Liebert 3000 - Manuals
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Manual Liebert 3000
Summary
i TABLE OF CONTENTS 1.0 I NTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.1 System Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1....
ii 3.7.1 Setup Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 3.7.2 Select Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 ...
iii 4.4.2 Sequential Load Activation Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 4.5 Additional Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 4.5.1 Connecting the ...
iv 6.5 Humidifier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 6.5.1 Infrared Humidifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 6.5.2...
Introduction 1 1.0 I NTRODUCTION 1.1 System Descriptions Challenger 3000 ™ Liebert environmental control systems are available in several configurations. Each configuration can operate with either Advanced Microprocessor Controls (A), or Advanced Microprocessor Controls with Graphics (G). A brief de...
Introduction 2 1.2 Start-Up Procedure Before beginning start-up, make certain that unit was installed according to the instructions in the Installation Manual. Verify that the fan shipping bolt has been removed, the check valve has been installed (on air cooled units), and that the scroll compressor...
Operation with Advanced Microprocessor Controls 3 2.0 O PERATION WITH A DVANCED M ICROPROCESSOR C ONTROLS The advanced microprocessor (A) control for your Liebert Challenger 3000 unit features an easy-to- use menu driven LCD display. The menus, control features, and circuit board details are describ...
Operation with Advanced Microprocessor Controls 5 2.2 Status Display The display normally shown includes the present room temperature, humidity, active status func- tions (cooling, heating, dehumidifying, humidifying), and active alarms. If no keys are pressed within 5 minutes, the system automatica...
Operation with Advanced Microprocessor Controls 6 2.4.4 Run Hours Log The total operating hours of all major components in the unit can be monitored from the display and are retained in nonvolatile memory. Run times are available for the following: • Compressor• GLYCOOL Coil (or CW Coil as used on D...
Operation with Advanced Microprocessor Controls 7 2.5.2 Setup System The Setup System menu includes the following selections: • SETUP OPERATION• SELECT OPTIONS• CALIBRATE SENSORS• SHOW DIP SWITCHES• SELECT CONTROL TYPE (Chilled Water or SCR Reheats only) • SETUP ALARMS• HUM CONTROL METHOD• ANALOG SE...
Operation with Advanced Microprocessor Controls 8 Table 2 lists the setup functions, their factory default values and the allowable programming ranges. Select Options The following table lists options which should match the options installed with your unit and should not need to be changed during no...
Operation with Advanced Microprocessor Controls 9 Select Control Type • Intelligent (Chilled Water only)• Proportional (all unit types)• Tunable PID (Chilled Water or SCR Reheats only) The type of system control method used by the microprocessor can be selected from the front panel. The default sett...
Operation with Advanced Microprocessor Controls 10 Enable Alarms —Each individual alarm can be selected to be ENABLED (annunciated audibly, visu- ally, and communicated to a Site Products System) or DISABLED (ignored). Enable Common Alarm —Each individual alarm can be selected to energize or to not ...
Operation with Advanced Microprocessor Controls 11 Analog Setup For installation of analog sensors, see 4.5.1 - Connecting the Analog Sensors . After selecting a compatible sensor and properly wiring it to the terminals, set up the control to mon- itor the sensor as follows: Slope —The slope is a mu...
Operation with Advanced Microprocessor Controls 12 2.5.3 Run Diagnostics By selecting Run Diagnostics, maintenance personnel can check system inputs, outputs, and complete a test of the microcontroller circuit board, all from the front panel. Review of the system inputs and the microcontroller test ...
Operation with Advanced Microprocessor Controls 13 2.5.4 Change Passwords The display prompts you to enter a three digit password when making changes. The system includes two (2) passwords, one for setpoints and one for setup. The system allows the passwords to be changed by first entering the prese...
Operation with Advanced Microprocessor Controls 14 2.8.2 Non-Volatile Memory All critical information is stored in nonvolatile memory. Setpoints, setup parameters, and component run hours are kept inside the microcontroller in EEPROM. Information retained for the alarm history is kept in non-volatil...
Operation with Advanced Microprocessor with Graphics Control 15 3.0 O PERATION WITH A DVANCED M ICROPROCESSOR WITH G RAPHICS C ONTROL The advanced microprocessor with graphics (G) control for your Liebert Challenger 3000 unit features an easy to use, menu driven LCD Graphics Display. The menus, cont...
Operation with Advanced Microprocessor with Graphics Control 17 3.2 Status Display The normal status screen is divided into two sections, a right half and a left half. The left half displays the return air temperature and humidity readings in large characters. The right half of the screen is divided...
Operation with Advanced Microprocessor with Graphics Control 18 3.4.3 Setup Alarms The list of alarms may be reviewed using the UP/DOWN keys. Any alarm may be selected to have it's parameters modified by pressing the ENTER key. All alarms have a time delay and alarm type parameter. The high/low temp...
Operation with Advanced Microprocessor with Graphics Control 19 3.4.4 Setup Custom Alarms Selecting SETUP CUSTOM ALARMS will step to the following menu: • SETUP CUSTOM ALARM TEXT• CHANGE CUSTOM TEXT 1• CHANGE CUSTOM TEXT 2• CHANGE CUSTOM TEXT 3• CHANGE CUSTOM TEXT 4 The custom alarm messages can be ...
Operation with Advanced Microprocessor with Graphics Control 20 3.5 Operating Status The Operating Status is intended to provide the user with displayed information about what the con- trol is calling for the system to do. For example: The display indicates the chilled water valve is 68% open. On a ...
Operation with Advanced Microprocessor with Graphics Control 21 Auto Restart Delay This feature allows for the unit to restart automatically after a loss of power. The programmed value is .1 minute (6 seconds) intervals. A programmed value of zero (0) would require the user to manually press the ON/...
Operation with Advanced Microprocessor with Graphics Control 22 3.7.2 Select Options The following table is a list of options which should match the options installed with your unit and should not need to change during normal operation. 3.7.3 Calibrate Sensors The temperature and humidity sensors ca...
Operation with Advanced Microprocessor with Graphics Control 23 3.7.6 Select Humidity Sensing Mode The user may select between RELATIVE (direct) and ABSOLUTE (predictive) humidity control. If relative is selected, the RH control is taken directly from the RH sensor. If absolute is selected, the RH c...
Operation with Advanced Microprocessor with Graphics Control 24 3.8.1 Show Inputs With the unit on and the fan running, the input state for the following devices may be displayed: • Air Sail Switch: normally off unless Loss of Air Alarm is active• Custom Alarm #1: normally off unless this alarm is a...
Operation with Advanced Microprocessor with Graphics Control 25 3.8.4 DIP Switches The DIP switch settings can be reviewed from the display panel. Changing the DIP switches requires opening the front panel for access to the DIP switches on the microprocessor control board. These selections should ma...
Operation with Advanced Microprocessor with Graphics Control 26 3.11 Analog/Digital Inputs Selecting ANALOG/DIGITAL INPUTS steps to the following menu: • READ ANALOG INPUTS• SETUP ANALOG INPUTS• READ DIGITAL INPUTS• SETUP DIGITAL INPUTS 3.11.1 Read Analog Inputs The four (4) analog sensor inputs can...
Operation with Advanced Microprocessor with Graphics Control 27 3.12.1 View 24 Hour Run Time History The history of each load for every hour during the past 24 hours is displayed in the run hour history. The percentage of each hour that the load was on is displayed from 0 to 100% in increments of 5%...
Operation with Advanced Microprocessor with Graphics Control 28 3.13.2 Nonvolatile Memory All critical information is stored in nonvolatile memory. Setpoints, setup parameters, and component run hours are kept inside the microcontroller in EEPROM. Information retained for data logging, 24 hour compo...
System Performance with Advanced Microprocessor Controls 29 4.0 S YSTEM P ERFORMANCE WITH A DVANCED M ICROPROCESSOR C ONTROLS This section provides details on how your Challenger 3000 unit responds to user inputs and room con- ditions. Refer to this section when you need specific information. This s...
System Performance with Advanced Microprocessor Controls 30 4.1.3 Cooling Operation 1-Step Cooling, Compressorized Direct Expansion (DX) Systems Cooling activates when the temperature control calculates a requirement for cooling of 100%. It is deactivated when the cooling requirement drops below 50%...
System Performance with Advanced Microprocessor Controls 31 4.1.4 Heating Operation Electric Reheat The two heat stages are activated when the temperature control calculates a requirement of 50% and 100%, respectively. Each stage is deactivated when the heat requirement is 25% less than the activa- ...
System Performance with Advanced Microprocessor Controls 32 4.2.4 Humidification Operation System Activation The humidifier (infrared or steam) is activated when the humidity control calculates a requirement of 100% humidification, and deactivated when the requirement falls below 50%. 4.3 Control Ty...
System Performance with Advanced Microprocessor Controls 33 A suggested tuning procedure is as follows:1. Initially adjust the integral and derivative settings to 0%/ degree-min and 0% /degree/min.2. Starting with 20% /degree, adjust the proportional setting in small increments (10% steps) until the...
System Performance with Advanced Microprocessor Controls 34 4.4 Load Control Features 4.4.1 Short Cycle Control The control system monitors the compressor and prevents it from turning on within 3 minutes of being turned off. If this (on, off, on) occurs too often, 10 times in one hour, a Short Cycle...
System Performance with Advanced Microprocessor Controls 35 Figure 5 Analog input jumpers 4.5.2 Water Detection Display The water detection display is designed to graphically display the location of water under a raised floor when connected to an LT750 water detection system. The graphical floor pla...
System Performance with Advanced Microprocessor Controls 36 Physical Connections Figure 6 shows the 4-20 mA output of LT750 connected to Analog Input #1 (41 and 42) on the exter- nal inputs terminal strip. This strip is provided on units ordered with analog inputs. (If this strip is not installed, t...
System Performance with Advanced Microprocessor Controls 37 4.6 Communications The control system uses a two-wire, RS-422 channel to communicate with remote monitoring systems via Liebert Site Products. This communication, directly out of the control, uses a proprietary protocol. Your unit can have ...
Alarm Descriptions 38 5.0 A LARM D ESCRIPTIONS The Advanced Microprocessor (A) and the Advanced Microprocessor with Graphics (G) Control sys- tems will audibly and visually annunciate all ENABLED alarms, including the four custom alarms. With the Advanced & Advanced with Graphics Controls, the c...
Alarm Descriptions 39 5.1.2 Compressor Overload An optional tri-block overload device can be used for the compressor. Compressor overload may be manual or automatic reset, depending on your model. Overload is located at the electric connection box on the compressor. 5.1.3 Custom Alarms Custom alarm ...
Alarm Descriptions 40 5.1.8 High Temperature and Low Temperature (Simultaneously) If these two alarms are displayed at the same time, the temperature input signal is lost (or the humidity is out of sensor range: 15 to 85% RH). Dashes will be displayed for the temperature reading. The control system ...
Alarm Descriptions 41 5.1.16 Short Cycle On compressorized systems, if the compressor has exceeded 10 cooling starts in one hour or if the compressor has cycled five times in 10 minutes on the low pressure switch during non-cooling, the Short Cycle alarm will occur. This can be caused by low refrige...
Component Operation and Maintenance 42 6.0 C OMPONENT O PERATION AND M AINTENANCE 6.1 System Testing 6.1.1 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 43 Firestat The optional firestat 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 between terminals 1 and 2 at plug P39. Smoke Det...
Component Operation and Maintenance 44 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 environmental unit or at a monitoring panel. Run...
Component Operation and Maintenance 45 6.3 Blower Package Periodic checks of the blower package include: belt, motor mounts, fan bearings, and impellers. 6.3.1 Fan Impellers and Bearings Fan impellers should be periodically inspected and any debris removed. Check to see if they are tightly mounted o...
Component Operation and Maintenance 46 6.4 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, peri- odic inspections can be a major...
Component Operation and Maintenance 47 6.4.4 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 valve operation can be dete...
Component Operation and Maintenance 48 6.4.6 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 will inhibit air flow. This...
Component Operation and Maintenance 49 6.4.7 Water/Glycol Cooled Condensers Coaxial Condenser Each water or glycol cooled module has a coaxial condenser which consists of a steel outside tube and a copper inside tube.Coaxial condensers do not normally require maintenance or replacement if the water ...
Component Operation and Maintenance 50 High Pressure Valve - 350 PSIG System (2413 kPa) for 3 Ton Units (Metrex Valve) Adjustment —The valve may be adjusted using a 1/8" diameter rod. Turn adjusting collar nut coun- terclockwise to raise head pressure. Turn it clockwise to lower head pressure. R...
Component Operation and Maintenance 51 6.4.8 Compressor Functional Check The following diagnostic procedure should be used to evaluate whether the compressor is working properly.1. Proper voltage to the unit should be verified.2. The normal checks of motor winding continuity and short to ground shou...
Component Operation and Maintenance 52 Electrical Failure An electrical failure will be indicated by a distinct pungent odor. If a severe burnout has occurred, the oil will be black and acidic.In the event that there is an electrical failure and a complete burnout of the refrigeration compressor mot...
Component Operation and Maintenance 53 6.5 Humidifier 6.5.1 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 54 Autoflush Infrared Humidifier Cleaning System The autoflush system will periodically flush the humidifier pan with water to prevent the buildup of water minerals due to saturation. Because water conditions vary, the amount of water flushing through the system m...
Component Operation and Maintenance 55 Operation 1. During start-up, 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 ...
Component Operation and Maintenance 56 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 57 Figure 14 Canister replacement 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...
Troubleshooting 58 7.0 T ROUBLESHOOTING Use this section to assist in troubleshooting your unit. Also refer to 5.0 - Alarm Descriptions . Sug- gestions are grouped by product function for convenience. ! WARNING Only qualified personnel should perform service on these units. Lethal voltage is present...
Troubleshooting 59 Table 23 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 61 Table 24 Dehumidification troubleshooting Symptom Possible Cause Check or Remedy No dehumidification Control not calling for dehumidification Check monitor status. Compressor contactor not pulling in See 6.4.8 - Compressor Functional Check and Table 23 . Compressor won't run; fuse...
Troubleshooting 62 Table 27 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 63 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 64 8.0 M ONTHLY M AINTENANCE I NSPECTION C HECKLIST Date:_______________________________________ Prepared by:_________________________________ Model #:_____________________________________ Serial #:____________________________________ Filters ___ 1. Restricte...
Semiannual Maintenance Inspection Checklist 65 9.0 S EMIANNUAL M AINTENANCE I NSPECTION C HECKLIST Date:________________________________________ Prepared by:_________________________________ Model #:_____________________________________ Serial #:_____________________________________ Filters ___ 1. R...
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