Emerson 3000- Manuals

iv TABLES Table 1 Unit net weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Table 2 Piping connection size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

1 I MPORTANT S AFETY I NSTRUCTIONS SAVE THESE INSTRUCTIONS This manual contains important safety instructions that should be followed during the installation and maintenance of the Liebert Challenger 3000 ™ . Read this manual thoroughly before attempting to install or operate this unit.Only qualifie...

2 NOTICE Risk of leaking water. Can cause equipment and building damage.This unit requires a water drain connection. It may also require an external water supply to operate.Improper installation, application and service practice can result in water leakage from the unit. Water leakage can result in ...

Introduction 3 1.0 I NTRODUCTION 1.1 System Descriptions Challenger 3000 ™ environmental control systems are available in three main system configurations: • self-contained system with a scroll compressor in the room unit• self-contained chilled water system• split system with an evaporator section ...

Introduction 4 1.1.3 Split Systems Each air-cooled split system consists of an evaporator section and one of the following condensing units. Prop Fan Air-Cooled Prop Fan units include scroll compressor, condenser coil, prop fan, high pressure switch, hot gas bypass and Liebert Lee-Temp head pressure...

Installation (Applicable to all Models) 5 2.0 I NSTALLATION (A PPLICABLE TO ALL M ODELS ) 2.1 Room Preparation The room should be well insulated and must have a sealed vapor barrier. The vapor barrier in the ceiling can be a polyethylene film type. Use a rubber or plastic base paint on concrete wall...

Installation (Applicable to all Models) 6 2.4.1 Handling With Skid • Always keep the unit upright, indoors and protected from damage.• If possible, transport the unit using a fork lift; otherwise, use a crane with belts or cables, avoid- ing pressing on the top edges of the packaging. • If using a f...

Installation (Applicable to all Models) 7 Figure 2 Upflow (BU) cabinet dimensions A Shaded area indicates a recommendedclearance of 34" (864mm) for componentaccess. Right side access suggested forG LYCOO L units. DPN000350Rev. 01 FRONT VIEW(front return configuration) 32-1/2" (826mm) Overall...

Installation (Applicable to all Models) 8 Figure 3 Downflow (BF) cabinet dimensions Shaded area indicatesa recommended clearance of34” (864mm) for componentaccess. Right side accesssuggested for G LYCOOL units DPN000351Rev. 01 32-1/2" (826mm) Overall Dimension 32-1/2" (826mm) Overall Dimensi...

Installation (Applicable to all Models) 9 2.5 Piping Considerations All piping below the elevated floor must be located so that it offers the least resistance to air flow. Careful planning of the piping layout under the raised floor is required to prevent the air flow from being blocked. When instal...

Installation (Applicable to all Models) 12 Figure 6 Piping connections for split system fan coil units - Downflow models PIPING OUTLE T LOCATIONS(See Cabinet and FloorPlanning Dimensional Datafor Piping Opening Sizes.) DPN000376Rev. 01 Condensate Drain3/4" FP TField pitch a minimumof 1/8" (3...

Installation (Applicable to all Models) 14 Figure 8 Piping connections for water/glycol and GLYCOOL units - Downflow models DPN000364Rev. 01 Condensate Drain3/4" FPTField pitch a minimumof 1/8" (3.2mm) per ft. (305mm).The drain line must comply withall applicable codes Humidifier Water Suppl...

Installation (Applicable to all Models) 15 Figure 9 Piping connections for water/glycol and GLYCOOL units - Upflow models PIPING OUTLET LOCATIONS(See Cabinet and Floor PlanningDimensional Data for PipingOpening Sizes.) Piping outlet locations through the plenumthe same as the unit. See below fordesc...

Installation (Applicable to all Models) 18 2.5.2 Humidifier Supply Water—Optional Infrared • 1/4" supply line; maximum water pressure is 150 psi (1034kPa) • Size humidifier supply line for 1 gpm (3.8 l/m), with a minimum water pressure of 20 psi (138kPa)• Do not supply de-ionized water to the hu...

Installation (Applicable to all Models) 19 Figure 12 Electrical connections 1. Electric conduit knockouts on top and bottom of electric box. Knockout size 1-3/4" (44.5mm). 2. Three-phase connection . Electric service connection terminals when factory disconnect is NOT supplied. 3. Three-phase co...

Installation (Applicable to all Models) 20 15. Heat rejection connection . Field-supplied 24V Class 1 wiring to interlock heat rejection from pigtails 70 + 71 which are factory-connected to compressor side switch (self-contained units only) or to GLYCOOL relay (K11, GLYCOOL units only). On Dual Cool...

Installation (Applicable to all Models) 21 2.8 Balancing the Air Distribution 2.8.1 Under-Floor Discharge Systems The systems are designed for constant air delivery, therefore any unusual restrictions within the air circuit must be avoided. For under-floor air distribution, observe the following gui...

Installation (Applicable to all Models) 22 2.9 Checklist for Completed Installation ___ 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.___ 4. Piping completed to refr...

Air-Cooled Models—Self-Contained Compressor 23 3.0 A IR -C OOLED M ODELS —S ELF -C ONTAINED C OMPRESSOR 3.1 Condenser Location The air-cooled condenser should be located for maximum security and maintenance accessibility. Avoid ground level sites with public access or areas that contribute to heavy ...

Air-Cooled Models—Self-Contained Compressor 24 Figure 14 Air-cooled condensers Table 4 Air-cooled condenser statistics Model Number of Fans Connection Sizes (OD Copper) Net Weight lb (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 (142.8)...

Air-Cooled Models—Self-Contained Compressor 25 3.3 Refrigerant Piping All refrigeration piping should be installed with high temperature brazed joints. Prevailing good refrigeration practices should be employed for piping supports, leak testing, dehydration and charg- ing of the refrigeration circui...

Air-Cooled Models—Self-Contained Compressor 26 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). For t...

Air-Cooled Models—Self-Contained Compressor 27 Variable Fan Speed Control Materials Supplied • Built-in, pre-wired condenser control box• Air-Cooled condenser• Piping access cover to be reinstalled when piping is complete• Bolts—four per leg (3/8" x 5/8")• Terminal block for two-wire, 24V in...

Air-Cooled Models—Self-Contained Compressor 28 Variable Fan Speed Charging 1. Check unit nameplate for refrigerant type to be used. Unit control configurations differ depending on refrigerant type. 2. Refrigerant charging requires unit operation. Refer to 2.9 - Checklist for Completed Installation ....

Air-Cooled Models—Self-Contained Compressor 29 Figure 15 General arrangement—Air-cooled models with fan speed control DPN000349Rev. 3 CondenserCoil SchraderValve FusiblePlug EvaporatorCoil Hot GasBypassValve Traps* every25 ft. (7.6m)of rise SolenoidValves SightGlass FilterDryer Liquid Return Shutoff...

Air-Cooled Models—Self-Contained Compressor 31 3.5 Air-Cooled Condenser with Liebert Lee-Temp “Flooded Condenser” Head Pressure Control System The Liebert Lee-Temp system consists of a modulating type head pressure control valve and insulated receivers with heater pads to ensure operation at ambient...

Air-Cooled Models—Self-Contained Compressor 32 6. 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 250 microns or less. Recheck the pressure after two hours. 7. Remove the jumper hose installed previously f...

Water-Cooled Models—Self-Contained Compressor 35 4.0 W ATER -C OOLED M ODELS —S ELF -C ONTAINED C OMPRESSOR 4.1 Piping Considerations Manual shutoff valves should be installed at the supply and return lines of each unit. This will pro- vide for routine maintenance or emergency isolation of the unit....

Water-Cooled Models—Self-Contained Compressor 38 4.3 Water Regulating Valve The water regulating valve automatically regulates the amount of fluid necessary to remove the heat from the refrigeration system, permitting more fluid to flow when load conditions are high and less fluid to flow when load ...

Water-Cooled Models—Self-Contained Compressor 39 Figure 22 Metrex Valve adjustment Manual Flushing The valve may be flushed by rotating the socket head screw clockwise. This screw must be in the OUT position (counterclockwise) for normal valve operation. 4.4 Motorized Ball Valve—Digital Scroll Compr...

Water-Cooled Models—Self-Contained Compressor 40 4.4.2 Adjustment Both pressure thresholds can be shifted simultaneously over a 50psi (345kPa) range (the 35psi [241kPa] differential remains constant). The ball valve setpoint offset parameter in the Liebert iCOM Service menu can be adjusted from 0 to...

Glycol/GLYCOOL-Cooled Models—Self-Contained Compressor 41 5.0 G LYCOL /GLYCOOL-C OOLED M ODELS —S ELF -C ONTAINED C OMPRESSOR 5.1 Drycooler Location The drycooler should be located for maximum security and maintenance accessibility. Avoid ground- level sites with public access or areas which contrib...

Glycol/GLYCOOL-Cooled Models—Self-Contained Compressor 42 5.4 Glycol Piping These guidelines apply to the field leak checking and fluid requirements for field piping systems. General Guidelines • Equipment damage and personal injury can result from improper piping installation, leak check- ing, flui...

Glycol/GLYCOOL-Cooled Models—Self-Contained Compressor 43 NOTICE Risk of debris or precipitate clogging pipes. Can cause equipment damage.Galvanized pipe must not be used in or with systems or units that contain glycol. The phosphates in the inhibitor can react with the zinc in the galvanized pipe, ...

Glycol/GLYCOOL-Cooled Models—Self-Contained Compressor 44 5.4.1 Expansion Tanks, Fluid Relief Valves and Other Devices An expansion tank must be provided for expansion and contraction of the fluid due to temperature change in this closed system. Vents are required at system high points to vent trapp...

Glycol/GLYCOOL-Cooled Models—Self-Contained Compressor 45 5.5.2 Glycol Solutions When considering the use of any glycol products in a particular application, you should review the lat- est Material Safety Data Sheets and ensure that the use you intend can be accomplished safely. For Material Safety ...

Glycol/GLYCOOL-Cooled Models—Self-Contained Compressor 46 NOTICE Risk of corrosion from water impurities. Can cause equipment damage.The quality of water used for dilution must be considered because water may contain corrosive elements which reduce the effectiveness of the inhibited formulation. Wat...

Glycol/GLYCOOL-Cooled Models—Self-Contained Compressor 47 Figure 23 Drycoolers and pump packages Notes 1. Single pump packages are 17-1/4" (438 mm) wide. Dual pump packages ar 32-1/4" (819 mm) wide. 2. Mounting holes are 15-1/4" (387 mm) apart on single pump packages and 30- 1/4" (76...

Glycol/GLYCOOL-Cooled Models—Self-Contained Compressor 48 Figure 24 Pump packages—expansion tank Table 17 Mounting hole dimensional data PUMP PACKAGE A in (mm) B in (mm) C in (mm) SINGLE (0.75 - 7.5 Hp) 15-1/4 (387.4) 2-1/2 (63.5) 22-1/2 (571.5) DUAL (0.75 - 5 Hp) 30-1/4 (768.4) 2-1/2 (63.5) 22-1/2 ...

Glycol/GLYCOOL-Cooled Models—Self-Contained Compressor 51 Figure 27 General arrangement—GLYCOOL models with scroll compressor Field-SuppliedReducersRequired on 3-Ton Units PumpHousing Pump Unions* Unions* IsolationValves* ExpansionValve EvaporatorCoil DrycoolerCoil DrycoolerElectric Box PressurePort...

Glycol/GLYCOOL-Cooled Models—Self-Contained Compressor 53 5.5.4 Motor Ball Valve—Digital Scroll Compressors Refer to 4.4 - Motorized Ball Valve—Digital Scroll Compressors for details on the motorized ball valve. 5.6 Condenser The condenser is designed to operate in conjunction with a drycooler. The ...

Chilled Water Models 54 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. This will pro- vide for routine service and emergency isolation of the unit.Consideration of the minimum water temperature to be suppl...

Chilled Water Models 55 Figure 30 Chilled water general arrangement - Downflow (BF) models SL-11899Pg. 6 A B FlowSwitch(optional) ChilledWaterReturn ChilledWaterSupply ChilledWaterReturn ChilledWaterCoil ChilledWaterCoil 2-Way ChilledWater Valve ChilledWaterSupply ShutoffValves * HoseBibs * 3-WAY VA...

Split System Models 56 7.0 S PLIT S YSTEM M ODELS Three condensing unit styles are available: two air-cooled and one water/glycol-cooled condensing unit. 7.1 Location Considerations 7.1.1 Air-Cooled Condensing Units To assure an adequate air supply, it is recommended that all condensing units be loc...

Split System Models 58 Refrigerant charge requirements: Total refrigerant charge will be required only if units are evacuated during installation or maintenance. Total refrigerant charge = evaporator + lines + condensing unit. Once all piping is complete, check for leaks and dehydrate the field pipi...

Split System Models 59 Figure 31 Refrigerant piping diagram 7.3.2 Quick Connect Fittings Be especially careful when connecting the quick connect fittings. Read through the following steps before making the connections.1. Remove protector caps and plugs.2. Carefully wipe coupling seats and threaded s...

Split System Models 60 7.4 Outdoor Air-Cooled Condensing Units Figure 32 Outdoor air-cooled condensing unit—horizontal air discharge models A B C Shaded area indicates a minimum clearance of 18" (457mm) for proper air flow Shaded area indicates a minimum clearance of 18" (457mm) for proper a...

Split System Models 61 Table 26 Horizontal air discharge cabinet and floor planning dimensional data Model Numbers Dimensional Data in. (mm) Module Weight lb (kg) net 60 Hz 50 Hz A B C PFC042A-_L PFC041A-_L 48 (1219) 31 (787) 18 (457) 241 (109) PFH042A-_L — PFC042A-_H PFC041A-_H 53 (1343) 36-1/4 (91...

Split System Models 63 Table 28 Cabinet and floor planning dimensional data - prop fan condensing modules, top air discharge Model Numbers Dimensional Data in. (mm) Module Weight lb (kg) net 60 Hz 50 Hz A B C D PFC067A-_H PFC066A-_H 53 (1343) 36-1/4 (918) 38-1/2 (978) 5-1/2 (140) 488 (222) PFH067A-_...

Split System Models 65 7.5 Centrifugal Air-Cooled Condensing Units 7.5.1 Installing the Indoor Condensing Unit Refer to drawings for unit dimensions and component locations. The indoor condensing unit is usually mounted above the ceiling and must be securely mounted to the roof structure. The ceilin...

Split System Models 66 Figure 35 Detail of ceiling hanging bracket 7.5.2 Ducting The total external static pressure for the inlet and outlet ducts, including grille, must not exceed 0.5 inches of H 2 O. Hood intake dimensions should be the same as the condensing unit duct dimen- sions.If the condens...

Split System Models 67 Figure 36 3-ton centrifugal air-cooled condensing unit dimensional data & piping connections C D B A Customer-suppliedthreaded rods for module supportfrom ceiling (typ. 4) SL-11085 Pg. 4 Air Outlet Duct Connection Air Outlet Duct Dimension Note:Unit is evenly spaced inrefe...

Split System Models 68 Figure 37 3-ton centrifugal air-cooled condensing unit (con't.) DPN000207Rev0 Single- or three-phaseelectric servicenot by Liebert Optional factory-installeddisconnect switch Factory-wiredto componentson electric panel Line voltage electric powersupply conduit entrance Field-s...

Split System Models 70 Figure 39 5-ton centrifugal air-cooled condensing unit dimensional data (con't.) DPN000226_Rev0 Field-Supplied Unit DisconnectSwitch when Factory UnitDisconnect Switch is not Supplied Electric servicenot by Liebert OptionalFactory-InstalledDisconnect Switch AIR COOLED Line Vol...

Split System Models 71 Figure 40 Split systems general arrangement CondenserCoil 1/2" (12.7mm) NPTPressure Relief Valve PressureBalancingValve SightGlass CheckValve Lee-TempReceiver High-PressureSwitch ScrollCompressor ScrollCompressor Head-PressureControl withIntegral CheckValve Liquid LineSole...

Split System Models 72 7.6 Water and Glycol-Cooled Condensing Units For installation guidelines, refer to Installing the Indoor Condensing Unit on page 65. 7.6.1 Piping Considerations It is recommended that manual service shut-off valves be installed at the supply and return line to each unit. This ...

Split System Models 73 7.6.4 Glycol Systems For split system glycol systems, use drycooler and pump data found in 5.0 - Glycol/GLYCOOL- Cooled Models—Self-Contained Compressor . See Table 18 - Drycooler data . Electrical control interconnect to drycooler is wired from water/glycol condensing unit. F...

R407C Refrigerant 77 8.0 R407C R EFRIGERANT Table 33 R407C pressure/temperature chart for operation and superheat (discharge/hot gas and suction gas) Temperature Gauge Pressure Temperature Gauge Pressure Temperature Gauge Pressure °F °C Psig kPa °F °C Psig kPa °F °C Psig kPa 0.0 -17.8 18.9 130 35.0 ...

R407C Refrigerant 78 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 liquid line (e.g., 90°F). Subtract the actual temperature from the liquid saturation ...

Ensuring The High AvailabilityOf Mission-Critical Data And Applications. Emerson Network Power, the global leader in enabling business-criticalcontinuity, ensures network resiliency and adaptability througha family of technologies—including Liebert power and coolingtechnologies—that protect and supp...

Important Safety Instructions 1 Liebert ® Challenger 3000 ™ I MPORTANT S AFETY I NSTRUCTIONS SAVE THESE INSTRUCTIONS This manual contains important safety instructions that should be followed during the installation and maintenance of the Liebert Challenger 3000. Read this manual thoroughly before a...

Important Safety Instructions Liebert ® Challenger 3000 ™ 2 NOTICE Risk of leaking water/glycol. Can cause equipment and building damage.This unit requires a water/glycol. drain connection. It may also require an external water/glycol supply to operate.Improper installation, application and service ...

Important Safety Instructions 3 Liebert ® Challenger 3000 ™ NOTICE Risk of damage from forklift. Can cause unit damage.Keep tines of the forklift level and at a height suitable to fit below the skid and/or unit to prevent exterior and/or underside damage. NOTICE Risk of improper storage. Can cause u...

Introduction Liebert ® Challenger 3000 ™ 4 1.0 I NTRODUCTION 1.1 System Descriptions Liebert Challenger 3000 Precision Cooling systems are available in three main system configurations: • self-contained system with a scroll compressor in the room unit• self-contained chilled water system• split syst...

Introduction 5 Liebert ® Challenger 3000 ™ 1.1.3 Split Systems Each air-cooled split system consists of an evaporator section and one of the following condensing units. Prop Fan Air-Cooled Prop Fan units include scroll compressor, condenser coil, prop fan, high pressure switch, hot gas bypass and Li...

Installation (Applicable to all Models) Liebert ® Challenger 3000 ™ 6 2.0 I NSTALLATION (A PPLICABLE TO ALL M ODELS ) 2.1 Room Preparation The room should be well insulated and must have a sealed vapor barrier. The vapor barrier in the ceiling can be a polyethylene film type. Use a rubber or plastic...

Installation (Applicable to all Models) 7 Liebert ® Challenger 3000 ™ 2.4.1 Handling With Skid • Always keep the unit upright, indoors and protected from damage.• If possible, transport the unit using a fork lift; otherwise, use a crane with belts or cables, avoiding pressing on the top edges of the...

Installation (Applicable to all Models) Liebert ® Challenger 3000 ™ 8 Figure 2 Upflow (BU) cabinet dimensions A Shaded area indicates a recommendedclearance of 34" (864mm) for componentaccess. Right side access suggested forGLYCOOL units. DPN000350Rev. 1 FRONT VIEW(front return configuration) 32...

Installation (Applicable to all Models) 9 Liebert ® Challenger 3000 ™ Figure 3 Downflow (BF) cabinet dimensions Shaded area indicatesa recommended clearance of34” (864mm) for componentaccess. Right side accesssuggested for GLYCOOL units DPN000351Rev. 1 32-1/2" (826mm) Overall Dimension 32-1/2...

Installation (Applicable to all Models) Liebert ® Challenger 3000 ™ 10 2.5 Piping Considerations All piping below the elevated floor must be located so that it offers the least resistance to air flow. Careful planning of the piping layout under the raised floor is required to prevent the air flow fr...

Installation (Applicable to all Models) 11 Liebert ® Challenger 3000 ™ Figure 4 Piping connections for air-cooled units - Downflow models Chilled Water Unit Connection Sizes—in. Model No. BF/BU (50 Hz) Supply Line CWS Return Line CWR 068C (072C) 1-1/8 1-1/8 102C (101C) 1-1/8 1-1/8 Table 2 Piping con...

Installation (Applicable to all Models) Liebert ® Challenger 3000 ™ 12 Figure 5 Piping connections for air-cooled units - Upflow models Condensate Drain3/4" FPTField pitch a min. of 1/8" (3.2mm) per ft. (305mm). Units withouta condensate pump have a factory-supplied trap in the unit, sodo no...

Installation (Applicable to all Models) 13 Liebert ® Challenger 3000 ™ Figure 6 Piping connections for split system fan coil units - Downflow models PIPING OUTLET LOCATIONS(See Cabinet and FloorPlanning Dimensional Datafor Piping Opening Sizes.) DPN000376Rev. 1 Condensate Drain3/4" FPTField pitc...

Installation (Applicable to all Models) Liebert ® Challenger 3000 ™ 14 Figure 7 Piping connections for split system fan coil units - Upflow models DPN000375Rev. 1 Piping outlet locations through theplenum are the same as the unit.See below for descriptions andconnection sizes. Humidifier Water Suppl...

Installation (Applicable to all Models) 15 Liebert ® Challenger 3000 ™ Figure 8 Piping connections for water/glycol and GLYCOOL units - Downflow models DPN000364Rev. 1 Condensate Drain3/4" FPTField pitch a minimumof 1/8" (3.2mm) per ft. (305mm).The drain line must comply withall applicable c...

Installation (Applicable to all Models) Liebert ® Challenger 3000 ™ 16 Figure 9 Piping connections for water/glycol and GLYCOOL units - Upflow models PIPING OUTLET LOCATIONS(See Cabinet and Floor PlanningDimensional Data for PipingOpening Sizes.) Piping outlet locations through the plenumthe same as...

Installation (Applicable to all Models) 19 Liebert ® Challenger 3000 ™ 2.5.2 Humidifier Supply Water—Optional Infrared • 1/4" supply line; maximum water pressure is 150 psi (1034kPa) • Size humidifier supply line for 1 gpm (3.8 l/m), with a minimum water pressure of 20 psi (138kPa)• Do not suppl...

Installation (Applicable to all Models) Liebert ® Challenger 3000 ™ 20 Figure 12 Electrical connections 2.7.1 Electrical Field Connections for Liebert Challenger 3000 Models Source: DPN00354, Rev. 21. Electric conduit knockouts on top and bottom of electric box. Knockout size 1-3/4" (44.5mm). 2....

Installation (Applicable to all Models) 21 Liebert ® Challenger 3000 ™ 14. Heat rejection connection . Field-supplied 24V Class 1 wiring to interlock heat rejection from pigtails 70 + 71, which are factory-connected to compressor side switch (self-contained units only) or to GLYCOOL relay (K11, GLYC...

Installation (Applicable to all Models) Liebert ® Challenger 3000 ™ 22 2.8 Balancing the Air Distribution 2.8.1 Under-Floor Discharge Systems The systems are designed for constant air delivery, therefore any unusual restrictions within the air circuit must be avoided. For under-floor air distributio...

Installation (Applicable to all Models) 23 Liebert ® Challenger 3000 ™ 2.9 Checklist for Completed Installation ___ 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.___...

Air-Cooled Models—Self-Contained Compressor Liebert ® Challenger 3000 ™ 24 3.0 A IR -C OOLED M ODELS —S ELF -C ONTAINED C OMPRESSOR 3.1 Condenser Location The air-cooled condenser should be located for maximum security and maintenance accessibility. Avoid ground level sites with public access or are...

Air-Cooled Models—Self-Contained Compressor 25 Liebert ® Challenger 3000 ™ Figure 14 Air-cooled condensers Table 4 Air-cooled condenser statistics Model Number of Fans Connection Sizes (OD Copper) Net Weight lb (kg) “A” Dimension in (mm) Hot Gas (in.) Liquid (in.) 083 1 7/8 5/8 295 (133.8) 42 (1067)...

Air-Cooled Models—Self-Contained Compressor Liebert ® Challenger 3000 ™ 26 3.3 Refrigerant Piping All refrigeration piping should be installed with high temperature brazed joints. Prevailing good refrigeration practices should be employed for piping supports, leak testing, dehydration and charging o...

Air-Cooled Models—Self-Contained Compressor Liebert ® Challenger 3000 ™ 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 ...

Air-Cooled Models—Self-Contained Compressor 29 Liebert ® Challenger 3000 ™ Variable Fan Speed Charging 1. Check unit nameplate for refrigerant type to be used. Unit control configurations differ depending on refrigerant type. 2. Refrigerant charging requires unit operation. Refer to 2.9 - Checklist ...

Air-Cooled Models—Self-Contained Compressor Liebert ® Challenger 3000 ™ 30 Figure 15 General arrangement—Air-cooled models with fan speed control DPN000349Rev. 5 CondenserCoil SchraderValve SchraderValve Optional Field-InstalledFusible Plug EvaporatorCoil Hot GasBypassValve Hot GasBypass * For rises...

Air-Cooled Models—Self-Contained Compressor Liebert ® Challenger 3000 ™ 32 3.5 Air-Cooled Condenser with Liebert Lee-Temp ™ “Flooded Condenser” Head Pressure Control System The Liebert Lee-Temp system consists of a modulating type head pressure control valve and insulated receivers with heater pads ...

Air-Cooled Models—Self-Contained Compressor 33 Liebert ® Challenger 3000 ™ 6. 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 250 microns or less. Recheck the pressure after two hours. 7. Remove the jumper...

Air-Cooled Models—Self-Contained Compressor Liebert ® Challenger 3000 ™ 34 Liebert Lee-Temp Receiver Refrigerant Level On each receiver at the condenser are two refrigerant-level sight glasses. Refrigerant level will vary with outside temperature. Check refrigerant level after the unit has been on f...

Water-Cooled Models—Self-Contained Compressor Liebert ® Challenger 3000 ™ 36 4.0 W ATER -C OOLED M ODELS —S ELF -C ONTAINED C OMPRESSOR 4.1 Piping Considerations Manual shutoff valves should be installed at the supply and return lines of each unit. This will provide for routine maintenance or emerge...

Water-Cooled Models—Self-Contained Compressor 37 Liebert ® Challenger 3000 ™ Figure 19 General arrangement—Water-cooled models with scroll compressor Field-SuppliedReducersRequiredon 3-Ton Units DPN000359 Rev. 2 EvaporatorCoil ExpansionValve SensingBulb ExternalEqualizers ScrollCompressor ServiceVal...

Water-Cooled Models—Self-Contained Compressor 39 Liebert ® Challenger 3000 ™ 4.3 Water Regulating Valve The water regulating valve automatically regulates the amount of fluid necessary to remove the heat from the refrigeration system, permitting more fluid to flow when load conditions are high and l...

Water-Cooled Models—Self-Contained Compressor Liebert ® Challenger 3000 ™ 40 4.3.2 High Pressure Valve - 350 psig (2413 kPa) System for 3-Ton Units (Metrex Valve) Adjustment The valve may be adjusted using a 1/8" diameter rod. Turn the adjusting collar nut counterclockwise to raise head pressure...

Water-Cooled Models—Self-Contained Compressor 41 Liebert ® Challenger 3000 ™ Control Method The control utilizes an upper and lower pressure threshold with a 35psi (241kPa) deadband to reduce valve movement. If the liquid pressure is between the upper and lower threshold, the valve remains at the cu...

Glycol/GLYCOOL-Cooled Models—Self-Contained Compressor Liebert ® Challenger 3000 ™ 42 5.0 G LYCOL /GLYCOOL-C OOLED M ODELS —S ELF -C ONTAINED C OMPRESSOR 5.1 Drycooler Location The drycooler should be located for maximum security and maintenance accessibility. Avoid ground- level sites with public a...

Glycol/GLYCOOL-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. General Guidelines • Equipment damage and personal injury can result from improper piping install...

Glycol/GLYCOOL-Cooled Models—Self-Contained Compressor Liebert ® Challenger 3000 ™ 44 from which it is prepared and may become increasingly corrosive with use if not properly inhibited. NOTICE Risk of no-flow condition. Can cause equipment and building damage from corrosion and resulting leaks.Do no...

Glycol/GLYCOOL-Cooled Models—Self-Contained Compressor 45 Liebert ® Challenger 3000 ™ 5.4.1 Expansion Tanks, Fluid Relief Valves and Other Devices An expansion tank must be provided for expansion and contraction of the fluid due to temperature change in this closed system. Vents are required at syst...

Glycol/GLYCOOL-Cooled Models—Self-Contained Compressor Liebert ® Challenger 3000 ™ 46 5.5.2 Glycol Solutions When considering the use of any glycol products in a particular application, you should review the latest Material Safety Data Sheets and ensure that the use you intend can be accomplished sa...

Glycol/GLYCOOL-Cooled Models—Self-Contained Compressor 47 Liebert ® Challenger 3000 ™ NOTICE Risk of corrosion from water impurities. Can cause equipment damage.The quality of water used for dilution must be considered because water may contain corrosive elements which reduce the effectiveness of th...

Glycol/GLYCOOL-Cooled Models—Self-Contained Compressor Liebert ® Challenger 3000 ™ 48 Figure 23 Drycoolers and pump packages Notes 1. Single pump packages are 17-1/4" (438 mm) wide. Dual pump packages are 32-1/4" (819 mm) wide. 2. Mounting holes are 15-1/4" (387mm) apart on single pump p...

Glycol/GLYCOOL-Cooled Models—Self-Contained Compressor 49 Liebert ® Challenger 3000 ™ Figure 24 Pump packages—expansion tank Table 17 Mounting hole dimensional data PUMP PACKAGE A in (mm) B in (mm) C in (mm) SINGLE (0.75 - 7.5 hp) 15-1/4 (387.4) 2-1/2 (63.5) 22-1/2 (571.5) DUAL (0.75 - 5 hp) 30-1/4 ...

Glycol/GLYCOOL-Cooled Models—Self-Contained Compressor Liebert ® Challenger 3000 ™ 54 5.5.4 Motor Ball Valve—Digital Scroll Compressors Refer to 4.4 - Motorized Ball Valve—Digital Scroll Compressors for details on the motorized ball valve. 5.6 Condenser The condenser is designed to operate in conjun...

Chilled Water 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 unit. This will provide for routine service and emergency isolation of the unit.Consideration of the minimum wate...

Chilled Water Models Liebert ® Challenger 3000 ™ 56 Figure 30 Chilled water general arrangement - Downflow (BF) models SL-11899Pg. 6 A B FlowSwitch(optional) ChilledWaterReturn ChilledWaterSupply ChilledWaterReturn ChilledWaterCoil ChilledWaterCoil 2-Way ChilledWater Valve ChilledWaterSupply Shutoff...

Split System Models 57 Liebert ® Challenger 3000 ™ 7.0 S PLIT S YSTEM M ODELS Three condensing unit styles are available: two air-cooled and one water/glycol-cooled condensing unit. 7.1 Location Considerations 7.1.1 Air-Cooled Condensing Units To assure an adequate air supply, it is recommended that...

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 evaporator and the condensing unit.Two possible methods exist for installing the copper suction and liquid lines.1. Using an opti...

Split System Models Liebert ® Challenger 3000 ™ 60 Figure 31 Refrigerant piping diagram Table 22 Line charges - refrigerant per 100 ft. (30 m) of Type “L” copper tube O.D. R407C Liquid Line lb (kg) Suction Line lb (kg) 1/2" 7.3 (3.3) - 5/8" 11.7 (5.3) 0.4 (0.2) 7/8" 24.4 (11.1) 1.0 (0.4)...

Split System Models 61 Liebert ® Challenger 3000 ™ 7.3.2 Quick Connect Fittings Be especially careful when connecting the quick connect fittings. Read through the following steps before making the connections.1. Remove protector caps and plugs.2. Carefully wipe coupling seats and threaded surfaces w...

Split System Models Liebert ® Challenger 3000 ™ 62 7.4 Outdoor Air-Cooled Condensing Units Figure 32 Outdoor air-cooled condensing unit—horizontal air discharge models A B C Shaded area indicates a minimum clearance of 18" (457mm) for proper air flow Shaded area indicates a minimum clearance of ...

Split System Models 63 Liebert ® Challenger 3000 ™ Table 26 Horizontal air discharge cabinet and floor planning dimensional data Model Numbers Dimensional Data in. (mm) Module Weight lb (kg) net 60 Hz 50 Hz A B C PFC042A-_L PFC041A-_L 48 (1219) 31 (787) 18 (457) 241 (109) PFH042A-_L — PFC042A-_H PFC...

Split System Models 65 Liebert ® Challenger 3000 ™ Table 28 Cabinet and floor planning dimensional data - prop fan condensing modules, top air discharge Model Numbers Dimensional Data in. (mm) Module Weight lb (kg) net 60 Hz 50 Hz A B C D PFC067A-_H PFC066A-_H 53 (1343) 36-1/4 (918) 38-1/2 (978) 5-1...

Split System Models 67 Liebert ® Challenger 3000 ™ 7.5 Centrifugal Air-Cooled Condensing Units 7.5.1 Installing the Indoor Condensing Unit Refer to drawings for unit dimensions and component locations. The indoor condensing unit is usually mounted above the ceiling and must be securely mounted to th...

Split System Models Liebert ® Challenger 3000 ™ 68 Figure 35 Detail of ceiling hanging bracket 7.5.2 Ducting The total external static pressure for the inlet and outlet ducts, including grille, must not exceed 0.5 inches of H 2 O. Hood intake dimensions should be the same as the condensing unit duct...

Split System Models 69 Liebert ® Challenger 3000 ™ Figure 36 3-ton centrifugal air-cooled condensing unit dimensional data & piping connections C D B A Customer-supplied threaded rods for module supportfrom ceiling (typ. 4) SL-11085 Pg. 4 Air Outlet Duct Connection Air Outlet Duct Dimension Note...

Split System Models Liebert ® Challenger 3000 ™ 70 Figure 37 3-ton centrifugal air-cooled condensing unit ( con’t. ) DPN000207Rev0 Single- or three-phaseelectric servicenot by Liebert Optional factory-installeddisconnect switch Factory-wiredto componentson electric panel Line voltage electric powers...

Split System Models Liebert ® Challenger 3000 ™ 72 Figure 39 5-ton centrifugal air-cooled condensing unit dimensional data ( con’t .) DPN000226Rev0 Field-Supplied Unit DisconnectSwitch when Factory UnitDisconnect Switch is not Supplied Electric servicenot by Liebert OptionalFactory-InstalledDisconne...

Split System Models 73 Liebert ® Challenger 3000 ™ Figure 40 Split systems general arrangement CondenserCoil 1/2" (12.7mm) NPTPressure Relief Valve PressureBalancingValve SightGlass CheckValve Lee-TempReceiver High-PressureSwitch ScrollCompressor ScrollCompressor Head-PressureControl withIntegra...

Split System Models Liebert ® Challenger 3000 ™ 74 7.6 Water and Glycol-Cooled Condensing Units For installation guidelines, refer to Installing the Indoor Condensing Unit on page 67. 7.6.1 Piping Considerations It is recommended that manual service shutoff valves be installed at the supply and retu...

Split System Models 75 Liebert ® Challenger 3000 ™ 7.6.4 Glycol Systems For split system glycol systems, use drycooler and pump data found in 5.0 - Glycol/GLYCOOL- Cooled Models—Self-Contained Compressor . See Table 18 - Drycooler data . Electrical control interconnect to drycooler is wired from wat...

R407C Refrigerant Liebert ® Challenger 3000 ™ 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 liquid line (e.g., 90°F). Subtract the actual temperature...

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