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52 Chapter 6 Maintenance

DataMate 3000 Series Air Conditioner User Manual

Liebert DataMate 3000 System

Date: Prepared

by:

Model: Serial

Number:

Type Maintenance

components

Item

Result

Check for restricted airflow

Check the filter

Filter

Clean the filter

Check canister for mineral deposits

Check conditon of electrodes

Humidifier (if applicable)

All hoses and fittings tight

Impellers free of debris and move freely

Fan section

Bearings in good conditon

Monthly

Drain system including
condensate pump

Check and clean out unit drain lines, humidifier and
tray, condensate pump and building drain line

Signs of oil leaks

Compressor section

Vibration isolation

Check the start point of the blower

Speed regulation system

Check the speed regulation performance of the blower

Suction pressure

Discharge pressure

Superheat

Evaporator tight and clean

Check refrigerant level

Refrigerant system

Check if there is evident temperature difference
between both ends of the filter drier

Condenser coil clean

Motor mount tight

Bearing in good conditon

Air cooled condenser

Refrigerant lines properly supported

Check electrical connections

Electric board

Check the surface for signs of corrosion

Semi-annually

Electric heater

Check element for signs of corrosion

Notes:

Signature:

Make photocopies of this form for your records.

Summary of Contents for DataMate 3000 Series

Page 1: ...act the nearest Emerson local sales office or service center Copyright 2004 by Emerson Network Power Co Ltd All rights reserved The contents in this document are subject to change without notice Emerson Network Power Co Ltd Address No 1 Kefa Rd Science Industry Park Nanshan District 518057 Shenzhen China Homepage www emersonnetworkpower com cn E mail support emersonnetwork com cn ...

Page 2: ...Considerations 6 2 2 Equipment Inspection 6 2 3 System Installation Arrangement 7 2 3 1 General Arrangement 7 2 3 2 System Installation Illustration 8 2 3 3 Unit Mechanical Parameters 9 2 4 Evaporator Installation 10 2 4 1 Room Preparation 10 2 4 2 Location Consideration 11 2 4 3 Installation Procedure 12 2 5 Condenser Installation 13 2 5 1 Location Considerations 13 2 5 2 Installation Procedure 1...

Page 3: ...peed Controlling For Condenser Blower 28 4 3 System Function Testing 28 4 3 1 Cooling Operation 28 4 3 2 Heating Operation 28 4 3 3 Humidification Operation 29 4 3 4 Dehumidification Operation 29 Chapter 5 Microprocessor Control 30 5 1 LCD Screen 30 5 2 Control Buttons 30 5 3 Setpoints 31 5 4 Control Screen 33 5 4 1 Off Screen 33 5 4 2 On Screen 33 5 4 3 Normal Screen 33 5 4 4 Password Screen 34 5...

Page 4: ...6 1 Electric Board 47 6 2 Evaporator 48 6 2 1 Filter 48 6 2 2 Blower 48 6 2 3 Drain Line 49 6 2 4 Heater 49 6 2 5 Thermal Expansion Valve 49 6 2 6 High Low Pressure Switch 49 6 2 7 Compressor 50 6 3 Condenser 51 6 3 1 Refrigeration System 51 6 3 2 Air Cooled Condensing Units 51 6 4 Maintenance Inspection Checklist 51 Chapter 7 Troubleshooting 53 Appendix Control System Menu Structure 55 ...

Page 5: ... for precise systems such as sensitive systems process control systems communication systems and computers This system has two models with nominal ratings of 7kW and 12kW respectively which can be selected according to the actual room heat loads Each DataMate3000 consists of an indoor direct expansion evaporator module and an outdoor air cooled condensing module Both modules are installed on the g...

Page 6: ...major parts by browsing the menu Expert level troubleshooting system enables the LCD to display the fault information automatically for convenient maintenance The controller can store up to 30 history alarms It can communicate to a host through the RS485 port The control panel is shown in Figure 1 1 Figure 1 1 Control Panel 1 2 2 Evaporator The DataMate3000 system uses a highly efficient fin tube ...

Page 7: ...ion position The max equivalent horizontal distance of the evaporator and condensing modules 50m Altitude distance H 5m H 20m Installation method Vertical Environmental temperature Indoor 0 C 30 C Outdoor 15 C 45 C Relative humidity 30 80 RH Protection level Condensing module IPX4 Altitude 1000m Range of operation voltage 380V 25 A negative altitude distance means that the condenser is mounted bel...

Page 8: ...t of the low pressure switch is 0 12MPa and the recovery point is 0 25MPa 1 4 4 Blower Speed Controller The controller regulates the air volume of the blower automatically according to the condensate pressure of the system to maintain a favorable temperature Thus the compressor can work normally even if the outdoor temperature is very low 1 5 Optional Parts 1 5 1 Humidifier It adds pure water vapo...

Page 9: ...id danger caused by over temperature There is a temperature switch on the surface of the heater and it will cut off the power supply of the heater when the surface temperature of the heater is too high When the surface temperature decreases to normal the heater will operate again automatically 1 5 3 Remote Monitoring Software The DataMate3000 communicates to the host and receives commands from the...

Page 10: ...on 1 3 and whether any building alteration is required to run piping wiring and duct work Carefully follow the design drawings and reserve proper clearances Refer to the submittal engineering dimensional drawings of individual units 2 2 Equipment Inspection When the DataMate3000 arrives inspect all items for any visible damage Do not accept a damaged unit from the shipper If possible do not uncrat...

Page 11: ...b Scroll compressor Distributor Feeder tubes Evaporator coil Thermal expansion valve Valve core Valve core Figure 2 1 DataMate3000 general arrangement diagram Factory piping Field piping by others Check valve and traps are optional and not supplied by Emerson But they are recommended for field installation for proper circuit operation and maintenance They should be installed on site by technical p...

Page 12: ...posed to sun Trap Evaporator Protection tube 1 200 Discharge line slope Insulation floor Humidifier water supplyline from water supply tube 1 200 Drain line trapped outside room Floor Insulation material Seal and vapor seal Max 20m 6m a Condenser higher than evaporator Liquid line not be exposed to sun Seal and vapor seal Condenser Max 5m Insulation material Floor 1 200 Drain line trapped outside ...

Page 13: ...cal parameters of the evaporator are shown in Figure 2 3 and Table 2 2 600 600 550 1900 600 Figure 2 3 Dimensions of evaporator unit mm The shadow in Figure 2 3 indicates a reasonable service access area The evaporator can be installed against a wall The mechanical parameters of the condenser are shown in Figure 2 4 and Table 2 2 ...

Page 14: ...stallation 2 4 1 Room Preparation The room should be well insulated and must have a sealed vapor barrier Use polyethylene as the vapor barrier of the ceiling and the wall Paint on concrete walls or floors should be vapor resistant Note The most important requirement for maintaining environmental control in the conditioned room is the vapor barrier Incoming fresh air should be kept to a minimum Inc...

Page 15: ...ined areas that affect the airflow pattern and result in short cycles and abnormal noise 3 Do no install the unit in an alcove or at the extreme end of a long narrow room 4 Do no install multiple units close to each other This can result in crossing air patterns uneven loads and competing operating modes 5 Do not attach additional devices such as smoke detectors and so on to the cabinet that will ...

Page 16: ...on or 25 25 2 square tube Rubber cushion 8mm Rubber cushion 8mm hole for installing expansive bolt M6 50 Sole Steel plate 60 60 4 H 150 Figure 2 6 Floorstand 2 Lay a rubber cushion with 8 10mm thickness as shown in Figure 2 6 3 Uncrate the evaporator and place it onto the floorstand 4 Rotate the grille to select the desired air discharge direction as shown in Figure 2 7 Grille can be rotated in th...

Page 17: ...vicinity of steam hot air or fume exhausts 5 Do not locate the condenser closer than 450mm from a wall obstruction or adjacent unit 6 Avoid areas where heavy snow will accumulate at air inlet and discharge locations 7 Install a solid base capable of supporting the weight of the condenser The base should be at least 50mm higher than the surrounding ground and 50mm larger than the dimensions of the ...

Page 18: ...is used piping joints must be brazed 2 Follow standard industry procedures in selection and placement of pipe supports system evacuation and charging with refrigerant only when pipeline is very long The standard refrigerant of this system is R22 3 Give considerations to pipeline pressure drop oil return to the compressor avoidance of oil logging in parts of the system and minimization of noise and...

Page 19: ...re required if condensate pump and humidifier are used 1 A drain line from the condensate pump 2 A water supply line to the humidifier and a drain line from it If a humidifier is used a drain line from the humidifier instead of the drain line from the evaporator coil drain pan should be connected Note During start up ensure that all piping connections have been completed without leaks 2 6 3 Piping...

Page 20: ... coil Connecting evaporator drain line Use a 20mm 3 4 in hose barb connection to connect the drain line to the drain outlet of the evaporator shown in Figure 2 11 and then trap the line outside the system room through the cutout shown in Figure 2 10 to a suitable place The drain line must be located so it will not be exposed to freezing temperature The drain line should be the full size of the dra...

Page 21: ... water inlet Supply pressure range is 0 7 kgf cm2 to 10kgf cm2 A shut off valve should be installed in this line to isolate the humidifier for maintenance 2 6 4 Connecting Refrigerant Lines Connecting discharge line Connect the discharge line between the evaporator refer to Figure 2 11 and the condenser refer to Figure 2 12 through the cutout of the evaporator shown in Figure 2 10 Note Pitch the d...

Page 22: ...ration practices in piping supports leak testing dehydration and charging of the refrigeration circuits Use vibration isolating support to isolate the refrigeration piping from the building 7 Use a soft and flexible material to pack around the tubes to protect them when sealing openings in walls and to reduce vibration transmission 8 When installing the condenser above the evaporator for 6 meters ...

Page 23: ... 4 Recommended torque value for quick connect fittings Coupling size kgf cm2 6 0 7 0 8 10 11 2 5 3 2 2 7 Checklist For Mechanical Installation 1 Proper clearances for service access have been maintained around the system 2 Equipment is vertical and mounting fasteners are tight 3 Piping is completed to refrigerant loop The valves of the quick connects have been fully opened 4 Condensate pump is ins...

Page 24: ...ontrols applicable 4 Control wiring for master standby transfer if applicable All power and control wiring and ground connections must be in accordance with the applicable local codes Refer to unit nameplate for full load ampere Cable size should be in accordance with the applicable local codes Mains requirement 380Vac 50Hz 3 L N PE Note 1 Only trained engineer can make electrical connection 2 Mea...

Page 25: ...e 3 1 Electric plate Figure 3 1 Removing electric plate 3 2 Connecting The Power Supply Of Evaporator The power supply terminals are shown in Figure 3 2 A power disconnect switch is required to isolate the system for maintenance Connect the supply power cable to the disconnect switch and then to the evaporator power supply terminals as shown in Figure 3 2 Connect the condenser power cable delivere...

Page 26: ...nly Ensure that all connections are solid when making connections 2 Make sure that power supply voltage matches the voltage specified on the system nameplate 3 A power disconnect switch is required in front of the power input of the evaporator to isolate the system for maintenance Connect the power cable to the disconnect switch and then to the system 4 System contains hazardous electrical voltage...

Page 27: ...the condenser as shown in Figure 3 3 Terminal Power cable L N PE Back view Power connection Terminal designation Slot screw driver Cable clamp PE N N L L Figure 3 3 Power supply terminals in condenser 3 4 Connecting Control Cables Control terminals are on the PCB shown in Figure 3 4 Control terminals on the PCB Figure 3 4 Control terminals location The terminal arrangement is shown in Figure 3 5 ...

Page 28: ...als are not shorted the air conditioner will stop In this way DataMate3000 air conditioner can be shut down through these terminals in case of emergency The three control circuits are shorted through the three terminals before delivery Remove the shorting wires if the smoke and fire sensor cables and the remote on off control cable are connected to the terminals of J8 J14 and J22 respectively 3 4 ...

Page 29: ... Enable Terminals J9 and J18 are for duty standby system changeover terminal and standby system enable terminal Two systems can be linked so that one is a duty system and the other is a standby system The connection is shown in Figure 3 6 Duty standby unit changeoverJ9 Duty standby unit changeover J9 Standby unit enable J18 Standby unit enable J18 Duty unit Standby unit Figure 3 6 Duty standby mod...

Page 30: ...cified on the system nameplate 2 The power cables and the grounding cables at the power disconnection switch the evaporator and the condenser have been connected solidly 3 The ratings of the circuit breakers are correct when installing the system 4 Control connections have been completed 5 All connections are solid Tightened screws are not loose After the inspection read the next chapter to commis...

Page 31: ...cables tubes etc in the discharge area The rated current of the fan motor is recorded The actual current of the fan motor is recorded 5 Humidifier if applicable Water supply line is connected Water level sensor is installed reliably Drain line is connected 6 Heater if applicable Heating components are reliable The heater current is recorded 7 Condenser The condenser location complies with the requ...

Page 32: ...rature setpoint to 5 C 10 F lower than the room temperature The controller should send a cooling command and the compressor should start running Three minutes later change the setpoint to a temperature of 5 C 10 F higher than the room temperature If the compressor is deactivated cooling operation is normal Note Change the setpoint to the default or the original point after the test 4 3 2 Heating O...

Page 33: ...ehumidification Operation According to section 5 7 set the humidification setpoint to 10 lower than the room relative humidity The controller should send a dehumidification command and the blower runs at low speed Set the setpoint to be higher than the room relative humidity If the blower runs at high speed dehumidification operation is normal During this progress pay attention that if the room te...

Page 34: ...It displays temperature and relative humidity readings operating mode cool heat dehumidify humidify alarm information current date and time as shown in Figure 5 1 2 8 Coo l 5 0 r h Hum H i gh Temp 1 4 2 0 0 4 0 1 0 1 0 0 0 0 Figure 5 1 LCD screen Users can browse more detailed information such as the operation status of a certain part and alarm information by activating the sub menus in the main m...

Page 35: ...put data field before validating the changes 4 Left This button moves the cursor left in the input data field 5 Down This button moves the cursor down the menu or decreases the number in the input data field 6 Enter This button allows entry into the next level of a menu or validates the modified data in the input data field 7 Right This button moves the cursor right in the input data field 8 Up Th...

Page 36: ...360 days 180 days 720 days Humidifier Chng Time 180 days 90 days 360 days Alam Menu Service Interval Filter Chng Time 180 days 90 days 360 days Temp Stpt 24 C 15 C 35 C Tem Bias 3 C 1 C 5 C Hum Stpt 50 RH 20 RH 80 RH Setpoin ts Hum Bias 5 RH 1 RH 10 RH Monitor Unit No 1 1 254 Cntl Brd 0 0 15 Teamwork Unit No 0 0 15 Cold Start 180 seconds 30 seconds 360 seconds Hot Start 10 seconds 10 seconds 240 s...

Page 37: ... LCD displays the On screen Press the ON OFF button from the Off screen and the On screen will also be displayed as shown in Figure 5 4 S t a r t i ng 1 0 s Figure 5 4 On screen 5 4 3 Normal Screen After the system is powered on the Normal screen will be displayed after 10 seconds default for heat startup delay or after Enter button is pressed The Normal screen displays the current temperature and...

Page 38: ...ormal screen Password screen is displayed as shown in Figure 5 6 P a s s w o r d 1 Figure 5 6 Password screen Method of entering password Press Left Right button to move the cursor to the digit to be changed and then Up Down button to change the value Press Enter button to validate the password and enter the main menu Press Esc button to return to the Normal screen If the password entered is incor...

Page 39: ...date and time and viewing environmental temperature and humidity readings the date time system output status and system operation records System Menu For setting system parameters configuring system optional components calibrating sensors changing password diagnosing components output and restoring default values 5 6 Alarm Menu Use the Up Down buttons to move the cursor to Alarm Menu in the main m...

Page 40: ...ore alarms This system can store up to 15 latest active alarms They will be lost when the system is powered off 5 6 2 Alarm History Select Alarm History from the Alarm Menu screen to view the Alarm History screen The screen displays the detailed inactive alarm information or No alarms if no inactive alarm exists The alarm No the total number inactive alarm name the time date occurrence are indicat...

Page 41: ...er to select it Press Enter again use Up Down buttons to change the value of each digit and then press Enter to validate the change Refer to Table 5 1 for the defaults and the setting ranges 5 6 4 Alarm Outputs The alarm output settings will not be lost when power fails Select Alarm Outputs from the Alarm Menu to browse or change the settings listed in Figure 5 12 H i g h P r s ON Low P r s S TP H...

Page 42: ...h control terminal J67 Custom 2 is input through control terminal J68 Use Up Down buttons to move the cursor to the corresponding row and use Up Down buttons to toggle among no alarm smoke sensor fire sensor water under floor no airflow filter obstructed and others LCD displays No Alarm Smk Snsr Fire Snsr High Water Loss Air Fltr Clog and Others Press Enter to validate the setting 5 6 6 Service In...

Page 43: ...ded Otherwise change it according to the actual condition The Reset indicates whether the component has been maintained or replaced or not Select YES if it is maintained or replaced and the service time will be reset to zero automatically and then be recounted again Otherwise select NO 5 7 Setpoints The setpoints will not be lost when power fails Select the Setpoints from the main menu and press E...

Page 44: ...re 5 19 I n T em p 2 4 6 I n Hum 6 7 8 RH Ou t T e mp 2 4 6 Figure 5 19 T H Status screen 5 8 2 Time Date The Time Date screen displays the current time of the system in the format of Year Month Date and Hour Minute Second Method of changing the time Press Enter button and use Left Right buttons to move the cursor to the digit to be changed Then use Up Down buttons to increase or decrease the valu...

Page 45: ...utput Status screen 5 8 4 Run Hours Run Hours screen displays the total operation hours of the system Press Up Down buttons to scroll the items as shown in Figure 5 22 F a n 8 0 0 h C o o l 2 0 0 h H e a t 2 0 0 h H um 2 0 0 h F C 1 0 0 h Figure 5 22 Run Hours screen 5 9 System Menu Select System Menu from the main menu and press Enter to display the items listed in Figure 5 23 S y s t e m S e t u...

Page 46: ...he default value is 1 U n i t N o 1 Figure 5 25 Monitor sub menu 1 Use Up Down buttons to move the cursor to Teamwork in the System Setup menu and press Enter to display the Teamwork sub menu as shown in Figure 5 26 Use Up Down buttons to move the cursor to Cntl Brd and press Enter to set the control board number for communication with other control boards It can be set from 0 to 15 and the defaul...

Page 47: ...menu and press Enter to set the backlight to ON or OFF The default setting is ON 7 Use Up Down buttons to move the cursor to Contrast in the System Setup menu and press Enter to set the contrast of the LCD The setting range is from 28 to 38 and the default setting is 30 5 9 2 Optional Func The optional function settings will not be lost when power fails Select Optional Func from the System Menu to...

Page 48: ...tch Time and press Enter to set the system transfer time delay The setting range is from 10 seconds to 90 seconds and the default setting is 30 seconds When the Unit Sta is set to SPR or SGL The Host Time Spare Time and Switch Time can be set but they are invalidated 5 9 3 Sensor Calibrate The technical person can use this function and a precise instrument 0 1 C or 0 1 RH in precision to calibrate...

Page 49: ... ON the other components will be set to OFF automatically There is a time limit for output diagnosis When the unit enters output diagnosis status it will exit the status automatically and returns to normal operation if the output diagnosis status has not changed for a certain period of time 15 seconds for compressor and 5 minutes for other components 5 9 5 Change Password The new password will not...

Page 50: ...stem Reset in the System Menu and press Enter Use Up Down buttons to set it to YES and press Enter to validating the setting Then all the setpoints will be restored to their default values but the operation time and alarm log will not be cleared Note As System Reset function will reset all the setpoints configured by the user be cautious to use it ...

Page 51: ...oose electrical connection and signs of circuit rusting There are four PCBs in the controller They detect the system fault input signals and output commands Inspect the electric boards one by one according to the procedures below 1 Do the system insulation test check and repair the failed contacts 2 Check if the contacts are flexible without blocking in statistic status 3 Clean the electric compon...

Page 52: ...6 1 Filter Figure 6 1 Taking out filter 6 2 2 Blower The blower package to be inspected includes motor impeller blower package fixation and clearance between blower and impeller Inspect the motor bearing and impeller thoroughly every month and remove any debris Check if the impeller is tightly mounted on the rotor of the motor and does not rub against its neighboring metal components during rotati...

Page 53: ...eat level to determine if the valve operation is proper The correct superheat setting is 5 6 C to 8 3 C 10 F to 15 F 6 2 6 High Low Pressure Switch The discharge pressure and suction pressure will vary greatly with load and ambient conditions refer to Table 6 1 during normal operation The high pressure switch will be activated and send an alarm signal to the controller when the discharge pressure ...

Page 54: ...ssure and low pressure readings and find out the cause of an alarm or a protection during periodical maintenance and inspection Note Avoid touching or contacting the gas and oils with exposed skin Wear long rubber gloves to handle contaminated parts Check according to the following procedures before replacing the compressor 1 Check if all fuses and circuit breakers are disconnected 2 Check the sta...

Page 55: ...essure ranges in normal operation and supplement some refrigerant if necessary 6 3 Condenser 6 3 1 Refrigeration System Each month the components of the refrigerant system should be inspected for proper function and signs of wear Refrigerant lines must be properly supported and not allowed to vibrate against ceiling floors or the unit frame Inspect all refrigerant lines every six months for signs ...

Page 56: ...y condensate pump and building drain line Signs of oil leaks Compressor section Vibration isolation Check the start point of the blower Speed regulation system Check the speed regulation performance of the blower Suction pressure Discharge pressure Superheat Evaporator tight and clean Check refrigerant level Refrigerant system Check if there is evident temperature difference between both ends of t...

Page 57: ...Remove debris from coil and air inlet High pressure alarm Condenser fan not operating Check fan operation Humidify function disabled Set Humidity to OPEN refer to section 5 9 2 No humidify demand from the controller Increase humidity control setpoint and sensitivity to require humidification Humidifier does not operate Humidity sensor failure Humdity display will indicate dashes Check wiring from ...

Page 58: ...rm External environment temperature too low Contact Emerson High temperature setpoint unreasonable Change the setpoint High temperature alarm Room cooling load exceeds the system capacity Check for room seal or make capacity extension Low temperature setpoint unreasonable Change the setpoint Low temeperature alarm Heater operation current unreasonable Check the heater operation Setpoint unreasonab...

Page 59: ...art Compressor Main fan Optional Func Heat Hum Standby Unit Sta Host Time Swtch Time Spare Time FC Sensor Calibrate Temp Snsr Hum Snsr Reset Output Diagnose Heater Humidifier Main Fan Compressor Change Password Level One Level Two Alarm Menu Alarm Status Alarm History Alarm Setpoint High Temp Low Temp Low Hum High Hum Alarm Outputs High Temp Low Temp Low Hum High Hum High Prs Low Prs Short Cyc Pwr...

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