Page 3 - TABLE OF CONTENTS
i TABLE OF CONTENTS 1.0 I NTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.1 System Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1....
Page 4 - ii
ii 5.2 Drycooler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 5.3 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 5.3.1 Line Voltag...
Page 5 - iii; FIGURES
iii FIGURES Figure 1 Removing Liebert Challenger ITR from skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Figure 2 Cabinet dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
Page 6 - iv; TABLES
iv TABLES Table 1 Unit shipping weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Table 2 Piping connection size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
Page 7 - Introduction; NTRODUCTION; System Descriptions; Liebert Challenger ITR; GLYCOOL Models; sure control. Unit is designed for outdoor location.; Centrifugal Fan
Introduction 1 1.0 I NTRODUCTION 1.1 System Descriptions Liebert Challenger ITR ™ environmental control systems are available in three main system configu- rations: • self contained system with a scroll compressor in the room unit• self contained chilled water system• split system with an evaporator...
Page 8 - Installation; NSTALLATION; Room Preparation; Table 1; reduce the effectiveness of the air distribution.; Remote Sensor Installation Location; highest point that equipment will draw in cooled air.; Equipment Handling; NOTE; Locate and remove shipping screw on fan motor base.; WARNING
Installation 2 2.0 I NSTALLATION 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 walls and floors. Doors should not be undercut or have grille...
Page 9 - ing pressing on the top edges of the packaging.; NOTICE; through a standard doorway will damage the unit.; or similar machine to ensure that the unit is lifted properly.; Figure 1; frame to lift the unit.
Installation 3 2.4.1 Handling With Skid • Always keep the Liebert Challenger ITR upright, indoors and protected from damage.• Do not use the extended rear door frame to lift the unit.• If possible, transport the unit using a fork lift; otherwise, use a crane with belts or cables, avoid- ing pressing...
Page 10 - Figure 2; Unit Weight
Installation 4 Figure 2 Cabinet dimensions DPN001523Pg. 2, Rev. 1 Filter Accessby Opening Door UNITTOP VIEW 32-1/2"(826mm) 5/8" (16mm) 9-5/8" (244mm) 8-1/2" (216mm) 31-1/2" (800mm) 1-7/8" (48mm) 12-1/2" (318mm) 30-1/2" (775mm) 30-1/2" (775mm) 32-1/2" (826mm) 3...
Page 11 - Figure 3
Installation 5 Figure 3 Optional floor stand dimensions 30-1/2" (775mm) 30-1/2" (775mm) 1" (25.4mm) See Specification Sheetfor height of floor stand ordered. SL-11897Pg. 7
Page 12 - Piping Considerations; electronic equipment.; Split System Fan Coil Unit Connection Sizes—in.
Installation 6 2.5 Piping Considerations Consideration should be given before installing refrigerant and liquid lines next to, under or above electronic equipment. 2.5.1 Drain Line A 3/4" (19.1 mm) female pipe thread (FPT) connection is provided for the evaporator coil condensate drain. This dra...
Page 13 - Figure 4; Monitoring Panel; PIPING OUTLET LOCATIONS; (See Cabinet and Floor Planning
Installation 7 Figure 4 Piping connections for air-cooled units Piping outlet locations through theplenum are the same as the unit.See below for descriptions andconnection sizes. Hot Water Return5/8" OD CU (optional) Hot Water Supply5/8" OD CU (optional) Liquid Refrigerant Line1/2" OD CU...
Page 14 - Figure 5
Installation 8 Figure 5 Piping connections for split system fan coil units Piping outlet locations through theplenum are the same as the unit.See below for descriptions andconnection sizes. Hot Water Supply5/8" OD CU (optional) Condensate Pump Line1/2" OD CU PIPING OUTLET LOCATIONS (See Cabi...
Page 15 - Figure 6
Installation 9 Figure 6 Piping connections for water/glycol and GLYCOOL units Piping outlet locations through theplenum are the same as the unit.See below for descriptions andconnection sizes. Hot Water Supply5/8" OD CU (optional) Condensate Pump Line1/2" OD CU PIPING OUTLET LOCATIONS (See C...
Page 16 - Figure 7
Installation 10 Figure 7 Piping connections for chilled water self-contained units Piping outlet locations throughthe plenum are the same as theunit. See below for descriptionsand connection sizes. Hot Water Return5/8" OD CU (optional) Chilled Water Return Line1-1/8" OD CU Hot Water Supply5/...
Page 17 - Electrical Connections; within the unit behind the front door.; Figure 8; service not by Liebert.; Electrical Handy Box*
Installation 11 2.6 Electrical Connections Three-phase electrical service is required for all models in either 208, 230, 460, or 575 V, 60 Hz; or 200, 230, or 380/415 V, 50 Hz. Electrical service shall conform to national and local electrical codes. Refer to equipment nameplate regarding wire size a...
Page 18 - Special alarm connections; . Field-supplied 24V Class 1 wiring for special alarm. Connection; Liebert SiteScan; . Field-supplied 24V Class 1 wiring to remote condensing; Smoke detector alarm connections; . Field-supplied 24V Class 1 wiring to remote alarm circuits.; Balancing the Air Distribution
Installation 12 9. Special alarm connections . Field-supplied 24V Class 1 wiring for special alarm. Connection made by adding normally open contacts between terminals 24 + 50. Optional additional connections available with Advanced or Advanced with Graphics controls and appropriate optional accessor...
Page 19 - Checklist for Completed Installation
Installation 13 2.8 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 refrigerant or coolant loop (if...
Page 20 - Condenser Location; denser to the steel supports or concrete pad.; with local and national codes.
Air-Cooled Models 14 3.0 A IR -C OOLED M ODELS 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 snow or ice accumula- tions. Utilize centrifugal condense...
Page 22 - Refrigerant Piping; coil; Equivalent Length
Air-Cooled Models 16 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 circuits.Unit refrigeration comp...
Page 23 - Fan Speed Control Systems; monitoring refrigerant pressure.
Air-Cooled Models 17 3.4 Fan Speed Control Systems Fan Speed Control provides an infinite number of speed variations on specially designed, permanent split-capacitor motors. The control module varies the air quantity passing over the condenser coil by monitoring refrigerant pressure. 3.4.1 Materials...
Page 24 - all compressor service valves.; CAUTION; All local codes for handling refrigerant must be followed.; type before topping off or recharging a system.; introduced and charged from the cylinder only as a liquid.
Air-Cooled Models 18 3.4.2 Dehydration/Leak Test and Charging Procedures for R22 (standard) or R407C (Optional) Fan Speed Control Type Condenser Dehydration/Leak Test 1. Make sure unit is OFF. Open all disconnects and remove all fuses except control fuses. On units supplied with circuit breakers, op...
Page 25 - Figure 10 Air-cooled fan speed control general arrangement; Li qu id Ret ur n
Air-Cooled Models 19 Figure 10 Air-cooled fan speed control general arrangement SL -11 89 7 PG 5 Con de nser Co il Sc hra de r Va lv e Fu si bl e Pl ug In ve rted Trap s* on disch ar ge an d retu rn li ne s to ex te nd ab ov e ba se of co il by a mi ni mu m of 7 1 /2" (1 90 mm ) Tr ap s* ev er y...
Page 26 - Lee-Temp/Flood Back Head Pressure Control Systems
Air-Cooled Models 20 3.4.3 Charging 1. Make sure unit is OFF. Open all disconnect switches and, on units supplied with circuit breakers, open all breakers. Replace all fuses for the Fan and Compressors or close breakers. 2. Remove jumper on the Fan Safety Switch and reconnect the system wire connect...
Page 27 - Lee-Temp Control Type Condenser; before topping off or recharging a system.
Air-Cooled Models 21 3.5.2 Materials Supplied 1. Built-in pre-wired condenser control box2. Air-cooled condenser3. Piping access cover to be reinstalled when piping is complete4. Bolts (four per leg) 3/8" x 5/8"5. Terminal block for two-wire 24 V interlock connection between the unit and the...
Page 28 - Dehydration/Leak Test; open during the dehydration process.; Low Pressure Cut Out
Air-Cooled Models 22 Dehydration/Leak Test 1. Make sure unit is OFF. Open all disconnect switches and pull all fuses except control fuses. On units supplied with circuit breakers, open all breakers except for the transformer. 2. Add a jumper to the Fan Safety Switch between Common and Normal Open an...
Page 29 - SINGLE CIRCUIT SHOWN
Air-Cooled Models 23 Figure 11 Air-cooled, Lee-Temp general arrangement FACTORY PIPING FIELD PIPING SINGLE CIRCUIT SHOWN SL-10061 PG 4 SL-10071 PG 4 Piping Assembly * * Condenser Coil Rotalock Valve ** 1/4" ( 6.4mm)Pressure ReliefValve * * Sight Glass Lee-TempReceiver Head PressureControl withIn...
Page 30 - installed near the base of the unit or below the elevated floor.; Condenser; is available as an option.
Water-Cooled Models 24 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. This will pro- vide for routine maintenance or emergency isolation of the unit.When the water source for the condenser is of poor quali...
Page 31 - Figure 12 Water-cooled general arrangement
Water-Cooled Models 25 Figure 12 Water-cooled general arrangement SL-11898 PG 5 EvaporatorCoil ExpansionValve SensingBulb ExternalEqualizers Hot GasBypassValve ScrollCompressor ServiceValves Hot GasBypassSolenoidValve SightGlass FilterDrier Hot GasBypass Tubein TubeCondenser BypassValve 2-Way WaterR...
Page 32 - Water Regulating Valve; Figure 13 Johnson Controls valve adjustment; Water Regulating Valve Manual Flushing; If this fails, the valve must be disassembled for cleaning the seat.
Water-Cooled Models 26 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 conditions are low. The va...
Page 33 - Drycooler Location; the drycooler to steel supports or concrete pad.
Glycol/GLYCOOL-Cooled Models 27 5.0 G LYCOL /GLYCOOL-C OOLED M ODELS 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 contribute to heavy snow or ice accumulations. To assure adequat...
Page 34 - Glycol Piping; trols, and flow switches are just a few of these devices.; result from freezing of residual water.; Room dew point temperatures; Dry Bulb
Glycol/GLYCOOL-Cooled Models 28 5.4 Glycol Piping NOTICE 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, precipitating an insoluble material that can eventually foul the system.To help p...
Page 35 - Filling Instructions; and; Volume in standard Type “L” copper piping; Volume
Glycol/GLYCOOL-Cooled Models 29 5.5 Filling Instructions 5.5.1 Preparing the System for Filling It is important to remove any dirt, oil or metal filings that may contaminate the cooling system piping in order to prevent contamination of the fresh glycol solution and fouling of the drycooler piping. ...
Page 36 - occur from either freezing or corrosion from water.; Ethylene glycol concentrations; Apparent Specific Gravity
Glycol/GLYCOOL-Cooled Models 30 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 Data Sheets and other prod...
Page 37 - Do not mix products of different manufacturers.
Glycol/GLYCOOL-Cooled Models 31 5.5.3 Filling the System Installation of hose bibs at the lowest point of the system is recommended. When filling a glycol sys- tem keep air to a minimum. Air in glycol turns to foam and is difficult and time-consuming to remove. (Anti-foam additives are available and...
Page 38 - Figure 14 Drycoolers and pump packages; apart on single pump packages and 30-; Angles located
Glycol/GLYCOOL-Cooled Models 32 Figure 14 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" (387 mm) apart on single pump packages and 30- 1/4" (768 mm) apart on dual pump ...
Page 39 - Gallon Expansion Tank
Glycol/GLYCOOL-Cooled Models 33 Figure 15 Pump packages—expansion tank Table 15 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 (571.5) DUAL (7.5 hp) 39-5...
Page 40 - Figure 16 Glycol general arrangement
Glycol/GLYCOOL-Cooled Models 34 Figure 16 Glycol general arrangement SL-11898 PG 6 Glyco l Pump PumpHousing Unions* IsolationValves* ExpansionValve DrycoolerElectricBox DrycoolerCoil FluidReturnto Pump FluidSupplyfromPump Unions* Fill * Expansion Tank Field Installed atHighest Point in System. Expan...
Page 41 - Figure 17 GLYCOOL general arrangement
Glycol/GLYCOOL-Cooled Models 35 Figure 17 GLYCOOL general arrangement SL-11901 PG 5 PumpHousing Glyco l Pump Unions* IsolationValves* ExpansionValve Evaporat orCoil DrycoolerCoil Dryco olerElectricBox Unions* PressurePort* HoseBib* Fill * FluidReturn toPump FluidSupplyfromPump Air Vents*at Top ofRis...
Page 42 - Regulating Valve Adjustment; ing the valve, refer to
Glycol/GLYCOOL-Cooled Models 36 5.6 Condenser The condenser is designed to operate in conjunction with a drycooler. The maximum coolant pressure is 350 psig (2413 kPa). 5.7 Glycol Regulating Valve The glycol regulating valve automatically regulates the amount of coolant necessary to remove the heat ...
Page 43 - Chilled Water Models; HILLED; near the base of the unit or below the elevated floor.; Figure 18 Chilled water general arrangement - horizontal flow (BR)
Chilled Water Models 37 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...
Page 44 - Split System Models; PLIT; Location Considerations; ing guidelines and to; Figure 23 - Detail of ceiling hanging bracket; for dimensional data.
Split System Models 38 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 unit. 7.1 Location Considerations 7.1.1 Air-Cooled Condensing Units To assure an adequate air supply, it is recommended that all condensin...
Page 45 - topping off or recharging a system.; for field
Split System Models 39 7.3 Piping Considerations 7.3.1 Refrigerant Loop 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 l...
Page 46 - Check system for leaks with a suitable leak detector.; Unit refrigerant charge
Split System Models 40 Once all piping is complete, check for leaks and dehydrate the field piping as follows:1. Pressurize the field piping to 150 PSIG (1034 kPa) using dry nitrogen with a trace of refrigerant. Check system for leaks with a suitable leak detector. 2. After completion of leak testin...
Page 47 - Figure 19 Refrigerant piping diagram
Split System Models 41 Figure 19 Refrigerant piping diagram Table 23 Equivalent lengths (feet) for various 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 1.3 0.4 2.5 0.26 7.0 4.0 5/8 0.9 1.4 0.5 2.5 0.28 9.5...
Page 48 - bodies “bottom out” or until a definite resistance is felt.; connecting quick connects.
Split System Models 42 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 with a clean cloth.3. Lubrica...
Page 49 - Outdoor Air-Cooled Condensing Units; UNIT DIMENSIONS
Split System Models 43 7.4 Outdoor Air-Cooled Condensing Units Figure 20 Outdoor air-cooled condensing unit—horizontal air discharge models A B C INDICATES A MINIMUM CLEARANCE OF 18" (457mm) FOR PROPER AIR FLOW . SHADED AREA INDICATES A MINIMUM CLEARANCE OF 18" (457mm)FOR PROPER AIR FLOW SHA...
Page 50 - Horizontal air discharge piping and electrical connection data; Model Numbers
Split System Models 44 Table 24 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 PFC067A-_L PFC066A-_L 53 (1343) 36-1/4 (918) 18 (457) 351 (159) PFH067A-_L Table 25 Horizontal air discharge piping...
Page 51 - FOOTPRINT; * System 1 and System 2 on
Split System Models 45 Figure 21 Outdoor air-cooled condensing unit—top air discharge models SL-11081 PG 5 C A 2 " B LEFT AIR INTAKE (51mm) D GUARD HEIGHT TOP AIR DISCHARGE RIGHT AIR INTAKE SHADED AREA INDI CATES A RECOMMENDED CLEARANCE OF 18" (457mm) FOR PROPER AIR FLOW SHADED AREA INDI CAT...
Page 52 - Piping and electrical connections - top air discharge
Split System Models 46 Table 26 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-...
Page 54 - Centrifugal Air-Cooled Condensing Units; Installing the Indoor Condensing Unit; Refer to drawings for unit dimensions and component locations.; Detail of ceiling hanging bracket; Use the Nylock nuts to “jam” the plain nuts.; Table 28 - Indoor centrifugal condensing unit; The units must be level in order to operate properly.; Indoor centrifugal condensing unit; Model
Split System Models 48 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...
Page 55 - Figure 23 Detail of ceiling hanging bracket; directed toward the air inlet of an adjacent unit.
Split System Models 49 Figure 23 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...
Page 57 - Removable access panels
Split System Models 51 Figure 25 Centrifugal air-cooled condensing unit dimensional data (con't.) DPN000226Rev. 0 Field-supplied unit disconnectswitch when factory unitdisconnect switch is not supplied. Electric servicenot by Emerson Optional factory-installeddisconnect switch Line voltage electric ...
Page 58 - Figure 26 Split systems general arrangement; AIR COOLED
Split System Models 52 Figure 26 Split systems general arrangement SL-11900 PG 5 CondenserCoil 1/2" (12.7mm) NPTPressure Relief Valve SightGlass Check Valve Lee-TempReceiver High PressureSwitch ScrollCompressor Head PressureControl withIntegral CheckValve Liquid LineSolenoid Valve Suction LineMa...
Page 59 - Water and Glycol-Cooled Condensing Units; For installation guidelines, refer to; Installing the Indoor Condensing Unit on page 48.; Regulating Valve Adjustment and Testing; Refer to; Cooled Models; Condenser Water Inlet; Water and glycol-cooled condensing unit data
Split System Models 53 7.6 Water and Glycol-Cooled Condensing Units For installation guidelines, refer to Installing the Indoor Condensing Unit on page 48. 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 ...
Page 60 - Figure 27 Water/glycol-cooled condensing unit dimensions
Split System Models 54 Figure 27 Water/glycol-cooled condensing unit dimensions SL-11087 PG 6 32 " 32 " 29 13/16 " 33 5/8 " 24 " (812.8mm) (610mm) (854.1mm) (757.2mm) CABINET DIMENSION THREADED ROD CENTERS (812.8mm) CABINET DIMENSION CABINET DIMENSION THREADED ROD CENTERS Hanger ...
Page 61 - NOTES
Split System Models 55 Figure 28 Water/glycol-cooled condensing unit (con't.) DPN000228_Rev0 Heat rejection connection.Field-supplied 24V NECClass 2 wiring. Wireconnections from evaporatormod:1. 24V ground2. 24V supply3. High pressure alarm (optional)4. Hot gas bypass connection (only on units with ...
Page 62 - EFRIGERANT
R407C Refrigerant 56 8.0 R407C R EFRIGERANT Table 32 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 ...
Page 63 - Calculating Subcooling; Example; on; Why There Are Two R407C Temperature and Pressure Tables; heat or operating controls.; Use this table for subcooling calculation ONLY. See
R407C Refrigerant 57 8.1 Calculating Subcooling Example Measure the liquid pressure (e.g., 200 psig). Find the liquid saturation temperature at that pressure on Table 33 (e.g., 93°F). Measure the temperature of the liquid line (e.g., 90°F). Subtract the actual temperature from the liquid saturation ...
Page 64 - Precision Cooling
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...