure offield-installed coolant-fluid supply and return shut-off valves to reduce the amount of coolant-fluid leakage andconsequential equipment and building damage. The shut-off valves must be sized to close-off against themaximum coolant-fluid system pressure in case of a catastrophic fluid leak

NOTICE

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

When piping or the cooling unit may be exposed to freezing temperatures, charge the system with the properpercentage of glycol and water for the coldest design ambient temperature. Automotive antifreeze isunacceptable and must NOT be used in any glycol fluid system. Use only HVAC glycol solution that meets therequirements of recommended industry practices.


NOTICE

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

NOTICE

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

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

NOTICE

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

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

Sagging condensate drain lines may inadvertently create an external trap.

NOTICE

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

NOTICE

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

NOTICE

Risk of improper storage. Can cause unit damage.

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

Agency Listed

Standard 60-Hz units are CSA Certified to the harmonized U.S. and Canadian product safety standard CSA C22.2 No236/UL 1995 for “Heating and Cooling Equipment” and are marked with the CSA c-us logo.


2 NOMENCLATURE AND COMPONENTS

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

2.1 Mini-Mate Model Number Nomenclature

The tables below describe each digit of the 25-digit configuration number. The 14-digit model number consists of the first10 digits and last 4 digits of the configuration number.

Model Number Digit Definitions below describes each digit of the model number.

Model Number Digits 1 to 10 Model Details Model Number Digits 11 to 14

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

M T 0 6 0 H E 1 A 0 S H 2 0 D 0 U 0 P 0 0 A # # #

Table 2.1 Mini-Mate 25-Digit Configuration Number

Digit and Description

Digits 1 and 2 = Unit Family

MT = Mini-Mate Ceiling System

Digits 3, 4, 5 = Nominal Cooling Capacity

036 = 36 kBtuh

048 = 48 kBtuh

060 = 60 kBtuh

Digit 6 = Air Direction and Discharge

H = Horizontal air flow

Digit 7 = System type

E = Split System evaporator

Digit 8 = Fan type

1 = Direct Drive EC motor (variable-speed)

Digit 9 = Supply power

A = 460 V / 3 ph / 60 Hz

B = 575 V / 3 ph / 60 Hz (048 and 060 models only)

C = 208 V / 3 ph / 60 Hz (048 and 060 models only)

D = 230 V / 3 ph / 60 Hz (048 and 060 models only)

P = 208-230/1ph/60Hz (036 model only)

Y = 208-230/3ph/60Hz (036 model only)

Digit 10 = Evaporator Type

0 =Split System evaporator

Digit 11 = Humidifier

0 = No humidifier

S = Steam-gen canister humidifier

Table 2.2 Model Number Digit Definitions


Digit and Description

Digit 12 = Display type

H = 9-in. remote display, IntelliSlot-based monitoring (048 and 060 models only)

1 = 9-in. remote display, iCOM-based monitoring (036 model only)

Digit 13 = Reheat

0 = No reheat

2 = Electric reheat

5 = SCR reheat (048 and 060 models only)

Digit 14 = Coil, Valve, Pressure

0 = Split System evaporator

Digit 15 = High-voltage options

D = Non-locking disconnect, 5k SCCR (048 and 060 models only)

L = Locking disconnect, 5kA SCCR (036 model only)

M = Locking disconnect, 65k SCCR (048 and 060 models only)

Digit 16 = Low-voltage options

0 = None

L = Low voltage terminal package (LVTP)

Digit 17 = Monitoring Cards

0 = No card, IntelliSlot only (048 and 060 models only)

U = IS-UNITY-DP card, factory-installed (048 and 060 models only)

B = BACnet, Modbus, SNMP using iCOM board (036 model only)

Digit 18 = Sensors

0 = None

S = Smoke sensor

H = High Temperature sensor

F = Smoke and high temperature sensor

Digit 19 = Packaging

P = Domestic

C = Wood crate export

Digits 20, 21 = Future use

Digit 22 = Factory configuration code

A = No SFA’s (Any Alpha letter except S)

S = SFA

Digit 23-25 = Factory Configuration Number

Table 2.2 Model Number Digit Definitions (continued)


2.2 Component Location

The unit component locations are described in the submittal documents included in the Submittal Drawings on page 63.

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

Document Number Title

DPN004808 Evaporator Unit, 3 Ton

DPN004179 Evaporator Unit, 4 Ton and 5 Ton

Table 2.3 Component Location Drawings



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3 PRE-INSTALLATION PREPARATION AND GUIDELINES

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

Refer to Model Number Digit Definitions on page 7, and submittal drawings to determine the type of system being installedand anticipate building alterations, piping and duct work needed.

The unit dimensions, pipe connection locations, and piping schematics are described in the submittal documents includedin the Submittal Drawings on page 63.

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

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

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

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

• We recommend installing a water detection system. Contact your Vertiv representative for information.

3.1 Planning Dimensions

The unit dimensions described in the submittal documents included in the Submittal Drawings on page 63.

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


DPN004800 Cabinet dimensions, 3 ton DX module

DPN004055 Cabinet dimensions, 4 ton and 5 ton DX module

Filter and Ducting Options

DPN004805 Dimensional data, filter box and duct flange, 3 ton

DPN004807 Dimensional data, air distribution plenum 3 ton

DPN004166 Dimensional data, filter box and duct flange, 4 and 5 ton

DPN004842 Dimensional data, bottom discharge grille, 4 and 5 ton

Table 3.1 Dimension Planning Drawings

3.2 Location Considerations

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

The evaporator is usually mounted above the dropped ceiling and must be securely mounted to the roof structure. Forducted systems, the evaporator may be located in a different room. See Guidelines for Ducted Systems on page 37 foradditional guidelines. For a split system with an air cooled, outdoor condensing unit, the condensing unit may be mountedon the roof or remotely in an outdoor area. See Location Considerations for Outdoor Condensing Unit on the next page foradditional guidelines.

Refer to Refrigerant Line Sizes and Equivalent Lengths on page 18 for maximum refrigerant line lengths.


The ceiling and ceiling supports of existing buildings may require reinforcement. See Mini-Mate Unit Weights on the facingpage. Be sure to follow all applicable national and local codes.

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

• Installed above the suspended ceiling near the evaporator.

• In any remote indoor area, subject to the requirements detailed in Table 4.3 on page 17.

Refer to Refrigerant Line Sizes and Equivalent Lengths on page 18 for maximum refrigerant line lengths.

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

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

3.2.1 Location Considerations for Outdoor Condensing Unit

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

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

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

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

• The condensing unit should be located for maximum security and maintenance accessibility. Avoid ground-level sites with public access. Install a solid base, capable of supporting the weight of the condensing unit.

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

Before beginning, refer to Piping and Refrigerant Requirements on page 15 for unit placement, piping guidelines, andrefrigerant charge requirements for your system.

3.3 Connections and System Setup

• The unit requires a drain, which must comply with all applicable codes. This drain line may contain boilingwater. See Drain Line Installation Requirements on page 28, for details.

• Electrical service is required for all models. Electrical service must conform to national and local electricalcodes. See equipment nameplate for details.

• Plan the routing of wiring, piping, and duct work to the unit. Refer to the appropriate piping connection locationdrawings, piping schematics, and electrical connection drawings for your system in .

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

3.4 Operating Conditions

The Liebert® Mini-Mate must be operated in a conditioned space within the operating envelope that ASHRAE recommendsfor data centers. Operating the Mini-Mate outside of this envelope can decrease equipment reliability. Refer to ASHRAE’spublication, “Thermal Guidelines for Data Processing Environments.”


3.4.1 Cooling, Humidification, and Dehumidification

For operation in the Cooling, Humidification, or Dehumidification modes, the Liebert® Mini-Mate unit’s return airrequirements for proper unit operation are:

• Maximum dew point of 59°F (15°C)

• Minimum 65°F (20°C) DB

• Maximum 85°F (29.4°C) DB

3.4.2 Heating

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

• Maximum humidity: less than 80% RH and less than 64°F (17.8°C) dew point.

• Maximum dry bulb of 80°F (27°C)

3.5 Mini-Mate Unit Weights

Model # Weight, lb (kg)

MT036 328 (149)

MT048* 498 (226)

MT060* 498 (226)

* for 575-V units, add 32 lb (14.5 kg)

Table 3.2 Mini-Mate Unit Weights

3.6 Equipment Inspection and Handling

SAFETY INFORMATION

WARNING! Risk of improper moving, lifting, or handling of the unit. Can cause equipment damage, injury ordeath. Read all of the following instructions and verify that all lifting and moving equipment is rated for theweight of the unit before attempting to move, lift, remove packaging from or prepare the unit for installation.Unit weights are specified in section Mini-Mate Unit Weights above.

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

NOTICE

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

NOTICE

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


NOTICE

Risk of improper storage. Keep the unit upright, indoors and protected from dampness, freezing temperaturesand contact damage.

Upon arrival of the unit and before unpacking:

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

• Carefully inspect all items for visible or concealed damage.

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

Equipment Recommended for Handling the Unit:

• Forklift

• Pallet jack


4 PIPING AND REFRIGERANT REQUIREMENTS

All fluid and refrigeration connections to the unit, with the exception of the condensate drain and humidifier supply line, aresweat copper. Factory installed piping brackets must not be removed. Field installed piping must be installed inaccordance with local codes and must be properly assembled, supported, isolated, and insulated. Avoid piping runsthrough noise sensitive areas, such as office walls and conference rooms.

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

The following pipe connections are required:

• Refrigerant piping connections between the evaporator unit and the condensing unit.

• A drain line from the unit or a drain line from the optional condensate pump (if applicable).

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

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

• On water/glycol systems: connections to a water or glycol loop. See Water/Glycol Loop Piping Guidelines onpage 21, for additional requirements.

The pipe connection locations, piping general arrangement, and schematics are described in the submittal documentsincluded in the Submittal Drawings on page 63.



Air Cooled System

DPN004060 Piping arrangement, 3, 4 and 5 ton split system

Water/Glycol Cooled System

DPN004893 Piping arrangement, 3, 4 and 5 ton split system

Table 4.1 Piping General Arrangement Drawings


DPN004801 Primary connection locations, 3 ton DX module

DPN004806 Condensate pump connection locations, 3 ton

DPN004056 Primary connection locations, 4 ton and 5 ton DX module

DPN004077 Condensate pump connection locations, 4 ton and 5 ton

Table 4.2 Piping Connection Drawings

4.1 Refrigerant Piping and Charging

WARNING! Risk of over-pressurization of the refrigeration system. Can cause explosive discharge of high-pressure refrigerant, loss of refrigerant, environmental pollution, equipment damage, injury, or death. Thisunit contains fluids and gases under high pressure. Use extreme caution when charging the refrigerantsystem. Do not pressurize the system higher than the design pressure marked on the unit's nameplate.


Consult local building and plumbing codes for installation requirements of additional pressure relief devices when isolationvalves are field installed. Do not isolate any refrigerant circuits from over-pressurization protection.

NOTICE

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

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

4.1.1 Refrigerant Piping Guidelines for Air Cooled Systems

• Evaporators and condensing units ship with an inert gas holding charge. Do not vent the evaporator andcondensing unit until all refrigerant piping is in place, ready for connection to the unit and condensing unit.

• Use copper piping with a brazing alloy with a minimum temperature of 1350°F (732°C), such as Sil-Fos. Avoidsoft solders, such as 50/50 or 95/5.

• Use a flow of dry nitrogen through the piping during brazing to prevent formation of copper oxide scale insidethe piping. When copper is heated in the presence of air, copper oxide forms. POE oils will dissolve theseoxides from inside the copper pipes and deposit them throughout the system, clogging filter driers andaffecting other system components.

• A pure dry nitrogen flow of 1-3 ft3/min (0.5-1.5 l/s) inside the pipe during brazing is sufficient to displace the air.Control the flow using a suitable measuring device.

• Ensure that the tubing surfaces to be brazed are clean and that all burrs have been removed from the ends ofthe tubes.

• Ensure that all loose material has been cleaned from inside the tubing before brazing.

• Protect all refrigerant line components within 18 in. (460 mm) of the brazing site by wrapping them with a wetcloth or with a suitable heat sink compound.

• Isolate piping from building using vibration isolating supports.

• When sealing openings in walls and to reduce vibration transmission, use a soft, flexible material to packaround the tubes to prevent tube damage.

• When installing remote condensing units above the evaporator, the suction gas lines should be trapped at theevaporator. These traps will retain refrigerant oil in the off cycle. When the unit starts, oil in the traps is carriedup the vertical risers and returns to the compressors. For rises over 25 ft (7.6 m), trap every 20 ft (6 m) orevenly-divided.

• Consult factory if piping run exceeds 150 ft (46 m) equivalent length.

• Keep piping clean and dry, especially on units with R-410A refrigerant.

• Avoid piping runs through noise sensitive areas.

• Do not run piping directly in front of discharge air stream.

• Refrigerant oil – do not mix oil types.

Refer to ASHRAE Refrigeration Handbook for general, good practice refrigeration piping.

NOTE: All indoor and outdoor suction line piping must have 1/2 in. minimum of insulation. All outdoor insulation mustbe UV and ozone resistant.


NOTE: Proper safety equipment and proper refrigeration tools are required when working with R-410A refrigerant.Check unit serial tag for correct refrigerant type before topping off or recharging a system.

NOTE: Refrigerant R-410A uses a POE (polyolester) lubricant. The refrigerant must be introduced and charged fromthe cylinder only as a liquid.

NOTE: When installing field piping, you must take care to protect all refrigerant lines from the atmosphere especiallywhen using refrigerants with POE oils. Do not allow the piping to stand open to air for more than 15 minutes. Unitsdesigned for R-410A have a compressor that contains POE oil, which quickly absorbs water from the air. The longerthat the refrigerant piping is left open to air, the harder it will be to fully evacuate the system. If left open too long, thePOE oil may require replacement to achieve the required vacuum level.

• Refer to Refrigerant Line Sizes and Equivalent Lengths on the next page, for recommended refrigerant pipingsizes based on equivalent pipe lengths.

• Refer to the condensing unit's Installer/User Guide for the complete charging procedure of the system.

4.1.2 Piping when Condensing Unit is Above or Below Evaporator

Refer to Table 4.3 below for the maximum vertical rise/fall between condensing unit and evaporator.

When installing remote condensing units above the evaporator, trap the suction gas line at the evaporator as shown inFigure 4.1 below. Traps recommended at the base of riser exceeding 5 ft. (1.5 m) and every 20 ft. (6 m) of vertical rise. Thistrap will retain refrigerant oil during the "Off" cycle. When the unit starts, oil in the trap is carried up the vertical riser andreturns to the compressor.

When installing remote condensing units below the evaporator, trap the suction gas line with an inverted trap the height ofthe evaporator as shown in the following figure. This prevents refrigerant migration to the compressor during "Off" cycles.

Maximum Equivalent Pipe Length, ft. (m)Maximum Condensing Unit Level Above

Evaporator, ft. (m)Maximum Condensing Unit Level Below

Evaporator, ft. (m)

150 (45) 50 (15) 15 (4.6)

Table 4.3 Pipe Length and Condensing Unit Elevation Relative to Evaporator

Figure 4.1 Refrigerant Piping Diagram When Condenser is Above or Below Evaporator

NOTE: Any horizontal pipe must be pitched down toward the condensing unit at a minimum rate of 1/2 in. (13 mm) per10 ft. (3 mm) to assure oil return to compressor.


4.2 Refrigerant Line Sizes and Equivalent Lengths

The following tables list the information required to field install the refrigerant piping for the system.

Equivalent Length, ft (m)

3 Ton 4 Ton 5 Ton

Suction Liquid Suction Liquid Suction Liquid

50 (15) 7/8 1/2 7/8 1/2 1-1/8 1/2

75 (23) 7/8 1/2 1-1/8 1/2 1-1/8 5/8

100 (30) 7/8 1/2 1-1/8 5/8 1-1/8 5/8

125 (38) 7/8 1/2 1-1/8¹ 5/8 1-1/8 5/8

150 (45) 7/8 1/2 1-1/8 5/8 1-1/8 5/8

Consult factory for proper line sizing for runs longer than maximum equivalent length shown.

1. Use one line size smaller on suction lines for vertical risers.

Source: DPN000788 Rev. 13

Table 4.4 Recommended Refrigerant Line Sizes, O.D. cu by Equivalent Length


4.2.1 Refrigerant Charge Requirements for Air Cooled Systems

To calculate the charge requirements:

1. Determine the charge for your units by model number from the following tables.

2. Determine the charge for the piping by line size and length.

3. Add these all together to obtain the total refrigerant charge for your system.

Model # Charge, lb (kg)

MT036HE 1 (0.45)

MT048HE 2.2 (1.0)

MT060HE 2.2 (1.0)

Table 4.5 Indoor Evaporator Approximate R-410A Refrigerant Charge

Line Size,O.D., in.

Liquid Line, lb/100 ft (kg/30 m) Suction Line, lb/100 ft (kg/30 m)

3/8 3.2 (1.4) —

1/2 5.9 (2.7) 0.2 (0.1)

5/8 9.6 (4.3) 0.4 (0.2)

3/4 14.3 (6.4) 0.6 (0.3)

7/8 19.8 (8.8) 0.8 (0.4)

1-1/8 33.8 (15.1) 1.4 (0.6)

1-3/8 51.5 (23.0) 2.1 (1.0)


Table 4.6 Interconnecting Piping Refrigerant Charge for R-410A using Type L Copper Tube


PFD037A-*L1 13.4 (6.1)

PFD037A-*H1 27 (12.2)

PFD054A-*L1 27 (12.2)

PFD067A-*L1 27 (12.2)

PFDZ67A-*L1 57 (25.8)

PFD067A-*H1 57 (25.8)

Table 4.7 PFD Condensing Unit R-410A Refrigerant Charge


4.2.2 Additional Oil Requirements for Digital Scroll Compressors

NOTICE

Risk of improper compressor lubrication. Can cause compressor and refrigerant system damage.

Failure to use oil types, viscosities and quantities recommended by the compressor manufacturer may reducecompressor life and void the compressor warranty.

• Do not mix polyolester (POE) and mineral-based oils.

• Do not mix oils of different viscosities.

• Consult your Vertiv sales representative, visit https://www.Vertiv.com/en-us/support/, or contact thecompressor manufacturer if questions arise.

System charges may require additional oil charge to be added. See Table 4.8 below, for the amount required for varioussystem charge levels.

After the system has been fully charged with refrigerant, use a hand pump to add the additional oil at the suction side of thesystem while the system is running.

On the tag marked “Oil Added Field Service Record,” attached to each compressor, record the date the oil was added andthe amount of oil added.

3 Ton 4 Ton 5 Ton

Refrigerant SystemCharge per Circuit,

lb (kg) *Additional Oil Required Per Circuit, oz (ml)

4.3 Water/Glycol Loop Piping Guidelines

WARNING! Risk of improper piping installation, leak checking, fluid chemistry and fluid maintenance cancause equipment damage and personal injury. Installation and service of this equipment should be done onlyby qualified personnel who have been specially trained in the installation of air conditioning equipment andwho are wearing appropriate, OSHA approved PPE.

NOTICE

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

When the cooling unit or piping may be exposed to freezing temperatures, charge the system with the properpercentage of glycol and water for the coldest design ambient temperature. Automotive antifreeze isunacceptable and must NOT be used in any glycol fluid system. Use only HVAC glycol solution that meets therequirements of recommended industry practices. Do not use galvanized pipe.

NOTICE

Risk of piping system corrosion and freezing fluids. Can cause leaks resulting in equipment and expensivebuilding damage. Cooling coils and piping systems are at high risk of freezing and premature corrosion. Fluidsin these systems must contain an inhibitor to prevent premature corrosion.

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

Fluid chemistry varies greatly as do the required additives, called inhibitors, that reduce the corrosive effect ofthe fluids on the piping systems and components.

The chemistry of the coolant fluid used must be considered, because some sources may contain corrosiveelements that reduce the effectiveness of the inhibited formulation. Sediment deposits prevent the formation ofa protective oxide layer on the inside of the coolant system components and piping. The coolant fluid must betreated and circulating through the system continuously to prevent the buildup of deposits and/or growth ofbacteria. Proper inhibitor maintenance must be performed to prevent corrosion of the system.

Consult fluid manufacturer for testing and maintenance of inhibitors.

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

Vertiv recommends installing a monitored fluid detection system that is wired to activate the automaticclosure of field installed coolant fluid supply and return shut-off valves to reduce the amount of coolant fluidleakage and consequential equipment and building damage. The shut-off valves must be sized to close offagainst the maximum coolant fluid system pressure in case of a catastrophic fluid leak.


NOTICE

Risk of no-flow condition. Can cause equipment damage.

Do not leave the water/coolant fluid supply circuit in a no-flow condition. Idle fluid allows the collection ofsediment that prevents the formation of a protective oxide layer on the inside of tubes. Keep unit switched Onand water/coolant fluid supply circuit system operating continuously.

• Use copper piping with a brazing alloy with a minimum temperature of 1350°F (732°C), such as Sil-Fos. Avoidsoft solders, such as 50/50 or 95/5.

• Follow local piping codes and safety codes.

• Qualified personnel must install and inspect system piping.

• The water/glycol cooled system will operate in conjunction with a cooling tower, city water or drycooler.

• Contact a local water consultant regarding water quality, corrosion protection and freeze protectionrequirements.

• Install manual shut-off valves at the supply and return line to each unit to permit routine service andemergency isolation of the unit.

• When the fluid quality is poor, we recommend installing a 16-20# mesh Y-strainer filter in the supply line toextend the service life of the coaxial condensers. These filters must be easily replaced or cleaned.

• Install a monitored, fluid-detection system that is wired to activate the automatic closure of field installedcoolant fluid supply and return shut-off valves to reduce the amount of coolant fluid leakage and consequentialequipment and building damage. The shut-off valves must be sized to close off against the maximum coolantfluid system pressure in case of a catastrophic fluid leak.

Coolant Regulating Valve Requires No Adjustment

Water/glycol cooled units include a coolant flow regulating valve that is factory adjusted and should not need fieldadjustment.

Contact Vertiv technical support before making any adjustments.

4.3.1 Refrigerant Charge Requirements for Water/Glycol Cooled Systems

To calculate the charge requirements:

1. Determine the charge for your units by model number from the following tables.

2. Determine the charge for the piping by line size and length.

3. Add these all together to obtain the total refrigerant charge for your system.


MTC38W 4.2 (1.9)

MTC55W 4.2 (1.9)

MTC69W 4.2 (1.9)

Table 4.10 Water/Glycol, Indoor Condenser R-410A Refrigerant Charge



MT036HE 1 (0.45)

MT048HE 2.2 (1.0)

MT060HE 2.2 (1.0)

Table 4.11 Indoor Evaporator Approximate R-410A Refrigerant Charge

Line Size,O.D., in.

Liquid Line, lb/100 ft (kg/30 m) Suction Line, lb/100 ft (kg/30 m)

3/8 3.2 (1.4) —

1/2 5.9 (2.7) 0.2 (0.1)

5/8 9.6 (4.3) 0.4 (0.2)

3/4 14.3 (6.4) 0.6 (0.3)

7/8 19.8 (8.8) 0.8 (0.4)

1-1/8 33.8 (15.1) 1.4 (0.6)

1-3/8 51.5 (23.0) 2.1 (1.0)


Table 4.12 Interconnecting Piping Refrigerant Charge for R-410A Using Type L Copper Tube

4.3.2 Evacuation and Leak Testing Water/Glycol Cooled Systems

For proper leak check and evacuation, you must open all system valves and account for all check valves, see Figure 4.2 onthe next page.


Figure 4.2 Valves and Connections for Water/Glycol Condensing Unit

Item Description

1 Suction line

2 Schrader port with valve core

3 Apply a manifold gauge hose on the suction line and discharge line Schrader port.

4 2-stage scroll compressor

5 High-pressure switch

6 Tube-in-tube condenser

7 Water/Glycol supply line

8 2-way water regulating valve

9 Water/Glycol return line

10 Fluid supply to unit

11 Fluid return from unit

12 Hose bibs (required, field supplied)

13 Shut-off valves (required, field supplied)

14 Liquid line


Item Description

15 3-way water regulating valve (optional)

To evacuate and leak test the system:

1. Connect a manifold gauge hose on the discharge and suction line Schrader ports, open the service valve, andplace a 150 Psig (1034 kPa) charge of dry nitrogen with a tracer of refrigerant, then check the system for leakswith a suitable leak detector.

2. After completion of leak testing, release the test pressure, (observe local code) and pull an initial deep vacuumof 500 microns on the system with a suitable pump.

3. After four hours, check the pressure readings and, if they have not changed, break vacuum with dry nitrogen.Pull a second and third vacuum to 500 microns or less. Re-check the pressure after two hours.When the three checks are complete, proceed to Charging Water/Glycol Cooled Systems on the next page.


4.3.3 Charging Water/Glycol Cooled Systems

WARNING! Risk of over-pressurization of the refrigeration system. Can cause explosive discharge of high-pressure refrigerant, loss of refrigerant, environmental pollution, equipment damage, injury, or death. Thisunit contains fluids and gases under high pressure. Use extreme caution when charging the refrigerantsystem. Do not pressurize the system higher than the design pressure marked on the unit's nameplate.Relieve pressure before cutting into or making connections/disconnections to the piping system. Localbuilding or plumbing codes may require installing a pressure-relief device in the system. Consult localbuilding and plumbing codes for installation requirements of additional pressure-relief devices whenisolation valves are field installed. Do not isolate any refrigerant circuit from over-pressurization protection.

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

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

NOTICE

Risk of improper refrigerant charging. Can cause equipment damage.

R-410A is a blended refrigerant and must be introduced and charged from the cylinder only as a liquid.

When adding liquid refrigerant to an operating system, it may be necessary to add the refrigerant through thevalve in the compressor suction line. Care must be exercised to avoid damage to the compressor. Werecommend connecting a sight glass between the charging hose and the compressor suction service valve.This will permit adjustment of the cylinder hand valve so that liquid can leave the cylinder while allowing vaporto enter the compressor.

To calculate the charge for the system:

1. Check the nameplate on the indoor unit for refrigerant type to use.

2. Refer to Refrigerant Charge Requirements for Water/Glycol Cooled Systems on page 22, and calculate theamount of charge for the system including the evaporator, condensing unit, and interconnecting piping.

3. Accurately weigh-in as much of the system charge as possible before starting the unit.


4.3.4 Optimizing Refrigerant Charge on Water/Glycol Units

1. Operate the unit at full heat load, normal room conditions and normal water/glycol fluid temperatures for aminimum of 30 minutes before measuring stable unit superheat and sub-cooling temperatures and adjustingcharge levels.

• Condensing temperatures should be in range of 100 to 130°F (38 to 54°C) depending on fluid type andfluid temperature.

• Full heat load is required to stabilize the system.

2. Attach pressure and temperature instruments to the liquid line of the condensing unit. Measure the initial sub-cooling.

NOTE: To determine sub-cooling measurement, a liquid line pressure reading (at the factory installed Schrader tap)must be measured along with the temperature reading on the liquid line. Convert the liquid line pressure reading intoa liquid temperature by utilizing a pressure temperature guide. Subtract the measured temperature from the liquidsaturation temperature. The difference is sub-cooling.

3. Adjust refrigerant charge levels as needed to achieve sub-cooling range of 8 to 10°F (4.4 to 5.5°C) whilemaintaining full load conditions.

4.3.5 Documenting Refrigerant Charge on Water/Glycol Cooled Units

When the unit is charged, you must record the total system charge value on the condensing unit's serial tag. The totalsystem charge includes the evaporator, condensing unit, and interconnecting lines.

4.4 Drain and Humidifier Piping

The following pipe connections are required:

• A drain line from the evaporator unit drain connection.

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

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

NOTICE

Risk of clogged or leaking drain lines and leaking water supply lines. Can cause equipment and buildingdamage.

This unit requires a water drain connection. Drain lines must be inspected at start-up and periodically, andmaintenance must be performed to ensure that drain water runs freely through the drain system and that linesare clear and free of obstructions and in good condition with no visible sign of damage or leaks.

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

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

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


4.4.1 Water Supply Line to the Humidifier

The following is required for units with the optional steam generating humidifier package:

• 1/4 in. (6.4 mm) copper compression fitting connection for water inlet.

• The supply pressure range is 10 psig to 150 psig (69 to 1034 kPa) at 1 gpm (3.8 (lpm).

• A shut-off valve in the supply line to isolate the humidifier for maintenance.

• Do not supply steam generating humidifier with softened water.

• Do not use hot water source.

• Water conductivity must be in the range of 330 - 750 microsiemens.

To install the water supply:

1. Cut the tube square and remove any burrs.

2. Slide nut, then the sleeve on tube. The threaded end of the nut faces the end of the tube.

3. Insert the tube into the fitting, seating it against the stop shoulder and tighten the nut hand tight to the body.

4. Use a wrench to tighten the nut 1-1/4 to 2-1/4 turns.

NOTICE

Risk of improper tightening of the piping fittings. Can damage fittings and cause leaks.

Use caution not to over tighten or under tighten the piping fittings.

Do not route the humidifier supply line in front of the filter box access panel.

4.4.2 Drain Line Installation Requirements

NOTICE

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

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

Sagging condensate drain lines may inadvertently create an external trap.

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


Observe the following requirements and refer to Correct and Incorrect Gravity Drains below, when installing and routing thedrain line:

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

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

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

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

• Do not externally trap the drain line.

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

• Use copper or other material suitable for draining water that can reach temperatures up to 212°F (100°C).

• When the evaporator is installed below the level of the gravity fed drain line, the optional condensate pump kitis required. See Condensate Drain Pump Kit on the next page.

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

Figure 4.3 Correct and Incorrect Gravity Drains

Item Description

1 Correct drain installation.

2 Incorrect. Do not trap externally.

3 Incorrect. Sagging between supports and bowed line causes unintentional external traps.

4 Continuous downward slope away from the unit.

5 Unit

6 External trap

7 Unintentional traps from bowing of line. Lines must be rigid enough not to bow or sag between supports, creating a trap.

Table 4.13 Gravity Fed Drain Line Figure Descriptions


4.4.3 Condensate Drain Pump Kit


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

A 3/4-in. NPT female connection is provided for the evaporator unit condensate drain.

• The drain is trapped internally, do not trap external to unit.

• Size the discharge piping based on the available condensate head.

The installation of the condensate drain pump is described in the submittal documents included in the Submittal Drawingson page 63.



DPN004806 Condensate pump connection locations, 3 ton models

DPN004077 Condensate pump connection locations, 4 and 5 ton models

Table 4.14 Condensate Drain Pump Drawings


5 ELECTRICAL CONNECTION REQUIREMENTS


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

NOTE: Seal openings around piping and electrical connections to prevent air leakage. Failure to do so could reducethe unit's cooling performance.

NOTICE

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

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

See transformer label for primary tap connections. Installer will need to change transformer primary taps ifapplied unit voltage is other than pre-wired tap voltage.

NOTE: For 208 VAC, 3 ton applications, the low voltage transformer tap must be changed. Refer to the electricalschematic.

All power and control wiring and ground connections must be in accordance with the National Electrical Code and localcodes. Refer to the equipment serial tag data for electrical requirements.

A manual electrical disconnect switch should be installed in accordance with local codes and distribution system. Consultlocal codes for external disconnect requirements.

NOTE: Input power requirements: For 3 phase units, only 3 power wires and an earth ground are required.

The electrical connections are described in the submittal documents included in the Submittal Drawings on page 63.

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



DPN004802 Electrical Field Connections, 3 Ton DX Module

DPN004057 Electrical Field Connections, 4 Ton and 5 Ton DX Module

DPN004803 3 ton iCOM Wall Mount Field Connection

DPN004238 4 and 5 Ton iCOM Wall Mount Field Connection

Unit-to-Unit Networking

DPN004840 3 Ton Model iCOM Unit-to-unit Field Connection

DPN004841 4 and 5 Ton Models iCOM Unit-to-unit Field Connection

Table 5.1 Electrical Field Connection Drawings

5.1 Low Voltage Electrical Field Connections

Typical Electrical Field Connection Overview on the facing page, shows an overview of the low voltage wiring connectionsbetween the Mini-Mate module and the condensing unit (on DX systems only), and the wiring and cabling between the wallmounted iCOM display for all system types. Detailed connection information is included in the submittal drawings listed inElectrical Field Connection Drawings above.

Connect field supplied, shielded, Class 1 wiring from the condensing unit to the indicated terminal strip locations.

Evaporator to outdoor air cooled condensing units require six conductors. Evaporator to indoor water/glycol condensingunits require five conductors. Two additional terminals are available in water/glycol units for activating heat rejectiondevices. Follow unit schematics.

For the wall mounted iCOM-controller display:

• Connect a field supplied, CAT5 Crossover Ethernet cable between P64 on the iCOM-control board in the Mini-Mate module and ETH-1 on the wall mount iCOM display.

• Locate the wire harness inside the wall mount display, and connect field supplied, Class 1 wiring between theharness and landing on the terminal strip 13, 14, and 15 in the Mini-Mate module to provide power for thedisplay.

For the wall mounted temperature/humidity sensor:

• Plug the factory supplied, CANbus cable into P66 on the iCOM-control board in the Mini-Mate module and intoP66, Ethernet connection on the temperature/humidity sensor.


Figure 5.1 Typical Electrical Field Connection Overview

Item Description

1 to 6 Terminal connections between the evaporator module and the condensing unit

7 Terminal strip in the evaporator module

8 iCOM control board in the evaporator module

9 Condensing unit

10 iCOM display, field mounted

11 Field supplied CAT5 cable

12 Field supplied, shielded class 1 wiring

13 to 15 Terminal strip connections on evaporator module for wiring connected to the harness wires from the wall mount display.

16 Factory supplied wiring harness with plug. Wires are identified as TS-13, TS-14, and TS-15 and are 8 in. (203-mm) long.

17 Field supplied, shielded class 1 wiring

18 Factory supplied CAT5 cable, 30 ft (9 m)

19 Temperature/Humidity sensor, field mounted


6 INSTALLATION

Refer to the appropriate installation procedures depending on the size and type of your Mini-Mate System

6.1 Installing Ceiling Mounted Units

WARNING! Risk of ceiling collapse and heavy unit falling. Can cause building and equipment damage, seriousinjury or death. Verify that the supporting roof structure is capable of supporting the weight of the unit(s)and the accessories, see Mini-Mate Unit Weights on page 13. Be sure to securely anchor the top ends of thesuspension rods. Make sure all nuts are tight.

NOTICE

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

Improper installation, application, and service practices can result in water leakage from the unit. Do not mountthis unit over equipment and furniture that can be damaged by leaking water. Install a water-tight drain panwith a drain connection under the cooling unit. We recommend installing monitored leak detection equipmentfor the unit and supply lines. Check drain lines periodically for leaks, sediment buildup, obstructions, kinksand/or damage and verify that they are free running.

6.1.1 Installing Suspension Rods and Mounting Ceiling Units

Refer to the Location Considerations on page 11 before beginning installation.

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

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

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

• Four 3/8-in. 16 TPI threaded suspension rods are required and field supplied. The factory supplied 3/8-in. 16 TPIhardware kit includes the remaining installation hardware for rod to unit.

To install the suspension rods:

1. Install the four field supplied rods by suspending them from suitable building structural members so that theywill align with the four mounting locations on the unit base.

2. Securely anchor the top ends of the suspension rods.

3. Make sure all nuts are tight.

To lift and install the unit on the rods:

1. Referring to Figure 6.1 on the next page, place the hex nuts (Item 2) on the threaded rods, and add thewasher, sleeve, and isolator (Items 3, 4, and 6) to the bracket holes on the unit.

2. Using a suitable lifting device that is rated for the weight of the unit (see Mini-Mate Unit Weights on page 13),raise the unit and pass the threaded rods through the four mounting locations in the unit base.

3. Attach the threaded rods to the flanges using the washer and plain nut (Items 7 and 8) from the hardware kit tohold the unit in place as shown in Figure 6.1 on the next page.

6 Installation 35

4. Adjust the plain nuts to distribute the weight of the unit evenly by the rods, making sure that the unit does notrest on the ceiling grid and that the unit is level.

NOTE: The unit must be level to properly drain condensate.

5. Use the Nylock nuts to jam the plain nuts in place as shown in Figure 6.1 below.

Figure 6.1 Installing Threaded Rods and Hardware of Ceiling Mounted Units

Item Description Item Description

1 3/8 in. threaded rod, field supplied 6 Isolator

2 3/8 in. hex nut 7 3/8 in. fender washer

3 3/8 in. washer 8 3/8 in. hex nut

4 Sleeve 9 3/8 in. Nylock locking nut

5 Bracket on unit 10 Unit base pan (reference)

6.2 Installing Air Distribution Components for Evaporators

Your indoor units may include filters, ducting, plenums, and grilles. Refer to the appropriate installation procedures includedwith each optional kit.

6.2.1 Installing a Filter Box for 3 Ton Models

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

• The filter box includes one MERV 8 filter (per ASHRAE 52.2-2007), 20 in. x 20 in. x 4 in. (508 mm x 508 mm x102 mm).

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


6.2.2 Installing an Air Distribution Plenum for 3 Ton Models

The optional plenum fastens to the bottom of the evaporator and provides three-way air distribution. The plenum includes aMERV 8 filter (per ASHRAE 52.2-2007), 16 in. x 25 in. x 4 in. (406 mm x 635 mm x 102 mm).

• When using the plenum, mount the evaporator above the bottom of the T-bar supports with at least 30-in. (762 mm) clearance from return air end to wall (for replacing filter).

• Follow the installation instructions included with the plenum kit.

6.2.3 Installing a Filter Box for 4 Ton and 5 Ton Models

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

• For return air opening, the filter box includes a duct flange connection with two MERV 8 filters (per ASHRAE52.2-2007), 20 in. x 20 in. x 4 in. (508 mm x 508 mm x 102 mm).

• For the supply air opening, a duct flange is included for ducted supply air.

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

6.2.4 Installing a Bottom Discharge Grille for 4 Ton and 5 Ton Models

The optional, bottom discharge grille is a three-way louvered air grille, painted white, and added to a T-bar grid assemblyfor air discharge directly into room from the bottom of the unit. Use a separate filter box kit for filtration and connection tofield provided room-air return duct work.

6.2.5 Guidelines for Ducted Systems

Observe the following for all duct work.

• Ductwork should be fabricated and installed in accordance with local and national codes.

• Use flexible duct work or non-flammable cloth collars to attach duct work to the unit and to control vibrationtransmission to the building.

• Attach the duct work to the unit using the flanges provided. Locate the unit and duct work so that thedischarge air does not short circuit to the return air inlet.

• Ductwork that runs through a conditioned space or is exposed to areas where condensation may occur must beinsulated. Insulation of duct work 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 theinsulation.

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

• Ductwork should be suspended using flexible hangers. Ductwork should not be fastened directly to the buildingstructure.

6 Installation 37

7 CHECKLIST FOR COMPLETED INSTALLATION

7.1 Moving and Placing Equipment

1. Unpack and check received material.

2. Proper clearance for service access has been maintained around the equipment.

3. Equipment is level and mounting fasteners are tight.

7.2 Electrical Installation Checks

1. Supply voltage and phase matches equipment nameplate.

2. Power wiring connections completed to the disconnect switch.

3. Power line circuit breakers or fuses have proper ratings for equipment installed.

4. Control wiring connections completed between indoor evaporator and heat-rejection equipment.

5. Wiring connection completed between the evaporator unit and the wall mount display and remote T/H sensor.

6. All internal and external high and low voltage wiring connections are tight.

7. Confirm that unit is properly grounded to an earth ground.

8. Control transformer setting matches incoming power.

9. Electrical service conforms to national and local codes.

10. Check blowers and compressors for proper rotation.

7.3 Piping Installation Checks

1. Piping completed to refrigerant or coolant loop (if required).

2. Piping has been leak-checked, evacuated and charged (if required).

3. Additional oil has been added for system charges over 40 pounds (18.1kg) per circuit. See Additional OilRequirements for Digital Scroll Compressors on page 20.

4. Piping is properly sized, sloped and trapped as shown in the piping schematics.

5. Check piping inside and outside of equipment for proper support and adequate spacing to prevent rub-through.

6. Ensure that factory clamps have been reinstalled.

7. Drain line connected, not obstructed, and pitched per local code.

8. Water supply line connected to humidifier and not leaking, and routed to allow filter removal.

9. Condensate pump, if applicable, is operational.

10. Condensate drain line piping has no leaks or visible damage.

7.4 Other Installation Checks

1. Ducting complete (if required), maintain access to filters.

2. Return air filter box and supply air duct collar installed.

3. Filters installed.

4. Check fasteners that secure reheats, humidifier and motors—some may have become loose during shipment.

5. Control panel DIP switches are set based on customer requirements. Verify water detection is properlyinstalled (recommended).

6. All fans are free of debris.

7 Checklist for Completed Installation 39

7. Seal openings around piping and electrical connections.

8. Installation materials and tools have been removed from equipment (literature, shipping materials, constructionmaterials, tools, etc.).

9. Field provided, water-tight, secondary drain pan with drain is installed under all cooling units and ceiling-mounted water/glycol condensing units.

10. Drain from secondary drain pan is routed to a frequently used maintenance sink with signs posted to alertpeople to report water/glycol flowing from drain pan.


8 INITIAL START-UP CHECKS AND COMMISSIONINGPROCEDURE FOR WARRANTY INSPECTION


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

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

• Confirm that all items on Checklist for Completed Installation on page 39 have been done.

• Locate “Liebert® Mini-Mate Warranty Inspection Check Sheet” in the unit’s electric panel. (PSWI-8542-437RE)

• Complete “Liebert® Mini-Mate Warranty Inspection Check Sheet” during start-up. (PSWI-8542-437RE)

• Forward the completed “Liebert® Mini-Mate Warranty Inspection Check Sheet” to your local sales office. Thisinformation must be completed and forwarded to validate warranty.

• Contact your local sales representative or technical support if you have any questions or problems during unitstart-up and commissioning. Visit https://www.Vertiv.com/en-us/support/ or call 1-800-543-2778 for contacts.

Local sales offices and product support contacts can be found at https://www.Vertiv.com/en-us/support/ or 1-800-543-2778.

8 Initial Start-up Checks and Commissioning Procedure for Warranty Inspection 41

9 MAINTENANCE



WARNING! Risk of improper wiring, piping, moving, lifting and handling. Can cause equipment damage,serious injury or death. I

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