Gebruiksaanwijzing /service van het product 3000 van de fabrikant Liebert
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Precision C ooling For Bu siness-Critical C ontinuity Li eb er t C ha l len ger ™ 3000 Install ation M anual - 3 & 5 T ons, 50 & 60Hz.
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i T ABLE OF CONTENTS 1.0 I NTRODUCTIO N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.1 System Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ii 5.2 Drycooler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 5.3 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
iii FIGURES Figure 1 Removing Challenger fro m skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Figure 2 Upflow (BU) cabinet dimensions . . . . . . . . . . . . . . . . . . . . . . . . . .
iv TA B L E S Table 1 Unit net weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Table 2 Piping connection size . . . . . . . . . . . . . . . . . . . . . . . . .
Introd uction 1 1.0 I NTRODUCTION 1.1 System Descriptions Challenger 30 00 ™ environmental control systems are availabl e in three main system configurations: • self contained system with a scro l.
Installation 2 2.0 I NST ALLATION 2.1 Room Prep aration The room should be well insulate d and must have a sealed vapor ba rrier. The vapor barrier in the ceiling can be a polyethylene film type. Use a rubber or plastic base paint on concrete walls and floors.
Installation 3 2.4.2 Removal of Skid • Remove the plywood skirti ng that keeps the skid and unit in place. • Raise the Challenger 3000 off the skid. Lieber t recommends using a fork lift ( see Figure 1) or similar machine to ensure that the unit is lifted properly .
Installation 4 Figure 2 Up flow (BU) cabinet dimensions 32 1/2 " 32 1/2 " 18 " 6 7/8 " (175mm) (826mm) Over al l Di mension (826mm) Overal l Dimensi on (457mm) Standard Electrical Outlet Location Through Plenum Air Di scharge Gril le 94 " (2388mm) 76 " (1930mm) Blower Outlet with 1" (25.
Installation 5 Figure 3 Downflow (BF) cabinet dimensions SL -11 897 P G 7 32 1/2 " (826m m) Ov erall Di me ns ion 32 1/2 " (826m m ) Ov erall Di me ns ion 30 1/2 " (775m m) 30 1/2 ".
Installation 6 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 from being blocked.
Installation 7 Figure 4 Piping connections for air coole d units Condensate Drain, 3/4” FPT Field pitch minimum of 1/8” (3.2mm) per foot (305mm). The drain line must comply with all applicable cod.
Installation 8 Figure 5 Piping connections for split s ystem fan coil unit s SL -11 900 P G 8 Pi ping out le t loca tio n s throu gh the ple nu m are the sam e a s the unit.
Installation 9 Figure 6 Piping connections for wa ter/glycol and GL YCOOL units Condensate Drain 3/4” FPT Fie ld p itch a min . of 1/8" (3.2m m) pe r ft.
Installation 10 Figure 7 Piping connections for chilled wa ter self-cont ained units SL-11898 PG 9 Piping outlet locations through the plenum are the same as the unit.
Installation 11.
Installation 12 2.6 Electrical Connections Three-phase electrical servi ce is required for all mode ls in either 208, 230, 460, or 575 V, 60 Hz; or 200, 230, or 380/415 V, 50 Hz. Electrical service sh all conform to national and local electrical codes.
Installation 13 13. Smoke detector alarm connections. Field-supplied 24V. Class 1 wiri ng to remote alarm circuits. Factory-wired contacts from optional smo ke detector are #91 -comm., #92-NO, and #93-NC. 14. Common alarm connection. Field-suppli ed 24V.
Installation 14 2.7.2 Ducted Applications For ducted applications on units, the duct work may be attached to the top perimeter of the unit. Refer to Figure 2 for i nformation on u pflow units and to Figure 3 for downflow units. The duct work on upflow units must allow access to the motors/blowers for maintenance.
Installation 15.
Air Cooled Models 16 3.0 A IR C OOLED M ODELS 3.1 Condenser Location The air cooled condenser should be located for maximu m security and mainte n ance accessibility. Avoid ground level sites with public access or area s that contribute to heav y snow or ice accumula- tions.
Air Cooled Models 17 Figure 9 Air cooled c ondensers T able 4 Air cooled conde nser st atistics Model Number of Fans Connection Sizes (OD Copper) Net Weight lbs (kg) “A” Dimension in (mm) Hot Gas (in.) Liquid (in.) 083 1 7/8 5/8 295 (133.8) 42 (1067) 104 1 1-1/8 5/8 315 (142.
Air Cooled Models 18 3.3 Refrigerant Piping All refrigeration pip ing should be installed with high temperat ure brazed joints. Prevailing good refrigeration practice s should be employ ed for piping supports, leak testing, de hydration and charg- ing of the refrigeration circuits.
Air Cooled Models 19 3.4 Fan Speed Control Systems Fan Speed Co ntrol provid es an infini te number of speed variations on spec ially designed, permanent split-capacitor motors. The control module varies the air quantity pa ssing over the condenser coil by monitoring refrigerant pressure.
Air Cooled Models 20 3.4.2 Dehydration/Leak T est and Charging Procedures for R22 (st andard) or R407C (Optional) Fan S peed Control T ype Condenser Dehydration/Leak T est 1. Make sure unit is OFF. Open all disco nnects an d remove all fuses except control fuses.
Air Cooled Models 21 Figure 10 Air cooled fan speed control general arra ngement SL -11 897 P G 5 Co n denser Co il Sc hrader Va lve Fusible Pl ug Inv erted Traps* on discha rge an d retu rn line s to e xt en d ab ov e b ase o f coi l by a min i mu m of 7 1/2" (19 0m m ) Trap s* e very 25 ft.
Air Cooled Models 22 3.4.3 Charging 1. Make sure unit is OFF. Open all disconnect swit c hes and, on units supplied with ci rcuit breakers, open all breakers. Replace all fuses for th e Fan and Compressors or close breakers. 2. Remove jumper on the Fan Safety Switch and reconnect the system wire connections.
Air Cooled Models 23 3.5.2 Materials Supplied 1. Built-in pre-wired condenser control box 2. Air cooled condenser 3. Piping access cover to be rein stalled when pipi ng is comple te 4. Bolts (four per leg) 3/8" x 5/8" 5. Terminal block for two-wire 24 V interlock connection between the unit and the cond enser 6.
Air Cooled Models 24 Dehydration/Leak T est 1. Make sure unit is OFF. Open all d isconnect swit ches and pull all fuses except control fuses. On units supplied with circuit breakers, open all breakers except for the transformer.
Air Cooled Models 25 Figure 1 1 Air cooled, Lee-T emp general arrangement FA CTO R Y PI PI NG FIEL D PIPI NG SING L E CIR C UIT S H OW N SL -10061 PG 4 SL -10071 PG 4 Piping Assembly * * Co ndenser Coil Rotalock Valve ** 1/4" ( 6.
Water Cooled Models 26 4.0 W ATER C OOLED M ODELS 4.1 Piping Considerations Manual shut-off valves should be installed at the supply and return lines of each unit.
Water Cooled Models 27 Figure 12 W ater cooled general arrangement SL -11 898 P G 5 E vap orato r Co il E xpa nsion Va lve Se nsin g Bu lb Ex te rn al Eq ualizers Hot Ga s Bypas s Va lve Scro ll Compr.
Water Cooled Models 28 4.3 W ater Regulating V alve The water regulating valve automati cally regulates the a mount of flui d necessary to remove the heat from the refrigeration system, permitting more flui d to flow when load conditions are high and less fluid to flow when load conditions are low.
Water Cooled Models 29 4.3.2 High Pressure V alve - 350 p sig (2413 kPa) System for 3 T on Units (Metrex V alve) Adjustment The valve may be adjusted using a 1/8" diameter ro d. Turn the adjusting co llar nut counterclockwise to raise head pressure; turn it clockwise to lower head pressure.
Glycol/GLYCOOL Cooled Models 30 5.0 G LYCOL /GL YCOOL C OOLED M ODELS 5.1 Drycooler Location The drycooler shou ld be located for ma ximum secu rity and maintenance acce ssibility. Avoi d ground- level sites with public access or areas which contribute to heavy snow or ice accu mulations.
Glycol/GLYCOOL Cooled Models 31 5.4 Glycol Piping It is recommended that manual serv ice shut-off va lves be installed at the supply and return connec- tions to each unit.
Glycol/GLYCOOL Cooled Models 32 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 system. Vent s are required at s ystem high poin ts to vent trapped air when fill- ing the system.
Glycol/GLYCOOL Cooled Models 33 5.5.2 Glycol Solutions When considering the use of any glycol products in a particular application, you should rev iew the lat- est Material Safety Data Sheets an d ensure that the use you intend can be accomplished safely.
Glycol/GLYCOOL Cooled Models 34 5.5.3 Filling the System Installation of hose bibs at th e lowest point of the system is recommended. When filling a glyco l sys- tem keep air to a minimum. Air in glycol turns to foam and is di ffic ult and time-consuming to remove.
Glycol/GLYCOOL Cooled Models 35 Figure 15 Drycoolers and pump pa ckages Notes 1. Single pump packages are 17-1 /4" (438 mm) wide. Dual pump p ackages ar 32-1/4" (819 mm) wide. 2. Mounting holes are 15-1/4" (387 mm) apart on single pump pa ckages and 30- 1/4" (768 mm) apart on dual pump packages.
Glycol/GLYCOOL Cooled Models 36 Figure 16 Pump p ackages—exp ansion tank T able 17 Mounting hole dimensional dat a PUMP PACKAGE A in (mm) B in (mm) C in (mm) SINGLE (0.75 - 7.5 Hp ) 15-1/4 (3 87.4) 2-1/2 (63.5) 22-1/2 (571.5) DUAL (0.75 - 5 Hp) 30-1/4 (768.
Glycol/GLYCOOL Cooled Models 37 Figure 17 Glycol general arrangement SL -11 898 P G 6 Glycol Pu mp Pump Hou sing Un ions* Isol ation Valves* Expa nsio n Va lve Dry coole r El ect ric Bo x Dryc oole r Co il Flu id Ret urn to Pu mp Fluid Su pply from Pu mp Un ions* Fill * E xpa nsio n T an k Fie ld In st alled a t Hi ghest Point in S ystem .
Glycol/GLYCOOL Cooled Models 38 Figure 18 GL YCOOL general arrangeme nt SL-1 19 01 PG 5 Pu mp Hou sin g Glycol Pu mp Un io ns* Isol ation Va lves* E xpan sio n Va lve Ev ap orato r Co il Dr yc oole r .
Glycol/GLYCOOL Cooled Models 39 5.6 Condenser The condenser is designed to operate in conjuncti on with a dry cooler. The maximum coolant pressure is 350 psig (2413 kPa).
Chilled Water Models 40 6.0 C HILLED W ATER M ODELS 6.1 Piping Considerations Manual shut-off valves should be installed at the supply and return lines to each unit.
Chilled Water Models 41 Figure 20 Chilled water general arrangement - downf low (BF) models SL-1 18 99 PG 6 Ai r Flow Ch ille d W ate r Co il Bl eed Va lve Va lve Actu a tor 3-W ay Ch ille d W ater Va.
Split System Models 42 7.0 S PLIT S YSTEM M ODELS Three (3) condensing unit styles are available: two (2) air cooled and one ( 1) water/glycol cooled con- densing un it.
Split System Models 43 7.3 Piping Considerations 7.3.1 Refrigerant Loop All split systems require two refrigerant lines (an in sulated copper suction line and a copper liquid line) between the evaporato r and the condensing unit. Two possible methods exist for installing the copper sucti on and liquid lines.
Split System Models 44 Once all piping is comp lete, check for leaks and dehydrate the field pi ping as follows: 1. Pressurize the field piping to 150 PSIG (1034 kPa) using dry nitrogen with a trace of refri gerant. Check system for leaks with a suitable leak detector.
Split System Models 45 Figure 21 Refrigerant p iping diagram T able 25 Equivalent lengths (feet) for va rious pipe fittings Copper Pipe OD in. 90 Degree Elbow Copper 90 Degree Elbow Cast 45 Degree Elbow Tee Gate Valve Globe Valve Angle Valve 1/2 0.8 1.
Split System Models 46 7.3.2 Quick Connect Fittings Be especially careful wh en connecting the quick connect fitti ngs. Read through the followin g steps before making the connectio ns. 1. Remo ve protector caps an d plugs. 2. Ca refully wipe coupli ng seats and th readed surfaces with a clean cloth.
Split System Models 47 7.4 Out door Air Cool ed Condensing Unit s Figure 22 Out door air cooled condensing unit—ho rizont al air discharge models A B C INDICATES A MINIMUM CLE ARA NCE OF 18" ( 457mm) FOR PROPER AIR FL OW.
Split System Models 48 T able 26 Horizonta l air discharge cabi net and floor planning dimensional dat a Model Numbers Dimensional Data in. (mm) Module Weight lbs (kg) net 60 Hz 50 Hz A B C PFC042A-_L.
Split System Models 49 Figure 23 Out door air cooled conde nsing unit —top air discharge models SL -11081 PG 5 C A 2" B LE FT AIR IN TAK E (5 1mm) D GUAR D HEI GHT TO P AIR DIS CHA RGE RI GH T .
Split System Models 50 T able 28 Cabinet and floor planning dimension al data - prop fan condensin g modules, top air discha rge Model Numbers Dimensional Data in.
Split System Models 51 Figure 24 Electrical field connect ions, prop fan condensing module SL -11081 PG 8 Fact o ry wi r ed to com po nent s on ele ct ric pa ne l.
Split System Models 52 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 53 Figure 25 Det ail of ceiling hanging bracket 3/8" threaded r od (field-supplied) 3/8" hex nut 3/8" washer Sleeve Isolator 3/8" fender washer 3/8" hex nu.
Split System Models 54 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.
Split System Models 55 Figure 26 2 and 3 ton centrifugal air cooled conde nsing unit dimensional dat a & piping connections 50 1/4" (1276 m m) O verall Di me nsion 46 1/2" (1181 m m) Cab.
Split System Models 56 Figure 27 3 ton centrifuga l air cooled condensing unit (c on't.) DPN000207_Rev0 NOTES: 1. Refer to specific atio n sheet for full load amp. and wire size amp. ratings. 2. Control volt age wiring must be a min imum of 16 GA (1.
Split System Models 57 Figure 28 5 ton centrifuga l air cooled condensing unit dimens ional dat a SL -11087 PG 4 51 13/ 16 " 1 3 /4 " 21 1/4 " 1 5 /8 " 48 " 33 5/8 " 54 " 32 " 8 1 5/16 " 15 3/4 " 3 3 /8 " 14 1/2 " 24 " (812.
Split System Models 58 Figure 29 5 ton centrifuga l air cooled condensing unit dimens ional dat a (con't.) DPN000226_Rev0 AIR COOLED Heat rejection connection. Fi eld-supplied 24V NEC Class 2 wiring. See Note 2 . Wire connections from e vaporator module.
Split System Models 59 Figure 30 Split systems general arrang ement SL-1 19 00 PG 5 Co n denser Co il 1/2" (12.7m m) NP T Press ure Reli ef Valve Si ght Glas s Check Va lv e Lee -Temp Re cei ver .
Split System Models 60 7.6 W ater and Glycol Cooled Con densing Unit s For installation gu idelines, refer to Installing the Indoor Condensing Unit on page 52. 7.6.1 Piping Considerations It is recommended that manual serv ice shut-off va lves be installed at the supply and return line to each unit.
Split System Models 61 Figure 31 2 and 3 ton water/gl ycol cooled conde nsing unit 14" (356m m ) Ov erall C abinet Di me nsio n 8 7/8" (225m m) 50 1/4" (12 76 mm ) O ve rall D ime nsion.
Split System Models 62 Figure 32 3 ton water/glycol coo led condensing unit (con't .) DPN000209_Rev0 Heat rejectio n co nn e cti on . Field-supp lie d 2 4V NEC Cla ss 2 wiri ng. Wire connections from evapor ator mod: 1. 24V GND 2. 24V supply 3. High pressure alarm (opt) 4.
Split System Models 63 Figure 33 5 ton water/glycol coo led condensing unit dimensional dat a SL -11087 PG 6 32 " 32 " 29 13/ 16 " 33 5/8 " 24 " (81 2.8mm ) (610m m) (854.1 mm ) (75 7.2m m) CA BIN ET DIM EN SIO N THRE AD ED RO D CEN TER S (812.
Split System Models 64 Figure 34 5 ton water/glycol coo led condensing unit (con't .) DPN000228_Rev0 NOTES 1. Refer to specif ication sheet for full load amp. a nd wire size amp. ratings. 2. Control volt age wiring must be a minimum of 16 GA (1.6mm) for up to 75' (23m) or not to exceed 1 volt drop in control line.
R407C Refrigera nt 65 8.0 R407C R EFRIGERANT T able 33 R407C pressure/tempera ture chart for oper ation and superheat (discharg e/hot gas and suction gas) Temperature Gauge Pressure T emperature G auge Pressure Temperature Gauge Pressure °F °C Psi g kP a °F °C Psig kPa °F °C Psig kPa 0.
R407C Refrigera nt 66 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.g., 90°F). Subtract the actual temperature from the liquid saturati on temperatur e to obtain the subc ooling (e.
R407C Refrigera nt 67 Notes.
R407C Refrigera nt 68.
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