Vertiv Liebert DSE060 Installation and maintenance instructions

Liebert®
DSE™ PackagedSolution
ThermalManagementSystem
Installer/User Guide
60-kW (15-ton)Capacity

Vertiv | Liebert® DSE060™ Installer/User Guide
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TABLE OF CONTENTS
1 Important Safety Instructions 5
2 Nomenclature and Components 9
2.1 Liebert DSE060 Packaged Solution Configuration-number Nomenclature 9
2.2 Component Location 12
2.3 Air-flow Configurations 12
3 Pre-installation PreparationandGuidelines 13
3.1 Planning Dimensions 14
3.2 Connections and System Setup 14
3.2.1 Electrical Connections 14
3.2.2 Evaporator Condensate-drain Connection 14
3.3 Operating Conditions 16
3.3.1 Cooling 17
3.4 Unit Weights 17
4 Equipment Inspection and Handling 19
4.1 Rigging to Lift the Unit 20
4.2 Using Forklift to Install the Unpackaged Unit 21
5 Electrical Field Connections 23
6 Checklist for Completed Installation 27
6.1 Moving and Placing Equipment 27
6.2 Electrical Installation Checks 27
6.3 Other Installation Checks 27
6.4 BMS and Sensor Installation Checks 28
7 Initial Start-up Checks andCommissioningProcedure forWarrantyInspection 29
8 Maintenance 31
8.1 Service/Maintenance Access to the Evaporator Compartment 32
8.2 Filters 32
8.2.1 Filter-replacement 32
8.3 Evaporator Blower Drive System—EC Fans 34
8.3.1 Protective Features 34
8.3.2 Fan Impellers and Bearings Maintenance 35
8.3.3 Fan Assembly Troubleshooting 35
8.3.4 Removing Evaporator EC Fans 39
8.4 Electronic Expansion Valve (EEV) Maintenance 41
8.5 Compressor Maintenance 42
8.5.1 Compressor Oil 42
8.5.2 Rotalock Valve 42
8.5.3 Replacement Compressors 43
8.5.4 Compressor Motor Burnout 43
8.5.5 Unloading Solenoid(s) on a Digital-scroll Compressor 43
8.5.6 Replacing the Compressor 43
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8.6 Evaporator Coil 44
8.7 General Condenser Maintenance 44
8.8 Condenser Cleaning 44
8.8.1 When to Clean the Condenser Coil 44
8.8.2 What to Use to Clean the Condenser Coil 45
8.8.3 Cleaning the Condenser Coil 45
8.8.4 Cleaning the Condenser Fan 46
8.9 Replacing the Condenser Fan 46
8.9.1 Verifing the Fan Address 53
8.10 Replacing the Premium-efficiency Control Board 57
8.10.1 Preparing to Replace the Board 57
8.10.2 Installing the Replacement Board 59
8.11 Pumped-refrigerant Economizer (PRE) 60
9 Preventive Maintenance Checklist 61
Appendices 67
Appendix A: Technical Support and Contacts 67
Appendix B: Submittal Drawings 69
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1 IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
This manual contains important safety instructions that should be followed during the installation and
maintenance of the Liebert®DP060. Read this manual thoroughly before attempting to install or operate
this unit.
Only qualified personnel should move, install or service this equipment.
Adhere to all warnings, cautions, notices and installation, operating and safety instructions on the unit
and in this manual. Follow all installation, operation and maintenance instructions and all applicable
national and local building, electrical and plumbing codes.
WARNING! Arc flash and electric shock hazard. Open all local and remote electric power-supply
disconnect switches, verify with a voltmeter that power is Off and wear appropriate,
OSHA-approved personal protective equipment (PPE) per NFPA 70E before working within the
electric control enclosure. Failure to comply can cause serious injury or death. Customer must
provide earth ground to unit, per NEC, CEC and local codes, as applicable. Before proceeding
with installation, read all instructions, verify that all the parts are included and check the
nameplate to be sure the voltage matches available utility power. The Liebert® controller does
not isolate power from the unit, even in the “Unit Off” mode. Some internal components require
and receive power even during the “Unit Off” mode of the controller. The factory-supplied
disconnect switch is on the exterior of the enclosure. The only way to ensure that there is NO
voltage inside the unit is to install and open a remote disconnect switch. Refer to unit electrical
schematic. Follow all local codes.
WARNING! Risk of electric shock. Can cause equipment damage, injury or death. Open all local
and remote electric power supply disconnect switches and verify with a voltmeter that power is
off before working within any electric connection enclosures. Service and maintenance work
must be performed only by properly trained and qualified personnel and in accordance with
applicable regulations and manufacturers’ specifications. Opening or removing the covers to
any equipment may expose personnel to lethal voltages within the unit even when it is
apparently not operating and the input wiring is disconnected from the electrical source.
WARNING! Risk of electric shock. Can cause serious injury or death. Open all local and remote
electric power supply disconnect switches and verify with a voltmeter that power is off before
working within the component electric-connection enclosures. Fan-motor controls can
maintain an electric charge for 10 minutes after power is disconnected. Wait 10 minutes after
power is verified as off before working within the fan electric control/connection enclosures.
1 Important Safety Instructions 5

WARNING! Risk of over-pressurization of the refrigeration system. Can cause explosive
discharge of high-pressure refrigerant, loss of refrigerant, environmental pollution, equipment
damage, injury, or death. This unit contains fluids and gases under high pressure. Use extreme
caution when charging the refrigerant system. Do not pressurize the system higher than the
design pressure marked on the unit's nameplate.
WARNING! Risk of pressurized doors flying open or slamming closed suddenly. Can cause
serious injury. Do not attempt to open doors while fans are running. Do not turn on fans with
doors open. Before opening the door, open all local and remote electric power supply
disconnect switches, verify with a voltmeter that power is off, and verify that all fans have
stopped rotating. Do not leave unsecured objects in the fan's bay after any maintenance
operation.
WARNING! Risk of contact with flying objects. Can cause serious injury or death. Do not leave
unsecured objects or tools in the fan's bay after performing maintenance operations. Re-install
all panels before starting up this unit after maintenance is performed.
WARNING! Risk of very heavy, 250-lb (113.4-kg) condenser fan modules and 125-lb (57-kg)
evaporator fan modules dropping downward suddenly. Can cause injury or death.
Support fan modules before removing mounting hardware. Use caution to keep body parts out
of the fan modules pathway during repositioning. Only properly trained and qualified personnel
should work on this equipment.
WARNING! Risk of improper moving. Can cause equipment damage, injury or death. Use only
lifting equipment that is rated for the unit weight by an OSHA-certified rating organization. The
center of gravity varies depending on the unit size and selected options. The slings must be
equally spaced on either side of the center of gravity indicator.
Unit weights are listed in Table 3.3 on page17. Use the center of gravity indicators on the unit
to determine the position of the slings.
WARNING! Risk of contact with high-speed rotating fan blades. Can cause serious injury or
death. Open all local and remote electric power-supply disconnect switches, verify with a
voltmeter that power is off, and verify that all fan blades have stopped rotating before working
in the unit cabinet or on the fan assembly. If control voltage is applied, the fan motor can restart
without warning after a power failure.
WARNING! Risk of improper wiring, piping, moving, lifting and handling. Can cause equipment
damage, serious injury or death. Installation and service of this equipment should be done only
by qualified personnel who have been specially-trained in the installation of air-conditioning
equipment and who are wearing appropriate, OSHA-approved PPE.
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WARNING! Risk of improper wire sizing/rating and loose electrical connections. Can cause
overheated wire and electrical connection terminals resulting in smoke, fire, equipment and
building damage, injury or death. Use correctly sized copper wire only and verify that all
electrical connections are tight before turning power On. Check all electrical connections
periodically and tighten as necessary.
CAUTION: Risk of contact with sharp edges, splinters, and exposed fasteners. Can cause
injury. Only properly trained and qualified personnel wearing appropriate, OSHA-approved PPE
should attempt to move, lift, remove packaging from or prepare the unit for installation.
CAUTION: Risk of contact with hot surfaces. Can cause injury. The compressor, refrigerant
discharge lines, fan motor, and some electrical components are extremely hot during unit
operation. Allow sufficient time for them to cool to a touch-safe temperature before working
within the unit cabinet. Use extreme caution and wear appropriate, OSHA-approved PPE when
working on or near hot components.
CAUTION: Risk of contact with hot surfaces. Can cause burn injury. The EC fans and
electronics housing are extremely hot during operation. Allow sufficient time for them to cool
to a touch-safe temperature before handling. Use extreme caution and wear appropriate,
OSHA-approved PPE when replacing or performing maintenance on the EC fans.
CAUTION: Risk of improper moving, lifting and handling. Can cause equipment damage or
injury. Only properly trained and qualified personnel should work on this equipment. Fan
modules weigh in excess of weigh in excess of 125lb (57kg). Use proper lifting techniques and
wear appropriate, OSHA-approved PPE to avoid injury and dropping the fan module during
removal. Equipment used in handling/lifting, and/or installing the fan assembly must meet
OSHA requirements. Use handling/lifting equipment rated for the weight of the fan assembly.
Use ladders rated for the weight of the fan assembly and technicians if used during installation.
Refer to handling/lifting, and/or installation equipment operating manual for manufacturer's
safety requirements and operating procedures.
CAUTION: Risk of exposure to harmful noise levels. Can cause hearing injury or loss.
Depending on the installation and operating conditions, a sound pressure level greater than
70dB(A) may arise. Take appropriate technical safety measures. Operating personnel must
wear appropriate, OSHA-approved PPE and observe all appropriate hearing-protection safety
requirements.
1 Important Safety Instructions 7

NOTICE
Risk of improper power-supply connection. Can cause equipment damage and loss of warranty
coverage.
Prior to connecting any equipment to a main or alternate power source (for example: back-up
generator systems) for start-up, commissioning, testing, or normal operation, ensure that these
sources are correctly adjusted to the nameplate voltage and frequency of all equipment to be
connected. In general, power-source voltages should be stabilized and regulated to within
±10% of the load nameplate nominal voltage. Also, ensure that no three-phase sources are
single-phased at any time.
NOTICE
Risk of oil contamination with water. Can cause equipment damage.
Liebert®DP060 systems require the use of POE (polyolester) oil. POE oil absorbs water at a
much faster rate when exposed to air than previously used oils. Because water is the enemy of
a reliable refrigeration system, extreme care must be used when opening systems during
service. If water is absorbed into the POE oil, it will not be easily removed and will not be
removed through the normal evacuation process. If the oil is too wet, it may require an oil
change. POE oils also have a property that makes them act as a solvent in a refrigeration
system. Maintaining system cleanliness is extremely important because the oil will tend to
bring any foreign matter back to the compressor.
NOTICE
Risk of improper operation in high-humidity conditions. Can cause unit damage and water
carryover.
The Liebert® DP060 operates only as a sensible cooling unit and does not provide
dehumidification.
NOTE: The Liebert® cooling unit has a factory-installed high pressure safety switch in the high-side
refrigerant circuit.
Agency Listed
Standard 60-Hz units are CSA Certified to the harmonized U.S. and Canadian product safety standard
CSA C22.2 No 236/UL 1995 for “Heating and Cooling Equipment” and are marked with the CSA c-us logo.
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2 NOMENCLATURE AND COMPONENTS
This section describes the configuration number for Liebert® DP060 units and components.
2.1 Liebert DSE060 Packaged Solution Configuration-number Nomenclature
The following tables describe each digit of the 40-digit DP060 configuration number. The 14-digit model
number consists of the first 10 digits and last 4 digits of the configuration number.
Configuration -number Digits 1 to 10 = first 10 digits of 14-digit model number
1 2 3 4 5 6 7 8 9 10
D P 0 6 0 T P 1 A D
Table 2.1 DSE060 Configuration-number Digits 1 to 10 Example
Configuration-number Detail Digits 11 to 21
11 12 13 14 15 16 17 18 19 20 21
0 2 0 8 1 6 L D B 0 P
Table 2.2 DSE060 Configuration-number Detail Digits 11 to 21 Example
Configuration-number Detail Digits 22 to 36
22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
0 A A 1 0 0 0 0 0 0 0 0 0 0 0
Table 2.3 DSE060 Configuration-number Detail Digits 22 to 36 Example
Configuration -number Digits 37 to 40 = last 4 digits of 14-digit model number
37 38 39 40
# # # A
Table 2.4 DSE060 Configuration-number
Digits37to40Example
Digit Description
Digits 1 and 2 = Product Family
DP = Liebert® Packaged DSE
Digit 3 to 5 = Cooling Capacity, kW
Nominal sensible capacity, kW
Digit 6 = Air Discharge
T = Perimeter, top inlet/front supply
Digit 7 = System Type
P = Air-cooled, EconoPhase ready
Table 2.5 DSE060 Packaged Solution Configuration-number Digit Definitions
2 Nomenclature and Components 9

Digit Description
Digit 8 = Air-flow (Fan Type)
1 = EC plug fans
Digit 9 = Power Supply
A = 460V / 3ph / 60Hz
B = 575V / 3ph / 60Hz
C = 208V / 3ph / 60Hz
D = 230V / 3ph / 60Hz
Digit 10 = Cooling System
D = Digital scroll, R-410A
Digit 11 = Humidifier
0 = None
Digit 12 = Display
2 = Liebert® iCOM High Definition
Digit 13 = Options
0 = None
Digit 14 = Air Filter
8 = MERV 8, 4-in.
9 = MERV 11, 4-in.
Digit 15 = Coil Option
1 = Non-coated coils, evaporator and condenser
Digit 16 = Enclosure Option
6 = Standard color, pebble-gray
Digit 17 = High-voltage option
L = Locking disconnect
6 = Dual disconnect with reversing starter
Digit 18 = Option packages
D = Low-voltage terminal package + Remote humidifier contact
Digit 19 = Monitoring
B = Base Comms & Connectivity
Digit 20 = Sensors
0 = None
Digit 21 = Packaging
P = Domestic
Table 2.5 DSE060 Packaged Solution Configuration-number Digit Definitions (continued)
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