Emerson Liebert Challenger 3000- Manuals

Liebert ® Challenger 3000 ™ 2 NOTICE Risk of internal system corrosion and frozen coolant fluid. Can cause equipment damage and major fluid leaks resulting in serious building damage, expensive repair costs and costly system down time.Cooling coils, heat exchangers and piping systems that are connec...

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 unit damage.Keep the Liebert Ch...

Introduction Liebert ® Challenger 3000 ™ 4 1.0 I NTRODUCTION 1.1 System Descriptions Liebert Challenger 3000 Thermal Management systems are available in several configurations. 1.1.1 Compressorized Systems These systems may be air-cooled, water-cooled or glycol-cooled, depending on the heat rejectio...

Startup 5 Liebert ® Challenger 3000 ™ 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...

Component Operation and Maintenance 7 Liebert ® Challenger 3000 ™ 3.0 C OMPONENT O PERATION AND M AINTENANCE 3.1 System Testing 3.1.1 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 th...

Component Operation and Maintenance Liebert ® Challenger 3000 ™ 8 High-Temp Sensor The optional high-temp sensor is a bimetal-operated sensing device with a normally closed switch. This device will shut down the entire unit when the inlet air temperature exceeds a preset point. It is connected betwe...

Component Operation and Maintenance 9 Liebert ® Challenger 3000 ™ 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 Thermal Management un...

Component Operation and Maintenance Liebert ® Challenger 3000 ™ 10 3.3 Blower Package Periodic checks of the blower package include: belt, motor mounts, fan bearings, and impellers. 3.3.1 Fan Impellers and Bearings Fan impellers should be periodically inspected and any debris removed. Check to see i...

Component Operation and Maintenance 11 Liebert ® Challenger 3000 ™ 3.4 Refrigeration System Each month, the components of the refrigeration system should be inspected for proper function and signs of wear. Since, in most cases, evidence of malfunction is present prior to component failure, periodic ...

Component Operation and Maintenance Liebert ® Challenger 3000 ™ 12 3.4.4 Thermostatic Expansion Valve Operation The thermostatic expansion valve performs one function. It keeps the evaporator supplied with enough refrigerant to satisfy load conditions. It does not effect compressor operation. Proper...

Component Operation and Maintenance 13 Liebert ® Challenger 3000 ™ 3.4.6 Air-Cooled Condenser Restricted airflow through the condenser coil will reduce the operating efficiency of the unit and can result in high compressor head pressure and loss of cooling.Clean the condenser coil of all debris that...

Component Operation and Maintenance Liebert ® Challenger 3000 ™ 14 3.4.7 Charging the Liebert MC ™ with Refrigerant—Basic and Premium Efficiency Control Liebert MC condensers are charge-sensitive and require accurate calculation of the system charge to avoid overcharging. To avoid overcharge, additi...

Component Operation and Maintenance 15 Liebert ® Challenger 3000 ™ 8. Attach pressure and temperature instruments to the liquid line of the indoor unit. Measure the initial subcooling and continue to add charge until the recommended subcooling for the current outdoor ambient temperature is reached (...

Component Operation and Maintenance Liebert ® Challenger 3000 ™ 16 9. Verify the subcooling calculated from measured values at the evaporator against the subcooling reading of the Liebert MC ™ control [menu ID F50 & F51]. If the subcooling calculated with gauges differs from the Liebert MC subco...

Component Operation and Maintenance 17 Liebert ® Challenger 3000 ™ Elevation Correction Subtract Line c . (Correction for Condenser Elevation above Evaporator) from Line h . (Calculated Subcooling) to obtain Corrected Subcooling. Line h : 7°F Line c : -4°F i. Corrected Subcooling 3°F Verification Ag...

Component Operation and Maintenance Liebert ® Challenger 3000 ™ 18 3.4.8 Water/Glycol-Cooled Condensers Coaxial Condenser Each water- or glycol-cooled module has a coaxial condenser that consists of a steel outside tube and a copper inside tube.Coaxial condensers do not normally require maintenance ...

Component Operation and Maintenance 19 Liebert ® Challenger 3000 ™ Control The valve actuator operates on 24VAC power and is controlled by a 2-10VDC proportional control signal. The valve full open to full close time is 60 seconds. At 2VDC the valve is closed; at 10VDC the valve is fully open. There...

Component Operation and Maintenance Liebert ® Challenger 3000 ™ 20 3.4.10 Regulating Valve—Scroll Compressor 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 ...

Component Operation and Maintenance 21 Liebert ® Challenger 3000 ™ Figure 5 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. Valve Disassembly 1. Shut o...

Component Operation and Maintenance Liebert ® Challenger 3000 ™ 22 3.4.11 Drycooler Settings Applications with the Optional Stat Setting require field piping to be insulated to prevent condensation. Table 9 shows acceptable applications where stats must be adjusted to Optional Setting. Aquastats mus...

Component Operation and Maintenance 23 Liebert ® Challenger 3000 ™ 3.5 Compressor Replacement Replacement compressors are available through your local Emerson office. Compressors are shipped in reusable packaging. If unit is under warranty, complete and include Liebert Service Credit Application (LS...

Component Operation and Maintenance Liebert ® Challenger 3000 ™ 24 3.5.2 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 l...

Component Operation and Maintenance 25 Liebert ® Challenger 3000 ™ NOTICE Risk of improper wiring/phase sequencing. Could cause backward compressor rotation, poor performance and compressor damage.Three-phase power must be connected to the unit line voltage terminals in the proper sequence so that t...

Component Operation and Maintenance Liebert ® Challenger 3000 ™ 26 3.7 Humidifier—Infrared During normal humidifier operation, deposits of mineral solids will collect in humidifier pan and on the float switch. These must be cleaned periodically to ensure proper operation. Frequency of cleaning must ...

Component Operation and Maintenance 27 Liebert ® Challenger 3000 ™ 3.7.2 Changing Humidifier Lamps 1. Remove humidifier pan (see 3.7.1 - Cleaning Humidifier Pan and Float Switch , Steps 1 through 10 ). 2. Disconnect power from unit.3. At humidifier, remove screws and cover from high-voltage compartm...

Component Operation and Maintenance Liebert ® Challenger 3000 ™ 28 Autoflush Operation The operation of the autoflush is divided into four steps, beginning with a call for humidification.1. If the humidifier has not been activated for over 30 hours, the autoflush will flow water into the pan for abo...

Component Operation and Maintenance 29 Liebert ® Challenger 3000 ™ 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. Th...

Component Operation and Maintenance Liebert ® Challenger 3000 ™ 30 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 sl...

Component Operation and Maintenance 31 Liebert ® Challenger 3000 ™ 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...

Troubleshooting Liebert ® Challenger 3000 ™ 32 4.0 T ROUBLESHOOTING Use this section to assist in troubleshooting your unit. Suggestions are grouped by product function for convenience. NOTICE Risk of improper control connection. Can cause equipment damage.When using jumpers for troubleshooting, alw...

Troubleshooting 33 Liebert ® Challenger 3000 ™ Table 15 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 co...

Troubleshooting Liebert ® Challenger 3000 ™ 34 Flooding Defective or improperly set expansion valve Increase superheat or replace valve Evaporator fan motor or belt Correct problem or replace fan motor and/or belts. Low condensing pressure Check head pressure control device Slipping belts Inspect an...

Troubleshooting 35 Liebert ® Challenger 3000 ™ Table 17 Glycol pump troubleshooting Symptom Possible Cause Check or Remedy Suddenly stops pumping Clogged strainer or impeller Clean out debris. Suddenly slow pumping Clogged impeller, diffuser, or line Clean out debris and use strainer. Excessive leak...

Troubleshooting Liebert ® Challenger 3000 ™ 36 Table 19 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 soft...

Troubleshooting 37 Liebert ® Challenger 3000 ™ 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 sup...

Maintenance Worksheet Liebert ® Challenger 3000 ™ 38 5.0 M AINTENANCE W ORKSHEET Source: DPN002952-Rev. 0 Good maintenance practices are essential to minimizing operation cost and maximizing product life. Read and follow all applicable maintenance checks listed below. At a minimum, these checks shou...

Maintenance Worksheet 39 Liebert ® Challenger 3000 ™ BLOWER SECTION (EC Fan) (If Equipped) ___ 1. Mounting bolts tight___ 2. Fan guard bolts tight___ 3. Impeller spins freely___ 4. Check/test air sail switch (if equipped) ___ 8. Compare to nameplate amps REHEAT (If Equipped) ___ 1. Inspect elements_...

Maintenance Worksheet Liebert ® Challenger 3000 ™ 40 CONTROLS ___ 1. Check/verify control operation (sequence)___ 2. Check/test changeover device(s) (if equipped)___ 3. Check/test water detection device(s) (if equipped)___ 4. Check/test CAN connection between indoor and outdoor units (if equipped) R...

Maintenance Worksheet 41 Liebert ® Challenger 3000 ™ CHILLED WATER / ECON-O-COIL (If Equipped) ___ 1. Verify proper water maintenance is being performed___ 2. Check for water/glycol leaks___ 3. Stroke freecooling valve open and closed AIR-COOLED FIN AND TUBE CONDENSER / DRYCOOLER (if Equipped) ___ 1...

Maintenance Worksheet Liebert ® Challenger 3000 ™ 42 LIEBERT MC ™ (if Equipped) ___ 1. Coil clean___ 2. Fans free of debris___ 3. Fans Securely Mounted___ 4. Motor bearings in good condition___ 5. Check all refrigerant lines for vibration isolation. support as necessary.___ 6. Check for refrigerant ...

Maintenance Worksheet 43 Liebert ® Challenger 3000 ™ NOTES Name Signature Company Make copies for your records. Compare readings / information to previous maintenance worksheetTo locate your local Emerson representative for Liebert-engineered parts, go to the Liebert Web site: www.liebert.com or cal...

While every precaution has been taken to ensure the accuracyand completeness of this literature, Liebert Corporation assumes noresponsibility and disclaims all liability for damages resulting from use ofthis information or for any errors or omissions.© 2014 Liebert CorporationAll rights reserved thr...