Emerson 3000-ITR User Manual
Precision Cooling
For Business-Critical Continuity™
Liebert® Challenger™ 3000/Liebert Challenger ITR™
with Liebert iCOM
Operation & Maintenance Manual - 50 & 60Hz
®
Control
TABLE OF CONTENTS
IMPORTANT SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SAVE THESE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.0 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.1 System Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.1 Compressorized Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.2 GLYCOOL
1.1.3 Chilled Water Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
™
(Chilled Glycol Cooling) Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.0 STARTUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2.1 Startup Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.0 OPERATION WITH ICOM CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3.1 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.0 LIEBERT ICOM DISPLAY COMPONENTS AND FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.1 Navigating Through the Liebert iCOM Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.1.1 Control Interface—Three Main Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.1.2 Accessing Menus and Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.1.3 Entering the Password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.1.4 Accessing Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
4.2 Changing Operational Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.3 Changing Liebert iCOM’s Display Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
4.4 Graphical Data Record. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.5 Liebert iCOM Service Menu Icons and Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.6 Wiring for Unit-to-Unit Communications—U2U . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.6.1 Liebert iCOM U2U Ethernet Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.6.2 Wiring a Liebert iCOM U2U Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.7 Entering Network Setup Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.8 Viewing Multiple Units with a Networked Large Display. . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.0 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
5.1 Single Unit Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.1.1 Unit/Fan Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.1.2 General Compressor Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.1.3 Compressor Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.2 Control Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.2.1 Proportional Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.2.2 PI Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.2.3 Intelligent Control (Chilled Water Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.0 ALARM DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
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6.1 Standard Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.1.1 Change Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.1.2 Compressor Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.1.3 High Head Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.1.4 High Humidity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.1.5 High Humidity and Low Humidity (Simultaneously) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.1.6 High Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.1.7 High Temperature and Low Temperature (Simultaneously) . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.1.8 Humidifier Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.1.9 Loss of Air Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.1.10 Loss of Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.1.11 Low Humidity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.1.12 Low Suction Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.1.13 Low Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.1.14 Main Fan Overload. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.1.15 Short Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.2 Optional Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.2.1 Loss of Water Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.2.2 Smoke Detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.2.3 Standby GC Pump On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.2.4 Standby Unit On. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.2.5 Water Under Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.3 Set Alarms—User Menus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
7.0 COMPONENT OPERATION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
7.1 System Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7.1.1 Environmental Control Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
7.2 Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7.3 Blower Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7.3.1 Fan Impellers and Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7.3.2 Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7.3.3 Air Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7.4 Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7.4.1 Suction Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7.4.2 Discharge Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7.4.3 Superheat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7.4.4 Thermostatic Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7.4.5 Hot Gas Bypass Valve—Not Available on Digital Scroll Units . . . . . . . . . . . . . . . . . . . . . . . . 42
7.4.6 Air Cooled Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7.4.7 Water/Glycol Cooled Condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7.4.8 Motorized Ball Valve—Digital Scroll Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7.4.9 Regulating Valve—Scroll Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7.4.10 Drycooler Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7.4.11 Compressor Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7.5 Compressor Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7.5.1 Compressor Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7.5.2 Standard Scroll Compressor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
7.5.3 Digital Scroll Compressor Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
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7.6 Facility Fluid and Piping Maintenance for Water and Glycol Systems . . . . . . . . . . . . . . . . 49
7.7 Humidifier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
7.7.1 Infrared Humidifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
7.7.2 Steam Generating Humidifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
8.0 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
9.0 MONTHLY MAINTENANCE INSPECTION CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
10.0 SEMIANNUAL MAINTENANCE INSPECTION CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
FIGURES
Figure 1 Liebert iCOM components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 2 Liebert iCOM display components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Figure 3 Liebert iCOM default screen symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Figure 4 Liebert iCOM default home screen—Graphical view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Figure 5 Liebert iCOM default home screen—Simple view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 6 Entering the password . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Figure 7 Menu tree—Large and small displays, stand-alone or networked. . . . . . . . . . . . . . . . . . . . . . . . . 13
Figure 8 Liebert iCOM User Menu icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Figure 9 Display setup screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Figure 10 Temperature graph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Figure 11 Liebert iCOM Service Menu icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Figure 12 U2U network setup diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Figure 13 Liebert iCOM wiring—Unit as shipped . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Figure 14 Wiring a small display for U2U network operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Figure 15 Wiring a large display for U2U network operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Figure 16 Liebert iCOM input-output control board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Figure 17 Control board U2U network setup screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Figure 18 Liebert iCOM display U2U network setup screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Figure 19 Menu tree—Large display, networked. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Figure 20 Start-stop priority switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Figure 21 Liebert leak detection units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Figure 22 Recommended liquid sensor locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Figure 23 Outdoor fan/condenser configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Figure 24 Johnson Controls valve adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Figure 25 Metrex valve adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Figure 26 Infrared humidifier lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Figure 27 Steam generating humidifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
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TABLES
Table 1 Keyboard icons and functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Table 2 Sample Liebert iCOM network configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Table 3 Set alarms—User Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Table 4 Zone leak detection kit installation scenarios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Table 5 Recommended free area ft
of 550 and 600 fpm (2.8 and 3.1 m/s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Table 6 Suction pressures - R407c. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Table 7 Discharge pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Table 8 Water/glycol system conditions requiring optional settings for aquastats . . . . . . . . . . . . . . . . . . 46
Table 9 Aquastat settings—two-fan through four-fan drycoolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Table 10 Compressor oil types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Table 11 Humidifier canister part numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Table 12 Blower troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Table 13 Chilled water troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Table 14 Compressor and refrigeration system troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Table 15 Dehumidification troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Table 16 Glycol pump troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Table 17 Infrared humidifier troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Table 18 Steam generating humidifier troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Table 19 Reheat troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2
(m2) for grilles or perforated panels at output velocities
iv
IMPORTANT SAFETY INSTRUCTIONS
!
!
!
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 install or operate this unit.
Only qualified personnel should move, install or service this equipment.
Adhere to all warnings, cautions and installation, operating and safety instructions on the unit and in
this manual. Follow all operating and user instructions.
WARNING
Risk of electric shock. Can cause injury or death.
Disconnect local and remote power supplies before working within.
Before proceeding with installation, read all instructions, verify that all the parts are included
and check the nameplate to be sure the voltage matches available utility power.
The Liebert iCOM microprocessor does not isolate power from the unit, even in the “Unit Off”
mode. Some internal components require and receive power even during the “Unit Off” mode
of Liebert iCOM control.
The factory-supplied optional disconnect switch is inside the unit. The line side of this switch
contains live high-voltage.
The only way to ensure that there is NO voltage inside the unit is to install and open a remote
disconnect switch. Refer to unit electrical schematic.
Follow all local codes.
WARNING
Risk of explosive discharge from high-pressure refrigerant. Can cause injury or death.
This unit contains fluids and gases under high pressure. Relieve pressure before working with
piping.
WARNING
Risk of refrigerant system rupture or explosion from overpressurization. Can cause
equipment damage, injury or death.
If a pressure-relief device is not provided with the condenser unit, the system installer must
provide and install a discharge pressure-relief valve rated for a maximum of 500 psig (34bar)
in the high side refrigerant circuit. Do not install a shutoff valve between the compressor and
the field installed relief valve.
One or more additional pressure-relief valves are required downstream of any and all
field-installed isolation valves. Do not isolate any refrigerant circuits from overpressurization
protection.
For systems requiring EU CE compliance (50Hz), the pressure-relief valve must be CE
certified to the EU Pressure Equipment Directive by an EU “Notified Body.”
NOTE
A pressure-relief valve is provided with Liebert Lee-Temp
provided on Liebert Fan Speed Control condensers. The Liebert indoor cooling unit has a
factory-installed high pressure safety switch in the high side refrigerant circuit.
™
condensers. A fusible plug is
1
!
WARNING
!
Risk of high-speed moving parts. Can cause injury or death.
Disconnect all local and remote electric power supplies before working in the unit.
Do not operate upflow units without installing a plenum, ductwork or guard over the blower
opening(s) on the top of the unit cabinet.
Ductwork must be connected to the blower(s), or a plenum must be installed on the blower
deck for protection from rotating blower wheel(s) on upflow units.
CAUTION
Risk of contact with hot surfaces. Can cause injury.
The compressors, refrigerant discharge lines, humidifiers and reheats are extremely hot
during unit operation. Allow sufficient time for them to cool before working within the unit
cabinet. Use extreme caution and wear protective gloves and arm protection when working on
or near hot compressors, discharge lines, humidifiers and reheats.
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 property damage and loss of critical data center
equipment.
Do not locate unit directly above any equipment that could sustain water damage.
Emerson recommends installing leak detection equipment for unit and supply lines.
2
1.0 INTRODUCTION
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
NOTE
Compressorized systems may be a self-contained system, with the compressor in the Liebert
Challenger 3000/Liebert Challenger ITR unit, or a split system, with the compressor in a
separate condensing unit.
These systems may be air, water, or glycol cooled, depending on the heat rejection method selected.
Cooling—One stage standard; variable capacity with digital scroll, optional.
Heating—Two stages of electric reheat standard; SCR controlled electric reheat, hot water reheat,
hot gas reheat on water and glycol cooled systems optional.
Humidification—Infrared standard; steam generating optional.
Dehumidification—Hot gas bypass locked out standard
Introduction
1.1.2 GLYCOOL™ (Chilled Glycol Cooling) Systems
GLYCOOL systems have all of the features of a compressorized water or glycol system, plus a second
cooling coil that is connected into the water circuit. When fluid temperature is sufficiently low (below
room temperature), cooling is provided by circulating the fluid through the second cooling coil (flow is
controlled by a motorized valve.) This is then the primary cooling source, and it greatly reduces the
compressor operation.
Cooling—Modulated cooling valve opens proportionally to match room needs (primary), one or two
stages of mechanical refrigeration (secondary)
Heating—Two stages of electric reheat standard; hot water reheat optional
Humidification—Infrared standard; steam generating optional
Dehumidification—Hot gas bypass locked out standard
1.1.3 Chilled Water Systems
These systems utilize a central chiller and control cooling by modulating a control valve in the chilled
water line.
Cooling—Proportional in response to room needs
Heating—Two stages of electric reheat standard; hot water reheat optional
Humidification—Infrared standard; steam generating optional
Dehumidification—Chilled water valve opens proportionally in response to room needs
3
Startup
!
2.0 STARTUP
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 rotating in the proper direction. All exterior panels must be in place with the front panel open.
Locate the startup form supplied with your unit documents. Complete the form during startup and
mail it to Liebert when startup is completed. Contact your Liebert supplier if you have any questions
or problems during unit installation, startup or operation.
WARNING
Risk of electric shock. Can cause injury or death.
Potentially lethal voltages exist within this equipment during operation. Observe all cautions
and warnings on unit and in this manual.
The Liebert iCOM microprocessor does not isolate power from the unit, even in the “Unit Off”
mode. The only way to ensure that there is NO voltage inside the unit is to install and open a
remote disconnect switch. Refer to unit electrical schematic.
2.1 Startup Procedure
___ 1. Disconnect all power to the environmental control unit.
___ 2. Tighten all electrical wiring connections that may have loosened during shipping (on electric panel
and at all major components, such as compressor, reheats, humidifier and motor).Retighten according
to values listed on component by component manufacturer.
___ 3. Remove all line voltage fuses except the main fan fuses at the far right of the electric panel and the
Control Voltage fuses at the far left of the electric panel. For units supplied with circuit breakers,
open the circuit breakers instead of removing fuses.
___ 4. Turn on power and check line voltage on main unit disconnect switch. Line voltage must be within
10% of nameplate voltage.
___ 5. Turn On main unit disconnect switch and check secondary voltage at transformer T1. Voltage at T1
must be 24 VAC ±2.5 VAC (check at TB1-1 and TB1-8). T1 voltage must not exceed 28 VAC. Change
primary tap if necessary.
___ 6. Push the On button. Blower will start.
___ 7. If you do not want your unit to operate at factory default settings, set temperature and humidity
setpoints, alarms, and other control functions. Refer to 3.0 - Operation with iCOM Control or 5.0 -
Operation.
___ 8. Stop the unit by depressing the On/Off button on the front display. Turn Off main unit disconnect and
main breaker.
___ 9. Replace all fuses (or reset circuit breakers) that were removed in Step 3.
___ 10. Restore power to unit; turn On the main unit disconnect switch.
___ 11. Push the On button—putting the unit into operation.
___ 12. Check the current draw on all line voltage components and match with serial tag.
___ 13. Verify that the scroll compressor is rotating in the proper direction.
NOTICE
Risk of improper scroll compressor installation. Could cause poor performance and
compressor damage.
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. Use a phase sequence and
motor rotation sensor to ensure that the three-phase power is correctly connected and that the
compressor is rotating properly.
4
14. Check for unusual noises and vibration.
15. Check all refrigerant and fluid lines for leaks.
16. Test all functions of your unit for proper operation.
17. Close high voltage dead front cover and latch.
18. Close front accent panel and latch.
Return completed startup form to:
Liebert Corporation
Warranty Registration
1050 Dearborn Drive
P.O. Box 29186
Columbus, OH 43229
Startup
5
3.0 OPERATION WITH ICOM CONTROL
Wall Mount Large Display
Unit Panel Mount
Small Display and Bezel
Unit Panel Mount Large Display
and Bezel
Liebert iCOM Input/Output Board
Liebert vNSA Network Switch
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 as a single
entity, enhancing the already-high performance and efficiency of Liebert’s units.
3.1 Features
Large and Small Displays
The Liebert iCOM control is available with either a large or small liquid crystal display.
•The Liebert iCOM with small display has a 128 x 64 dot matrix screen that shows text and
icons. This display is capable of controlling only the unit it is directly connected to.
•The Liebert iCOM with large display has a 320 x 240 dot matrix screen that shows text and
icons of 32 connected units (see Figure 4). This display can be used to control a single cooling unit
or any cooling unit within a connected group over a network.
Liebert iCOM’s menu-driven display is used for all programming functions. The Status menu shows
the temperature of the return or supply air and the and humidity of the return air.
Figure 1 Liebert iCOM components
Operation with iCOM Control
6
Liebert iCOM Display Components and Functions
ESC
?
Liquid Crystal Display
Keypad
Large Liebert iCOM Display
shown - Keypad and LEDs are
identical on all displays.
LED Status Indicators
(top LED is red or
flashing red; bottom
LED is green or amber)
ESC
?
On/Off Key
Escape Key Down Arrow Key
Up Arrow Key
Left Arrow Key Right Arrow KeyEnter Key
Alarm Key
Help Key
4.0 LIEBERT ICOM DISPLAY COMPONENTS AND FUNCTIONS
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 what is being viewed.
7
Table 1 Keyboard icons and functions
?
ESC
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 Confirms all selections and selects icons or text.
Liebert iCOM Display Components and Functions
Increase Key
(Up Arrow)
Decrease Key
(Down Arrow)
Left and Right
Arrow Keys
Upper LED
Lower LED
Moves upward in a menu or increases the value of a selected parameter.
Moves downward in a menu or reduces the value of a selected parameter.
Navigates through text and sections of the display.
Blinking Red—Active, unacknowledged alarm exists
Solid Red—Active, acknowledged alarm exists
Amber—Power is available to the unit, unit is NOT operating
Green—Power is available to the unit, unit is operating
8
Figure 3 Liebert iCOM default screen symbols
fan
cooling
maintenance
hot water
electric heat
dehumidification humidification
freecooling
7/29 /2009 08 :28 (01 ) MSG UNIT ON
7/29 /2009 08 :27 (01 ) MSG POWER ON
UNIT 1
7/29 /2009 09 :18:07
50
72.0°F 50%
51.6
°F
%
SET
ACT
UNIT ON
for next / prev unit for s ystem vi ew
for menu for previous screen ? for help
ESC
73.6
°F
100%
60%
FC
0%
03/2010
0%
0%
0%
0%
System or
Unit # view
Temperature
Sensor Reading
Evaporator
Fan Speed
Percent
Cooling
Free-Cooling
Percentage
Next
Maintenance
Date and
Time
Temperature
Setpoint
Return Air
Humidity
Setpoint
Humidity Sensor
Reading
Supply Air (requires
optional supply air
sensor)
Supply
Air Temperature
Percent
Electric
Heating
Percent
Dehumidifying
System
(or Unit)
On/Off
Most recent Message (MSG), Alarm
(ALM) or Warning
(WRN) with Date,
Time, Unit and
Description)
Percent
Hot Water
Heating
Liebert iCOM Display Components and Functions
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 display size.
The Liebert iCOM offers two different types of views: graphical and simple. The graphical view is the
default; to set the simple view refer to 4.3 - Changing Liebert iCOM’s Display Settings. The Liebert iCOM’s home screen is shown in Figure 4 (graphical view) and in Figure 5 (simple view).
Figure 4 Liebert iCOM default home screen—Graphical view
9
Figure 5 Liebert iCOM default home screen—Simple view
9/29 /2010 08 :28 (01 ) MSG UNIT ON
9/29 /2010 08 :27 (01 ) MSG POWER ON
UNIT 1
9/29 /2010 09 :18:07
50
72.0°F
74.1
°F
50%
51.6
°F
%
SET
ACT
72%100%
UNIT ON
for next / prev unit for s ystem vi ew
for menu for previous screen ? for help
ESC
52.0°F
03/2011
System or
Unit # view
Temperature
Sensor Reading
Evaporator
Fan Speed
Percent
Cooling
Next
Maintenance
Date and
Time
Return Air
Tem per atu re
Setpoint
Return Air
Humidity
Setpoint
Humidity Sensor
Reading
Supply Air Setpoint
Supply
Air Temperature
System (or Unit)
On/Off
Most Recent
Alarms
(Date, Time, Unit,
Description)
Liebert iCOM Display Components and Functions
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 information. The Service menu contains settings and features used to set up unit communications and for unit maintenance. The Advanced menu contains settings used to set up the unit at the factory.
NOTE
The Liebert iCOM’s Advanced menu is for factory use only or in consultation with the factory
service department.
NOTE
Menu settings may be viewed without a password, but changing settings requires a password.
If a password is required, the Liebert iCOM shows a prompt to enter the password. The
password for the User menu is 1490. The password for Service menu is 5010. For details on
When the buttons on the Liebert iCOM control have not been pressed for a short period, the display
backlight turns Off. Pressing any key will turn the backlight On (wake up the screen) and display the
Status menu of the last cooling unit viewed. The Status menu will show the cooling unit’s operational
mode(s), return air temperature and humidity readings, temperature and humidity setpoints and any
active alarm conditions.
If the cooling unit has a large display and is not on a network, or if the unit has a small display,
whether it is networked or stand-alone, the Status menu will display only that cooling unit’s information. Any large display that is connected to a network can be used to view any cooling unit on the network or show an average view of the entire system of cooling units.
entering a password, see 4.1.3 - Entering the Password
10
4.1.2 Accessing Menus and Settings
SETPOINTS
for next /prev unit to sel ect parameter
then to change parameter to confirm
UNIT 01
PASSWORD (Actual Level 3)
Temperature Setpoint
Humidity Setpoint
Humidity Control Type
Supply Sensor
Supply Setpoint
Backup Temperature Setpoint
U101
U102
U103
U104
U105
U106
U107
U108
U109
U110
U111
????
72°F
50.0%
Relative
Disabled
°F
73°F
Password command line—highlight
by pressing Enter
After highlighting the Password command line, press
Enter again to highlight the first digit. Use the Up and
Down arrow keys to change the first digit. Move to the
next digit in the Password with the right arrow.
Password is
factory-set
at 1490
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 the keyboard’s arrow keys to move to the icon for the data you wish to view.
4. Once that icon is highlighted, press Enter again to open that menu.
• If a password is required, see 4.1.3 - Entering the Password.
• If a menu has more than one screen, the Liebert iCOM display will have text at the top similar to this: (page 1 of 2).
5. Press Enter to select the first line of data.
6. Use the Up and Down arrow keys to scroll to the desired data point.
7. Press ESC to move back to higher level menus.
4.1.3 Entering the Password
Most settings in the Liebert iCOM are protected by a factory-set password, 1490. To enter the password:
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 the keyboard’s arrow keys to move to the icon for the data you wish to change.
4. Once that icon is highlighted, press Enter again to open that menu.
5. Press Enter to highlight the Password line.
6. With the Password line highlighted, press Enter to highlight the first digit in the password
7. Enter the password, 1490.
Use the Up and Down arrow keys to select a numeral for the first digit of the password.
Move to the next digit of the password with the Right arrow key.
Select the numerals for all four digits with the same process.
8. After all four digits of the password have been entered, press the Enter key.
Liebert iCOM Display Components and Functions
NOTE
Do not press the ESC key or the Liebert iCOM will move to the previous screen and the
password must be re-entered before changes may be made.
Figure 6 Entering the password
11
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 the right arrow key.
Accessing Submenus on Small Displays
While viewing the menu you wish to access (User, Service or Advanced), use the up and down arrow
keys to scroll through the icons page-by-page. To scroll through the icons one-by-one, press the enter
key and then use the up and down arrow keys. With the desired icon highlighted, press the enter key
to enter that submenu. Once in a Submenu, a list of parameters is displayed.
Press the enter key and use the up and down arrow keys to scroll through the parameters one-by-one.
Pressing the ESC key will go back a level. Figure 7 shows the Liebert iCOM control menus for a
small display.
Accessing Submenus on Large Displays
While viewing the menu you wish to access (User, Service or Advanced), press the enter key to highlight the first icon. Use the arrow keys to navigate through the icons. With the desired icon highlighted, press the enter key to enter that submenu. Once in a Submenu, a list of parameters will be
displayed.
The up and down arrow keys may be used to scroll through the parameters page-by-page if the submenu has multiple pages. To scroll item-by-item, press the Enter key and then use the up and down
arrow keys. Using the right or left arrow keys on large displays attached to a network will change the
unit being viewed. Pressing the ESC key will go back a level. Figures 7 and 19 show the Liebert
iCOM control menus for a stand-alone large display and for a networked large display, respectively.
Liebert iCOM Display Components and Functions
NOTE
Settings are readable without a password, but changing settings requires a password.
12
Liebert iCOM Display Components and Functions
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
(Large Display Only)
Set Alarms
Sensor Data
Active Alarms
Display Setup
Total Run Hours
Sleep Mode
(Large Display Only)
Service Contact Info
Service Menu
Unit 1
Password
Setpoints
Unit Diary
(Large Display Only)
Maintenance/Wellness Settings
(Maintenance on Large
Display Only)
Diagnostics / Service Mode
(Service Mode on Large
Display Only)
Set Alarms
Sensor Calibration/Setup
(Setup on Large Display Only)
System/Network Setup
(System on Large Display Only)
Options Setup
Service Contact Info
Advanced Menu
Unit 1
Password
Factory Settings
Compressor Info
(Large Display Only)
Access Passwords
Unit 1 will be displayed
in the top left corner of
the screen on the large
display only.
Figure 7 Menu tree—Large and small displays, stand-alone or networked
13
4.2 Changing Operational Settings
°C / °F
% RH
SET
EVENT
LOG
SET
ALARMS
!
ACTIVE
ALARMS
1 2
39
6
SET
1234h
1 2
39
6
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 Figure 8).
2. Press Enter again to highlight the first icon.
3. Use the keyboard’s arrow keys to move to the icon for the data you wish to change.
4. Once that icon is highlighted, press Enter again to open that menu.
• If a password is required, see 4.1.3 - Entering the Password.
5. After entering the password, use the Up and Down arrow keys to scroll to and highlight the
operational setting to be changed.
6. Press Enter to highlight the values for that setting.
7. Use the Up and Down arrow keys to change the value.
8. Press Enter to accept the change. (The value will no longer be highlighted.)
9. Press ESC to deselect the operational setting. (The setting will no longer be highlighted.)
10. Press ESC again to move to previous screens.
Figure 8 Liebert iCOM User Menu icons
Liebert iCOM Display Components and Functions
Setpoints
View and change
operational
setpoints
Sensor Data
Shows readings
of sensors; View
Only
Spare Parts List
Contains spare
parts available on
site; Large Display
Only
Active Alarms
Lists all current
alarms; View Only
Event Log
Lists last 400
events and
alarms
View Only
Display Setup
Change settings
for display:
language and
time
Graphic Data Record
Displays average room
air temperature and
supply refrigerant
temperature graphs;
Data is View Only;
Display scale is
adjustable
Total Run Hours
Records the run time of
all components and
allows setting of limits on
run time; View Only
View Network
Shows status of
all connected
units; View Only;
Large Display
Only
Sleep Mode
Used to set
operating period,
including startup
and shutdown;
Large Display
Only
Set Alarms
Allows user to
change settings for
alarms
Service
Contacts
Contains key
contact information
for service
NOTE
Menu shows icons only; text is explanatory and does not appear on the Liebert iCOM display.
14
4.3 Changing Liebert iCOM’s Display Settings
DISPLAY SETUP
to change parameter
to confirm
to select parameter
for next/previous unit
then
Language
Date
Time
Temperature Indication
Display Contrast
Buzzer Frequency
Backlite Off after
Screen
Display Shows
Display Colors
Date Format
SYSTEM
U401
U402
U403
U404
U405
U406
U407
U408
U409
U410
U411
ENGLISH (US)
7/7/2008
09:24 :17
°C
50
Off/ 50
5 min
XDP
ACT+SET
Normal
mm/dd/yyyy
Highlight the
setting to be
changed by
pressing Enter.
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 screen, press the Enter key to view the User Menu (see Figure 8).
2. Press Enter again to highlight the first icon.
3. Use the keyboard’s arrow keys to move to the Display Setup icon.
4. Once that icon is highlighted, press Enter again to open that menu.
5. Press the Enter key to select the first setting.
Either change that setting or navigate to another setting with the Up and Down arrow keys.
6. Once the desired setting is highlighted, press the Enter key to access that parameter’s display
setting options.
7. Use the Up and Down arrow keys to make changes.
8. Press the Enter key to accept the changes.
9. Press the ESC key twice to return to Liebert iCOM’s user menu.
Figure 9 Display setup screen
Liebert iCOM Display Components and Functions
15
4.4 Graphical Data Record
UNIT 1
+11
RETURN AIR TEMPERATURE
73°F
-11
18ht:24h 12h 6h 09:21
+25
RETURN AIR HUMIDI TY
50%
-25
18ht:24h 12h 6h 09:21
GRAPHS (system average )
°C / °F
% RH
SET
WELLNESS
SERVICE
SET
ALARMS
+ / -
NETWORK
SET
UP
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 of several selectable values. Changing the time scale eliminates all
previous graphical data and the unit will begin recording new data.
Figure 10 Temperature graph
Liebert iCOM Display Components and Functions
4.5 Liebert iCOM Service Menu Icons and Legend
Figure 11 Liebert iCOM Service Menu icons
Setpoints
View and change
operational
setpoints
Sensor
Calibration/Setup
Setup and calibrate
sensors for site
NOTE
Menu shows icons only; text is explanatory and does not appear on the Liebert iCOM display.
Unit Diary
Shows all program
changes and
maintenance
performed,
Network
Setup or alter
network setting.
Maintenance/
Wellness
Settings
Shows all mainte-
nance records, cal-
culates next
maintenance date
Options Setup
Enter specific
settings for various
options
Diagnostics/
Service Mode
Enter Diagnostics/
Service Mode for
troubleshooting
and repair; Large
Display Only
Set Alarms
Change settings for
alarms
Service Contacts
Contains key
contact information
for service
16
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