Emerson 3000/ITR - Manuals
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Manual Emerson 3000/ITR
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i TABLE OF CONTENTS I MPORTANT S AFETY I NSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 SAVE THESE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.0 I NTRODUCTION . . . . ...
ii 6.1 Standard Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 6.1.1 Change Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 6.1.2 C...
iii 7.6 Facility Fluid and Piping Maintenance for Water and Glycol Systems . . . . . . . . . . . . . . . . 49 7.7 Humidifier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 7.7.1 Infrared Humidifier . . . . . . . . ....
iv TABLES Table 1 Keyboard icons and functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Table 2 Sample Liebert iCOM network configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Table 3 ...
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/Liebert Challenger ITR with Liebert iCOM. Read this manual thoroughly before attempting to inst...
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 leaking from the unit. Water leaks can cause severe...
Introduction 3 1.0 I NTRODUCTION 1.1 System Descriptions The Liebert Challenger 3000 ™ and Liebert Challenger ITR ™ Precision Cooling systems are available in several configurations. 1.1.1 Compressorized Systems These systems may be air, water, or glycol cooled, depending on the heat rejection metho...
Startup 4 2.0 S TARTUP Before beginning startup, make certain that unit was installed according to the instructions in the installation manual, SL-11962. Verify that the fan shipping bolt has been removed, the check valve has been installed (on air cooled units), and that the scroll compressor is ro...
Operation with iCOM Control 6 3.0 O PERATION WITH I COM C ONTROL The Liebert iCOM ™ control offers the highest capabilities in unit control, communication and moni- toring of Liebert mission-critical cooling units.Liebert iCOM may be used to combine multiple cooling units into a team that operates a...
Liebert iCOM Display Components and Functions 7 4.0 L IEBERT I COM D ISPLAY C OMPONENTS AND F UNCTIONS The small and the large display have a common key layout, as shown in Figure 2 . Figure 2 Liebert iCOM display components NOTE The Help key may be pressed at any time for a brief explanation of wha...
Liebert iCOM Display Components and Functions 8 Table 1 Keyboard icons and functions Icon Key Name Function On/Off Key Controls the operational state of the cooling unit. Alarm Key Silences an alarm. Help Key Accesses integrated help menus. ESCape Key Returns to the previous display view. Enter Key ...
Liebert iCOM Display Components and Functions 9 Figure 3 Liebert iCOM default screen symbols 4.1 Navigating Through the Liebert iCOM Display Liebert iCOM displays icons and text for monitoring and controlling your Liebert cooling unit. The number of icons and amount of text shown depends on the disp...
Liebert iCOM Display Components and Functions 10 Figure 5 Liebert iCOM default home screen—Simple view 4.1.1 Control Interface—Three Main Menus The Liebert iCOM control has three main menus: User, Service and Advanced.The User menu contains the most frequently used features, settings and status info...
Liebert iCOM Display Components and Functions 11 4.1.2 Accessing Menus and Settings Viewing Data No password is required to view data or settings.To view data:1. From the home screen, press the Enter key to view the User Menu (see Figure 8 ). 2. Press Enter again to highlight the first icon. 3. Use ...
Liebert iCOM Display Components and Functions 12 4.1.4 Accessing Submenus To access the User, Service or Advanced menu, press the Enter or down arrow key while viewing the Status menu of the unit you wish to access. The User menu will be displayed first. To view the Service or Advanced menus, press ...
Liebert iCOM Display Components and Functions 13 Figure 7 Menu tree—Large and small displays, stand-alone or networked Status Menu – System View (Large Display Only ) Status Menu Unit 1 View User Menu Unit 1 Password Setpoints Spare Part List (Large Display Only) Event Log Graphics View Network (Lar...
Liebert iCOM Display Components and Functions 14 4.2 Changing Operational Settings Changes to the Liebert Challenger 3000/Liebert Challenger ITR’s operation settings in the Set Alarms and Setpoints menus require a password. 1. From the home screen, press the Enter key to view the User Menu (see Figu...
Liebert iCOM Display Components and Functions 15 4.3 Changing Liebert iCOM’s Display Settings No password is required to change the way Liebert iCOM displays data. The Display Setup controls how the unit shows data, such as temperature, date and time.To change the display settings:1. From the home s...
Liebert iCOM Display Components and Functions 16 4.4 Graphical Data Record The Graphical Data Record charts the average temperature from the return air temperature sensor (see Figure 10 ). The temperature scales can be changed to expand or compress the data. The time scale also can be altered to any...
Liebert iCOM Display Components and Functions 17 4.6 Wiring for Unit-to-Unit Communications—U2U The Liebert Challenger 3000/Liebert Challenger ITR with Liebert iCOM comes from the factory wired for stand-alone operation. Multiple units can be set up in a network for efficiency, ease of operation and...
Liebert iCOM Display Components and Functions 18 Large Displays A network switch is required to enable Ethernet communication on one or more cooling units with large displays. Each cooling unit with a large display requires two straight-through Ethernet cables from a network switch. One cable connec...
Liebert iCOM Display Components and Functions 19 Figure 12 U2U network setup diagram Network Switch Liebert Challenger with Small Liebert iCOM Display Liebert Challenger with Small Liebert iCOM Display Liebert Challenger with Large Liebert iCOM Display Display Service /Network Liebert iCom Display M...
Liebert iCOM Display Components and Functions 20 Notes on Wiring for a U2U Network—Refer to Figures 13 and 15 1. See unit electrical schematic.2. Cable ‘A’ and ‘B’ are provided with each unit. One only is used as follows: • Liebert IntelliSlot based communications - Cable ‘A’ is preconnected to P65 ...
Liebert iCOM Display Components and Functions 21 Figure 13 Liebert iCOM wiring—Unit as shipped Liebert IntelliSlotPower Supply Liebert IntelliSlot 1 Liebert IntelliSlot 2 P64A ConnectionLocated NearI/O Board Cable 'A' Cabl e†‘ D’ Cabl e ' C ' Ribbon Cables Cable 'B' Liebert iCOM Microprocessor and I...
Liebert iCOM Display Components and Functions 22 Figure 14 Wiring a small display for U2U network operation Standard Small Graphics Display (Rear View) Liebert iCOMI/O Board Straight-ThroughEthernet Cable To / From OtherNetworked Units CANCable U2U Networking Switch(Field-Supplied) NotUsed Cable 'C'...
Liebert iCOM Display Components and Functions 23 Figure 15 Wiring a large display for U2U network operation CrossoverCoupler(See Note 6) Red CrossoverEthernet Cable Liebert iCOMI/O Board Straight-ThroughEthernet Cables CANCable See Note 4 Optional Large Graphics Display (Rear View) To / From OtherNe...
Liebert iCOM Display Components and Functions 24 Figure 16 Liebert iCOM input-output control board P65 P64 (RJ-45 Jack) P66 P63 P61 P67
Liebert iCOM Display Components and Functions 25 4.7 Entering Network Setup Information Setting up a U2U network requires setting a unique IP addresses for each unit, choosing a U2U address and designating the U2U group. Refer to Figure 17 for the setup screen for the control board (installed inside...
Liebert iCOM Display Components and Functions 26 4.8 Viewing Multiple Units with a Networked Large Display When you first wake up the control, press the ESC key to return to the System view Status menu. This view shows an average of all the units on the network and any alarms present. To view a spec...
Operation 27 5.0 O PERATION The Liebert iCOM display for your Liebert cooling unit features an easy-to-use, menu-driven liquid crystal display (LCD). All unit settings and parameters can be viewed and adjusted through three menus: User, Service and Advanced. All active alarms are displayed on the LC...
Operation 28 Autorestart When there is a loss of power to the cooling unit and power comes back, the unit will return to its pre- vious operating status—On if it was On before the power failed, Off if it was Off. When power returns, the autorestart time—time-selectable: Single Unit Auto Restart (Ser...
Operation 29 Pump Down—Air Cooled with Condenser Only Units The Pump Down operation is performed to protect the compressor oil from being diluted with liquid refrigerant, which helps ensure that the compressor is properly lubricated for the next startup. The Pump Down operation operates in the follo...
Operation 30 Evaluate the start operation of the unit (with pump down).1. Close LLSV2. Wait for LPS to make or ignore for WSK time If LPS is made before WSK has expired, allow the compressor to continue running, if not then stop compressor and alarm low pressure alarm. 3. Once LPS makes start compre...
Alarm Descriptions 32 6.0 A LARM D ESCRIPTIONS The Liebert iCOM will audibly and visually annunciate all enabled alarms. Alarms are wired from Terminal 24 through a normally open contact to locations 50, 51, 55 and 56, respectively, for alarms 1 through 4. The alarms can be delayed from 0 to 255 sec...
Alarm Descriptions 33 6.1.3 High Head Pressure Compressor high head is monitored with a pressure switch. One SPDT pressure switch is used for the compressor in the unit. If head pressure exceeds 360 PSIG, the switch opens the compressor contactor and sends an input signal to the control. On a self-c...
Alarm Descriptions 34 6.1.9 Loss of Air Flow A differential air pressure switch is used to indicate loss of air flow in Liebert Challenger 3000/Lie- bert Challenger ITR units.Check for blockage of unit air outlet or inlet. Check blower motor fuses and overload reset. Check for broken belts. Make sur...
Alarm Descriptions 35 6.2 Optional Alarms 6.2.1 Loss of Water Flow Available only with 3-way valves and occurs when no water flow is detected in the chilled water or condenser water supply line. An optional flow switch is required for this alarm. Check for service valves closed, pumps not working, e...
Component Operation and Maintenance 36 7.0 C OMPONENT O PERATION AND M AINTENANCE 7.1 System Testing 7.1.1 Environmental Control Functions The performance of all control circuits can be tested by actuating each of the main functions. This is done by temporarily changing the setpoints. Cooling To tes...
Component Operation and Maintenance 37 Control Transformer and Fuses The control system is divided into four separate circuits. The control voltage circuits are individually protected by fuses located on the transformer/fuse board. If any of the fuses are blown, first eliminate shorts, then use spar...
Component Operation and Maintenance 38 Figure 22 Recommended liquid sensor locations The zone leak detection kit provides leak detection for a defined zone. This kit is ideal for perimeter sensing or serpentine coverage of small areas. A simple, two-wire connection signals the alarms at a Liebert en...
Component Operation and Maintenance 39 7.2 Filters Filters are usually the most neglected item in an environmental control system. To maintain efficient operation, they should be checked monthly and changed as required. Because replacement intervals vary with environmental condition and filter type,...
Component Operation and Maintenance 40 7.3.3 Air Distribution All unit models are designed for constant volume air delivery. Therefore any unusual restrictions within the air circuit must be avoided. For downflow models operating on a raised floor, refer to the following table for recommended free a...
Component Operation and Maintenance 41 7.4.2 Discharge Pressure Discharge Pressure can be increased or decreased by load conditions or condenser efficiency. The high pressure switch will shut the compressor down at its cut-out setting. Refer to Table 7 , below. 7.4.3 Superheat Superheat can be adjus...
Component Operation and Maintenance 42 7.4.5 Hot Gas Bypass Valve—Not Available on Digital Scroll Units Operation—Self-Contained Units The hot gas bypass is inserted between the compressor discharge line and the leaving side of the expansion valve through the side outlet distributor. The system, wit...
Component Operation and Maintenance 43 Checking Refrigerant Charge (Lee–Temp / Flood Back Head Pressure Control) The system refrigerant level must be checked periodically. To do so:1. Adjust temperature setpoint in the unit so that the compressor will run continuously.2. The refrigerant level is vis...
Component Operation and Maintenance 44 7.4.8 Motorized Ball Valve—Digital Scroll Compressor On water-cooled and glycol-cooled digital scroll units, the discharge pressure is controlled by a motor- ized ball valve. During unloaded operation, the pressure changes during each digital cycle could result...
Component Operation and Maintenance 45 To raise the head pressure setting, turn the adjusting screw counterclockwise until the desired set- ting is obtained. Figure 24 Johnson Controls valve adjustment Manual Flushing —The valve may be flushed by inserting a screwdriver or similar tool under the two...
Component Operation and Maintenance 46 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. Valve Disassembly 1. Shut off the water supply by using isolating valves.2. Relieve the ...
Component Operation and Maintenance 47 7.4.11 Compressor Oil NOTICE Risk of improper compressor lubrication. Can cause compressor and refrigerant system damage.Failure to use oil types, viscosities and quantities recommended by the compressor manufacturer may reduce compressor life and void the comp...
Component Operation and Maintenance 48 7.5.2 Standard Scroll Compressor Replacement Infrequently a fault in the motor insulation may result in a motor burn, but burnouts rarely occur in a properly installed system. Of those that do, most are the effects of mechanical or lubrication fail- ures, resul...
Component Operation and Maintenance 49 Three-phase power must be connected to the unit line voltage terminals in the proper sequence so that the scroll compressor rotates in the proper direction. Rotation in the wrong direction will result in poor performance and compressor damage.Record compressor ...
Component Operation and Maintenance 50 7.7 Humidifier 7.7.1 Infrared Humidifier During normal humidifier operation, deposits of mineral solids will collect in the humidifier pan. This should be cleaned out periodically to ensure efficient operation. Each water supply has different char- acteristics,...
Component Operation and Maintenance 51 Changing Humidifier Lamps 1. Open disconnect switch.2. Open front panel.3. Remove screws securing line voltage compartment cover, then remove the cover.4. In line voltage compartment, disconnect one end of the purple jumpers, then locate the burned out bulb wit...
Component Operation and Maintenance 52 Autoflush Controls Use the LCD display, menu, and keys on the front control panel to program the autoflush controls. 7.7.2 Steam Generating Humidifier Steam generating humidifiers are designed to operate in voltage ranges from 200 to 575 volts and generate 11 p...
Component Operation and Maintenance 53 Operation 1. During startup, when the humidity control calls for humidification, the fill valve opens and allows water to enter the canister. When the water level reaches the electrodes, current flows and the water begins to warm. The canister fills until the a...
Component Operation and Maintenance 54 Replacing the Canister Over a period of operation, the humidifier electrodes become coated with mineral solids. This coating insulates the electrodes and decreases the current flow. To maintain humidifier capacity, the water level slowly rises to expose fresh e...
Component Operation and Maintenance 55 Circuit Board Adjustments Humidifier operation is governed by the humidifier control board. This board is located on the right side of the humidifier compartment. There are three potentiometers mounted on the board. These pots can be used to adjust for extreme ...
Troubleshooting 56 8.0 T ROUBLESHOOTING Use this section to assist in troubleshooting your unit. Also refer to 6.0 - Alarm Descriptions . Sug- gestions are grouped by product function for convenience. NOTICE Risk of improper control connection. Can cause equipment damage.When using jumpers for troub...
Troubleshooting 57 Table 14 Compressor and refrigeration system troubleshooting Symptom Possible Cause Check or Remedy Compressor will not start Power Off Check main switch, fuses or CBs and wiring Current overload open Re-set units with overload option manually. Allow compressor to cool for interna...
Troubleshooting 59 Table 15 Dehumidification troubleshooting Symptom Possible Cause Check or Remedy No dehumidification Control not calling for dehumidification Check monitor status. Compressor contactor not pulling in See 7.5.1 - Compressor Functional Check and Table 14 . Compressor won't run; fuse...
Troubleshooting 60 Table 18 Steam generating humidifier troubleshooting Symptom Possible Cause Check or Remedy False canister full indication Foaming Check drain valve to ensure that it drains freely. Check and replace if defective.Check water supply. If commercially softened, reconnect to raw water...
Troubleshooting 61 Excessive arcing in the canister Drain valve clogged or defective Verify that drain valve operates freely when activated. Clean valve and replace coil or valve if defective. Flush canister several times and replace if arcing persists. Improper water supply If water is commercially...
Monthly Maintenance Inspection Checklist 62 9.0 M ONTHLY M AINTENANCE I NSPECTION C HECKLIST Date:_______________________________________ Prepared by:_________________________________ Model #:_____________________________________ Serial #:____________________________________ Filters ___ 1. Restricte...
Semiannual Maintenance Inspection Checklist 63 10.0 S EMIANNUAL M AINTENANCE I NSPECTION C HECKLIST Date:________________________________________ Prepared by:_________________________________ Model #:_____________________________________ Serial #:_____________________________________ Filters ___ 1. ...
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...
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