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Precision Cooling For Bu siness-Criti cal C ontinuity™ Li eb er t ® Ch a ll eng er ™ 3000 with Liebe r t iC OM ® Install ation M anual - 3 & 5 T ons, 50 & 60Hz.
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i T ABLE OF CONTENTS I MPORT AN T S AFE TY I NSTRUC TIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 S AVE T HESE I NSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 Water Regulating Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 4.3.1 Standa rd Valve - 150 psig (1034 kPa) System for 3 & 5-Ton Units (Johnson Control s Valve) High Pressure Valve - 350 psig (2413 kPa) System for 5-Ton Uni ts (Johnson Controls Valve) .
iii 7.4 Outdoor Air-Cooled Condensing Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 7.5 Centrifugal Air-Cooled Condensing Un its . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 36 3-ton centrifugal ai r-cooled condensing unit dimensio nal data & piping connections . . . . . . . . . 69 Figure 37 3-ton centrifugal ai r-cooled condensing unit ( con’t. ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Important Safety Instructions 1L i e b e r t ® Challenger 3000 ™ I MPORT ANT S AFETY I NSTRUCTIONS SAVE THESE INSTRUCTIONS This manual co ntains important sa fety instructio ns that should be followed durin g the installa tion and maintenance of the Liebert Ch allenger 3000.
Important Safety Instructions Liebert ® Challenger 30 00 ™ 2 NOTICE Risk of leaki ng water/glycol. C an cause equipment and building da mage. This unit requires a water/glycol. drain co nnection . It may also require an external water/glycol supply to operate.
Important Safety Instructions 3L i e b e r t ® Challenger 3000 ™ NOTICE Risk of damage from fork lift. Can cause unit damage. Keep tines of the forklift level and at a height suit able to fit below the skid and/or unit to prevent exterior and/or underside damage.
Introd uction Liebert ® Challenger 30 00 ™ 4 1.0 I NTRODUCTION 1.1 System Descriptions Liebert Chal lenger 3000 Precision C ooling systems ar e av ailable in three main system configurations: • s.
Introd uction 5L i e b e r t ® Challenger 3000 ™ 1.1.3 Split Sy stems Each air-cooled spli t system consists of an evaporator sect ion and one of the fo llowing condensing units.
Installation (Applicab le to all Models) Liebert ® Challenger 30 00 ™ 6 2.0 I NST ALLATION (A PPLICABLE TO ALL M ODELS ) 2.1 Room Prep aration The room should be well insulate d and must have a sealed vapor barrier. The va por barrier in the ceiling can be a polyethylene film type.
Installation (Applicab le to all Models) 7L i e b e r t ® Challenger 3000 ™ 2.4.1 Handling With Skid • Always keep the unit upright, in doors and protected from damage. • If possible, transport the unit us ing a fork l ift; otherwise, use a crane with be lts or cables, avoiding pressi ng on the top edges of the packaging.
Installation (Applicab le to all Models) Liebert ® Challenger 30 00 ™ 8 Figure 2 Up flow (BU) cabinet dimensions A Shaded area indicates a recommended clearance of 34" (864mm) for component access. Right side access suggested for GL YCOOL units.
Installation (Applicab le to all Models) 9L i e b e r t ® Challenger 3000 ™ Figure 3 Downflow (BF) cabinet dimensions Shaded area indicates a recommended clearance of 34” (864mm) for component access. Right side access suggested for GL YCOOL units DPN000351 Rev .
Installation (Applicab le to all Models) Liebert ® Challenger 30 00 ™ 10 2.5 Piping Considerations All piping below the elevated floor must be located so that it offers the leas t resistance to air flow. Careful planning of the piping layout und er the rais ed floor is required to prevent the air flow fro m being blocked.
Installation (Applicab le to all Models) 11 Liebert ® Challenger 3000 ™ Figure 4 Piping connections for air- cooled units - Downflow models Chilled Water Unit Connection Sizes—in.
Installation (Applicab le to all Models) Liebert ® Challenger 30 00 ™ 12 Figure 5 Piping connections for ai r-cooled units - Up flow models Condensate Drain 3/4" FPT Field pitch a min.
Installation (Applicab le to all Models) 13 Liebert ® Challenger 3000 ™ Figure 6 Piping connections for sp lit system fan coil unit s - Downflow models PIPING OUTLET LOCA TIONS (See Cabinet and Floor Planning Dimensional Data for Piping Opening Sizes.
Installation (Applicab le to all Models) Liebert ® Challenger 30 00 ™ 14 Figure 7 Piping connections for split s ystem fan coil unit s - Upflow mode ls DPN000375 Rev . 1 Piping outlet locations through the plenum are the same as the unit. See below for descriptions and connection sizes.
Installation (Applicab le to all Models) 15 Liebert ® Challenger 3000 ™ Figure 8 Piping connections for wate r/glyc ol and GL YCOOL units - Downflow models DPN000364 Rev . 1 Condensate Drain 3/4" FPT Field pitch a minimum of 1/8" (3.2mm) per ft.
Installation (Applicab le to all Models) Liebert ® Challenger 30 00 ™ 16 Figure 9 Piping connections for wate r/glyc ol and GL YCOOL units - Up flow models PIPING OUTLET LOCA TIONS (See Cabinet and Floor Planning Dimensional Data for Piping Opening Sizes.
Installation (Applicab le to all Models) 17 Liebert ® Challenger 3000 ™ Figure 10 Piping connections for chilled wate r self-contained units - Downflow models PIPING OUTLET LOCA TIONS (See Cabinet and Floor Planning Dimensional Data for Piping Opening Sizes.
Installation (Applicab le to all Models) Liebert ® Challenger 30 00 ™ 18 Figure 1 1 Piping connections for chilled wate r self-cont ained units - Up flow models Condensate Drain 3/4" FPT Field pitch a min. of 1/8" (3.2mm) per ft. (305mm).
Installation (Applicab le to all Models) 19 Liebert ® Challenger 3000 ™ 2.5.2 Humidifier Supply W ater—Optional Infrared • 1/4" supply l ine; maximum water pressure is 150 psi (1034kPa) • Size humidifie r supply line for 1 gpm (3.
Installation (Applicab le to all Models) Liebert ® Challenger 30 00 ™ 20 Figure 12 Electrical connections 2.7.1 Electrical Field Co nnections for Liebert Challenger 3000 Models Source: DPN00354, Rev. 2 1. Electric conduit knockouts on top and bottom of electric bo x.
Installation (Applicab le to all Models) 21 Liebert ® Challenger 3000 ™ 14. Heat rejection connection . Field-suppl ied 24V Class 1 wiring to interlock heat rejection from pigtails 70 + 7 1, which are factory-connect ed to compressor side switch (self- contained units only) or to GLYCOOL relay (K11, GLY COOL units only).
Installation (Applicab le to all Models) Liebert ® Challenger 30 00 ™ 22 2.8 Balancing the Air Distribution 2.8.1 Under-Floor Discharge Systems The systems are designed for consta nt air delivery, therefore any unusual restrictions within the air circuit must be avoided.
Installation (Applicab le to all Models) 23 Liebert ® Challenger 3000 ™ 2.9 Checklist for Completed Inst allation ___ 1. Unpack and check received material. ___ 2. Proper clearance for service access has been maintained around the equipment. ___ 3.
Air-Cooled Models—Sel f-Contained Compressor Liebert ® Challenger 30 00 ™ 24 3.0 A IR -C OOLED M ODELS —S ELF -C ON T AINED C OMPRESSOR 3.1 Condenser Location The air-cooled condenser should be located for maximum security and maintenance accessibility.
Air-Cooled Models—Sel f-Contained Compressor 25 Liebert ® Challenger 3000 ™ Figure 14 Air-cooled condensers T able 4 Air-c ooled condenser st atistics Model Number of Fans Connection Sizes (OD Copper) Net Weight lb (kg) “A” Dimension in (mm) Hot Gas (in.
Air-Cooled Models—Sel f-Contained Compressor Liebert ® Challenger 30 00 ™ 26 3.3 Refrigerant Piping All refrigeration pip ing should be installed with high temperature brazed joints. Prevaili ng good refrigeration p ractices should be emp loyed for piping supports, leak tes ting, dehydratio n and charging of the re fri geration circuits.
Air-Cooled Models—Sel f-Contained Compressor 27 Liebert ® Challenger 3000 ™ T able 5 Rec ommended line sizes — OD copper , inches * Equivalent Length 3.5-ton 042A (040A) 5-ton 067A (065A) Hot Gas Line Liquid Line Hot Gas Line Liquid Line 50 ft.
Air-Cooled Models—Sel f-Contained Compressor Liebert ® Challenger 30 00 ™ 28 3.4 Fan Speed Control Systems The Variable Fan Speed Control systems (FSC & VFD) uses pressure-activated electronic fan speed control systems and remotely located thermostat(s) to ensure operation at ambient temperatures as low as 0°F (-18°C).
Air-Cooled Models—Sel f-Contained Compressor 29 Liebert ® Challenger 3000 ™ V ariable Fan Spe ed Charging 1. Check un it nameplate for refriger ant type to be used. Unit contro l configurations differ depending on refrigerant type. 2. Refrigerant chargin g requires unit o peration.
Air-Cooled Models—Sel f-Contained Compressor Liebert ® Challenger 30 00 ™ 30 Figure 15 General arrangement—Air -cooled models with fan speed control DPN000349 Rev .
Air-Cooled Models—Sel f-Contained Compressor 31 Liebert ® Challenger 3000 ™ Figure 16 General arrangement—Air -cooled models with digit al scroll and fan speed control DPN001726 Re v .
Air-Cooled Models—Sel f-Contained Compressor Liebert ® Challenger 30 00 ™ 32 3.5 Air-Cooled Condenser with Liebert Lee-T emp ™ “Flooded Condenser” Head Pressure Control System The Liebert L.
Air-Cooled Models—Sel f-Contained Compressor 33 Liebert ® Challenger 3000 ™ 6. Aft er four hours, check the pres sure readings and, if they have no t changed, br eak vacuum wi th dry nitrogen. Pull a second and third vacuum to 250 microns or less.
Air-Cooled Models—Sel f-Contained Compressor Liebert ® Challenger 30 00 ™ 34 Liebert Lee-T emp Receiver Refrigerant Level On each receiver at the condense r are two refr igerant-level sig ht glasses. Ref rigerant level will vary with outside temperature.
Air-Cooled Models—Sel f-Contained Compressor 35 Liebert ® Challenger 3000 ™ Figure 18 General arrangement—Air -cooled models with digit al scroll and Liebert Lee-T emp ™ Digital Solenoid V alve DPN001725 Rev . 1 * Components are not supplied by Liebert but are recom mended for proper circuit operation and maintena nce.
Water-Cooled Models—Sel f-Contained Compressor Liebert ® Challenger 30 00 ™ 36 4.0 W ATER -C OOLED M ODELS —S ELF -C ONT A INED C OMPRESSOR 4.1 Piping Considerations Manual shutoff valves should be installed at the supply and return lines of each unit.
Water-Cooled Models—Sel f-Contained Compressor 37 Liebert ® Challenger 3000 ™ Figure 19 General arrangement—W ater-cooled models with scroll co mpressor Field-Supplied Reducers Required on 3-T on Units DPN000359 Rev .
Water-Cooled Models—Sel f-Contained Compressor Liebert ® Challenger 30 00 ™ 38 Figure 20 General arrangement diagram—W a ter-co oled models with di gital scroll DPN001727 Rev .
Water-Cooled Models—Sel f-Contained Compressor 39 Liebert ® Challenger 3000 ™ 4.3 W ater Regulating V alve The water regulating valve automati cally regulates the a mount of flui d necessary to r.
Water-Cooled Models—Sel f-Contained Compressor Liebert ® Challenger 30 00 ™ 40 4.3.2 High Pressure V alve - 350 psig (2413 kPa) Syste m for 3-T on Unit s (Metrex V alve) Adjustment The valve may be adjusted using a 1/8" diameter ro d.
Water-Cooled Models—Sel f-Contained Compressor 41 Liebert ® Challenger 3000 ™ Control Method The control utilizes an up per and lower pressure thre shold with a 35psi (241kPa) deadband to reduce valve movement. If the liquid pre ssure is between the upper and lo wer threshold, the valve remains at the current position.
Glycol/GL YCOOL-Cooled Models —Self-Contained Compressor Liebert ® Challenger 30 00 ™ 42 5.0 G LYCOL /GL YCOOL-C OOLED M ODELS —S ELF -C ONT AINED C OMPRESSOR 5.1 Drycooler Location The drycooler shou ld be located for maxi mum secu rity and maintenance acce ssibility.
Glycol/GL YCOOL-Cooled Models —Self-Contained Compressor 43 Liebert ® Challenger 3000 ™ 5.4 Glycol Piping These guidelines apply to the field leak checking and fluid requirements for field piping systems.
Glycol/GL YCOOL-Cooled Models —Self-Contained Compressor Liebert ® Challenger 30 00 ™ 44 from which it is prepared and may become increasingly corrosive wit h use if not properly inhibited. NOTICE Risk of no-flow condition. Can cause equipm ent and building damage from corrosi on and resulting leaks.
Glycol/GL YCOOL-Cooled Models —Self-Contained Compressor 45 Liebert ® Challenger 3000 ™ 5.4.1 Exp ansion T anks, Fluid Relief V alves and Other Devices An expansion tank must be provided for expansion and contraction of the fluid due to temperature change in this closed sy stem.
Glycol/GL YCOOL-Cooled Models —Self-Contained Compressor Liebert ® Challenger 30 00 ™ 46 5.5.2 Glycol Solutions When considering the use of any gl ycol products in a particular application, you should review the latest Material Safety Da ta Sheets and ensure that the use you intend can be accomplished safely.
Glycol/GL YCOOL-Cooled Models —Self-Contained Compressor 47 Liebert ® Challenger 3000 ™ NOTICE Risk of corrosion from water impu rities. Can cause equipment damage. The quality of water used for dilutio n must be considered because water may contain corrosive elements which reduce the effectiveness of the inhibite d fo rmulation .
Glycol/GL YCOOL-Cooled Models —Self-Contained Compressor Liebert ® Challenger 30 00 ™ 48 Figure 23 Drycoolers and pump packages Notes 1. Single pump packages a re 17-1/4" (438 mm) wide.
Glycol/GL YCOOL-Cooled Models —Self-Contained Compressor 49 Liebert ® Challenger 3000 ™ Figure 24 Pump p ackages—exp ansion t ank T able 17 Mountin g hole dimensional dat a PUMP PACKAGE A in (mm ) B in (mm) C in (mm) SINGLE (0.75 - 7.5 hp) 15-1/4 (387.
Glycol/GL YCOOL-Cooled Models —Self-Contained Compressor Liebert ® Challenger 30 00 ™ 50 Figure 25 General arrangement—Glycol-c ooled models with scroll compressor Glycol Pump Pump Housing Unio.
Glycol/GL YCOOL-Cooled Models —Self-Contained Compressor 51 Liebert ® Challenger 3000 ™ Figure 26 General arrangement—Glycol-cooled mode ls with digital sc roll Digital Solenoid V alve Glycol P.
Glycol/GL YCOOL-Cooled Models —Self-Contained Compressor Liebert ® Challenger 30 00 ™ 52 Figure 27 General arrangement—GL YC OOL models with scroll compressor Field-Supplied Reducers Required o.
Glycol/GL YCOOL-Cooled Models —Self-Contained Compressor 53 Liebert ® Challenger 3000 ™ Figure 28 General arrangement—GL YCOOL models with digita l scroll compressor r Digital Solenoid V alve P.
Glycol/GL YCOOL-Cooled Models —Self-Contained Compressor Liebert ® Challenger 30 00 ™ 54 5.5.4 Motor Ball V alve—Digit al Scroll Compressors Refer to 4.4 - Motorized Ball Valv e—Digital Scroll Compres sors for details on the motorized ball valve.
Chilled Wa ter Models 55 Liebert ® Challenger 3000 ™ 6.0 C HILLED W ATER M ODELS 6.1 Piping Considerations Manual shutoff valves should be installed at the supply and return lines to each uni t. This will provide for routine service and emerg ency isolation of the unit.
Chilled Wa ter Models Liebert ® Challenger 30 00 ™ 56 Figure 30 Chilled water general arrangement - Downflow (BF) mode ls SL-11899 Pg. 6 A B Flow Switch (optional) Chilled Wat er Retu rn Chilled Wa.
Split System Models 57 Liebert ® Challenger 3000 ™ 7.0 S PLIT S YSTEM M ODELS Three condensing unit styles are available: two ai r-cooled and one wate r/gl ycol-cooled condensing unit.
Split System Models Liebert ® Challenger 30 00 ™ 58 7.2.1 Line V oltage Line voltage e lectrical service is required for a ll condensing units at the lo cation of the condensing unit. This power supply does no t ha ve to be the same voltage as the indoor unit.
Split System Models 59 Liebert ® Challenger 3000 ™ All split systems require two refrigerant lines ( an insulated copper suction line and a copper liquid line) between the evaporato r and the condensing unit. Two possible methods exist for installi ng the copper suction and liquid lines.
Split System Models Liebert ® Challenger 30 00 ™ 60 Figure 31 Refrigerant p iping diagram T able 22 Line c harges - refrigera nt per 100 f t. (30 m) of T ype “L” copper tube O.D. R407C Liquid Line lb (kg) Suction Line lb (kg) 1/2" 7.3 (3.3) - 5/8" 11.
Split System Models 61 Liebert ® Challenger 3000 ™ 7.3.2 Quick Connect Fittings Be especially careful wh en connecting the quick conne ct fittings. Read through the follow ing steps before making the connectio ns. 1. Remove protector caps and p lugs.
Split System Models Liebert ® Challenger 30 00 ™ 62 7.4 Out door Air-Cool ed Condensing Unit s Figure 32 Out door air-cooled condensing unit—horizont al air discharge models A B C Shad ed area in.
Split System Models 63 Liebert ® Challenger 3000 ™ T able 26 Horizont al air discharge cabi net and floor planning dimensional dat a Model Numbers Dimensional Data in.
Split System Models Liebert ® Challenger 30 00 ™ 64 Figure 33 Out door air-cooled conde nsing unit—top air discharge models C A 2" (51mm) B D 36-1/8" (918mm) 25-3/32" (637mm) 46-7/32" (1174mm) 4-23/32 " (120mm) 53-3/16" (1351mm) 4" (ty p.
Split System Models 65 Liebert ® Challenger 3000 ™ T able 28 Cabinet an d floor planning dimensional dat a - prop fan condensin g modules, top air discharge Model Numbers Dimensional Data in.
Split System Models Liebert ® Challenger 30 00 ™ 66 Figure 34 Electrical field connect ions, prop fan condensing module NOTE: Refer to specifi cation sheet for full load amp and wire size amp ratings SL-1 1081 P g. 8 Factory-wired to components on electric panel.
Split System Models 67 Liebert ® Challenger 3000 ™ 7.5 Centrifugal Air-Cool ed Condensing Unit s 7.5.1 Inst alling the Indoor Condensing Unit Refer to drawings for unit dime nsions and component locations. The indoor condensing unit is usual ly mounted abov e the ceiling and must be securely mounted to the roof structure.
Split System Models Liebert ® Challenger 30 00 ™ 68 Figure 35 Det ail of ceiling hanging bracket 7.5.2 Ducting The total external static pressure for the inlet an d outlet ducts, including grille, must not exceed 0.5 inches of H 2 O. Hood intake dimensions should be the same as the cond ensing unit duct dimensions.
Split System Models 69 Liebert ® Challenger 3000 ™ Figure 36 3-ton centrifugal air-cooled conde nsing unit dimensional dat a & piping connections C D B A Customer- supplied threaded rods for module su pport from ceiling (typ. 4 ) SL-1 1085 Pg.
Split System Models Liebert ® Challenger 30 00 ™ 70 Figure 37 3-ton centrifugal air-coole d condensing unit ( con’t. ) DP N000207 Rev0 Si ngle- or three-phas e electri c servi ce not by Li ebert .
Split System Models 71 Liebert ® Challenger 3000 ™ Figure 38 5-ton centrifugal air-coole d condensing unit dimensional dat a SL-1 1087 Pg. 4 24" (610mm) Cabinet Dimens ion 32" (812.8mm) Cabinet Dimens ion 3-3/8" (85.7mm) 14-1/2" (368.
Split System Models Liebert ® Challenger 30 00 ™ 72 Figure 39 5-ton centrifugal air-coole d condensing unit dimensional dat a ( con’t .) DPN000226 Rev0 Field-Supplied Unit Disconnect Switch when .
Split System Models 73 Liebert ® Challenger 3000 ™ Figure 40 Split sys tems general arrangement Conden ser Coil 1/2" (1 2.7mm) NP T Pressure Re lief V alve Pressure Balancing Va l v e Sigh t G.
Split System Models Liebert ® Challenger 30 00 ™ 74 7.6 W ater and Glycol-Coo led Condensing Unit s For installation gu idelines, refer to Installing the Indoor Condensing Unit on page 67. 7.6.1 Piping Considerations It is recommended that manual serv ice shutoff valves be installed at the supply and return line to each unit.
Split System Models 75 Liebert ® Challenger 3000 ™ 7.6.4 Glycol Systems For split system glycol syst ems, use drycooler and pump data found in 5.0 - Gl ycol/GLYCOOL- Cooled Models—Self-Contained Compressor . See Table 18 - Drycooler data . Electrical control interconnect to drycooler is wired from water/glycol condensing unit.
Split System Models Liebert ® Challenger 30 00 ™ 76 Figure 42 3-ton water/gly col-cooled condensing unit ( con’t. ) DPN000209 Rev . 0 Single- or three-phase electric service not by Liebert Field-.
Split System Models 77 Liebert ® Challenger 3000 ™ Figure 43 5-ton water/gly col-cooled condensing unit d imensional dat a 7/8" (22.2mm) & 1-1/8" (28.6mm) dia. knockouts electrical entrance for line voltage connection (S ingle Point Power Kit) Removable Acce ss Pa ne l 1/2" (12.
Split System Models Liebert ® Challenger 30 00 ™ 78 Figure 44 5-ton water/gly col-cooled condensing unit ( con’t. ) DPN000228 Rev . 0 Field-supplied unit disconnect switch when factory unit disco.
R407C Refrigera nt 79 Liebert ® Challenger 3000 ™ 8.0 R407C R EFRIGERANT T able 33 R407C pres sure/temperature chart for oper ation and superheat (discharge/hot gas and suc tion gas) Temperature Gauge Pressure Temperature Gauge Pressure Temperature Gauge Pressure °F °C Psig kPa °F °C Psig kPa ° F °C Psig kPa 0.
R407C Refrigera nt Liebert ® Challenger 30 00 ™ 80 8.1 Calculating Subcooling Example Measure the liquid pressure (e.g., 200 psig). Find the liquid saturation temperature at that pressure on Table 34 (e.g., 93°F). Measure the temperature of the li quid line (e.
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Een belangrijk punt na aankoop van elk apparaat Emerson 3000 (of zelfs voordat je het koopt) is om de handleiding te lezen. Dit moeten wij doen vanwege een paar simpele redenen:
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In een situatie waarin je al een beziter van Emerson 3000 bent, maar toch heb je de instructies niet gelezen, moet je het doen voor de hierboven beschreven redenen. Je zult dan weten of je goed de alle beschikbare functies heb gebruikt, en of je fouten heb gemaakt die het leven van de Emerson 3000 kunnen verkorten.
Maar de belangrijkste taak van de handleiding is om de gebruiker bij het oplossen van problemen te helpen met Emerson 3000 . Bijna altijd, zal je daar het vinden Troubleshooting met de meest voorkomende storingen en defecten #MANUAl# samen met de instructies over hun opplosinge. Zelfs als je zelf niet kan om het probleem op te lossen, zal de instructie je de weg wijzen naar verdere andere procedure, bijv. door contact met de klantenservice of het dichtstbijzijnde servicecentrum.