Emerson WORLD CLASS 3000 User Manual
Liebert Challenger™ 3000 with iCOM
Installation Manual - 3 & 5 Tons, 50 & 60Hz
Precision Cooling
For Business-Critical Continuity™
TABLE OF CONTENTS
IMPORTANT SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.0 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.1 System Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.1 Self-Contained Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.2 Chilled Water Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1.3 Split Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.0 INSTALLATION (APPLICABLE TO ALL MODELS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2.1 Room Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 Equipment Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Location Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4 Equipment Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4.1 Handling With Skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.4.2 Removal of Skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.5 Piping Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.5.1 Drain Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.5.2 Humidifier Supply Water—Optional Infrared . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.6 Facility Fluid and Piping Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.7 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.8 Balancing the Air Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.8.1 Under-Floor Discharge Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.8.2 Ducted Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.8.3 Plenum Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.9 Checklist for Completed Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.0 AIR-COOLED MODELS—SELF-CONTAINED COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . .23
3.1 Condenser Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.2 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.2.1 Line Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.2.2 Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.2.3 Liebert Lee-Temp/Flood Back Head Pressure Control Condensers . . . . . . . . . . . . . . . . . . . . 23
3.3 Refrigerant Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.4 Fan Speed Control Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.5 Air-Cooled Condenser with Liebert Lee-Temp “Flooded Condenser” Head Pressure
Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.0 WATER-COOLED MODELS—SELF-CONTAINED COMPRESSOR . . . . . . . . . . . . . . . . . . . . . .35
4.1 Piping Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.2 Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.3 Water Regulating Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.3.1 Standard Valve - 150psig (1034 kPa) System for 3 & 5-Ton Units (Johnson Controls
Valve) High Pressure Valve - 350psig (2413kPa) System for 5-Ton Units (Johnson
Controls Valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.3.2 High Pressure Valve - 350 psig (2413 kPa) System for 3-Ton Units (Metrex Valve) . . . . . . . 38
4.4 Motorized Ball Valve—Digital Scroll Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.4.1 Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.4.2 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.4.3 Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.4.4 Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.4.5 Manual Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
i
5.0 GLYCOL/GLYCOOL-COOLED MODELS—SELF-CONTAINED COMPRESSOR . . . . . . . . . . . .41
5.1 Drycooler Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.2 Drycooler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.3 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.3.1 Line Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.3.2 Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.3.3 Pump and Drycooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.4 Glycol Piping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.4.1 Expansion Tanks, Fluid Relief Valves and Other Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.5 Filling Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.5.1 Preparing the System for Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.5.2 Glycol Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.5.3 Filling the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.5.4 Motor Ball Valve—Digital Scroll Compressors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.6 Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.7 Glycol Regulating Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.7.1 Standard Valve - 150psig (1034 kPa) System for 3 & 5-Ton Units (Johnson Controls
Valve) High Pressure Valve - 350psig (2413kPa) System for 5-Ton Units (Johnson
Controls Valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.7.2 High Pressure Valve - 350 psig (2413 kPa) System for 3-Ton Units (Metrex Valve) . . . . . . . 53
5.7.3 Testing Valve Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6.0 CHILLED WATER MODELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
6.1 Piping Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
7.0 SPLIT SYSTEM MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
7.1 Location Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
7.1.1 Air-Cooled Condensing Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
7.1.2 Water/Glycol-Cooled Condensing Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
7.2 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
7.2.1 Line Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
7.2.2 Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
7.3 Piping Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
7.3.1 Refrigerant Loop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
7.3.2 Quick Connect Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
7.4 Outdoor Air-Cooled Condensing Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
7.5 Centrifugal Air-Cooled Condensing Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
7.5.1 Installing the Indoor Condensing Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
7.5.2 Ducting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
7.6 Water and Glycol-Cooled Condensing Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
7.6.1 Piping Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
7.6.2 Condenser Water Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
7.6.3 Regulating Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
7.6.4 Glycol Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
8.0 R407C REFRIGERANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
8.1 Calculating Subcooling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
ii
FIGURES
Figure 1 Removing Challenger from skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Figure 2 Upflow (BU) cabinet dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Figure 3 Downflow (BF) cabinet dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Figure 4 Piping connections for air-cooled units - Downflow models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 5 Piping connections for air-cooled units - Upflow models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Figure 6 Piping connections for split system fan coil units - Downflow models . . . . . . . . . . . . . . . . . . . . . 12
Figure 7 Piping connections for split system fan coil units - Upflow models . . . . . . . . . . . . . . . . . . . . . . . 13
Figure 8 Piping connections for water/glycol and GLYCOOL units - Downflow models . . . . . . . . . . . . . . 14
Figure 9 Piping connections for water/glycol and GLYCOOL units - Upflow models . . . . . . . . . . . . . . . . . 15
Figure 10 Piping connections for chilled water self-contained units - Downflow models . . . . . . . . . . . . . . . 16
Figure 11 Piping connections for chilled water self-contained units - Upflow models . . . . . . . . . . . . . . . . . 17
Figure 12 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Figure 13 Electrical field connections for Liebert iCOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Figure 14 Air-cooled condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Figure 15 General arrangement—Air-cooled models with fan speed control . . . . . . . . . . . . . . . . . . . . . . . . . 29
Figure 16 General arrangement—Air-cooled models with digital scroll and fan speed control . . . . . . . . . . 30
Figure 17 General arrangement—Air-cooled models with Liebert Lee-Temp . . . . . . . . . . . . . . . . . . . . . . . . 33
Figure 18 General arrangement—Air-cooled models with digital scroll and Lee-Temp . . . . . . . . . . . . . . . . 34
Figure 19 General arrangement—Water-cooled models with scroll compressor . . . . . . . . . . . . . . . . . . . . . . 36
Figure 20 General arrangement diagram—Water-cooled models with digital scroll . . . . . . . . . . . . . . . . . . 37
Figure 21 Johnson Controls valve adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Figure 22 Metrex Valve adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Figure 23 Drycoolers and pump packages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Figure 24 Pump packages—expansion tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Figure 25 General arrangement—Glycol-cooled models with scroll compressor . . . . . . . . . . . . . . . . . . . . . . 49
Figure 26 General arrangement—Glycol-cooled models with digital scroll . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Figure 27 General arrangement—GLYCOOL models with scroll compressor. . . . . . . . . . . . . . . . . . . . . . . . 51
Figure 28 General arrangement—GLYCOOL models with digital scroll compressor . . . . . . . . . . . . . . . . . . 52
Figure 29 Chilled water general arrangement - Upflow (BU). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Figure 30 Chilled water general arrangement - Downflow (BF) models . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Figure 31 Refrigerant piping diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Figure 32 Outdoor air-cooled condensing unit—horizontal air discharge models . . . . . . . . . . . . . . . . . . . . . 60
Figure 33 Outdoor air-cooled condensing unit—top air discharge models . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Figure 34 Electrical field connections, prop fan condensing module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Figure 35 Detail of ceiling hanging bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Figure 36 3-ton centrifugal air-cooled condensing unit dimensional data & piping connections . . . . . . . . . 67
Figure 37 3-ton centrifugal air-cooled condensing unit (con't.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Figure 38 5-ton centrifugal air-cooled condensing unit dimensional data . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Figure 39 5-ton centrifugal air-cooled condensing unit dimensional data (con't.) . . . . . . . . . . . . . . . . . . . . . 70
Figure 40 Split systems general arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Figure 41 3-ton water/glycol-cooled condensing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Figure 42 3-ton water/glycol-cooled condensing unit (con't.). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Figure 43 5-ton water/glycol-cooled condensing unit dimensional data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Figure 44 5-ton water/glycol-cooled condensing unit (con't.). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . 76
iii
TABLES
Table 1 Unit net weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Table 2 Piping connection size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Table 3 Recommended free area ft
and 600 fpm (2.8 and 3.1 m/s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Table 4 Air-cooled condenser statistics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Table 5 Recommended line sizes — OD copper (inches)* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Table 6 Equivalent lengths (feet) for various pipe fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Table 7 Indoor unit refrigerant charge lb (kg) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Table 8 Line charges - refrigerant per 100 ft. (30 m) of Type “L” copper tube . . . . . . . . . . . . . . . . . . . . . . 26
Table 9 Condenser refrigerant (per serial tag) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Table 10 Fan speed suction pressure transducer settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Table 11 Lee-Temp suction pressure transducer settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Table 12 Refrigerant control settings psi (kPa) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Table 13 Room dew point temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Table 14 Indoor unit glycol volume approximate gallons (liters) max. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Table 15 Volume in standard Type “L” copper piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Table 16 Ethylene glycol concentrations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Table 17 Mounting hole dimensional data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Table 18 Drycooler data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Table 19 Glycol pump data* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Table 20 Refrigerant control settings psi (kPa) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Table 21 Unit refrigerant charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Table 22 Line charges - refrigerant per 100 ft. (30 m) of Type “L” copper tube . . . . . . . . . . . . . . . . . . . . . . 58
Table 23 Recommended refrigerant lines (R407C) sizes OD copper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Table 24 Line coupling sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Table 25 Equivalent lengths (feet) for various pipe fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Table 26 Horizontal air discharge cabinet and floor planning dimensional data. . . . . . . . . . . . . . . . . . . . . 61
Table 27 Horizontal air discharge piping and electrical connection data . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Table 28 Cabinet and floor planning dimensional data - prop fan condensing modules, top air
discharge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Table 29 Piping and electrical connections - top air discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Table 30 Indoor centrifugal condensing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Table 31 Airflow CFM (CMH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Table 32 Water and glycol-cooled condensing unit data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Table 33 R407C pressure/temperature chart for operation and superheat (discharge/hot gas and
suction gas). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Table 34 R407C pressure/temperature chart for subcooling only (liquid measurements). . . . . . . . . . . . . . 78
2
(m2) for grilles or perforated panels at output velocities of 550
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
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.
™
. Read this manual thoroughly before attempting to
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
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.
®
microprocessor does not isolate power from the unit, even in the “unit off”
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.
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
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 surface 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.
1
!
CAUTION
Risk of contact with hot surfaces. Can cause injury.
The compressor, 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 leakage from the
unit. Water leakage can result in 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
Challenger 3000™ environmental control systems are available in three main system configurations:
• self-contained system with a scroll compressor in the room unit
• self-contained chilled water system
• split system with an evaporator section and a remote condensing unit
All three types are available in upflow or downflow configurations. The standard upflow configuration
is front return. All models require three-phase power. Units are available in 208, 230, 460, or 575V,
60Hz; and 200, 230 or 380/415V, 50Hz.
The following features are included as standard in all room units regardless of the type of system: Liebert iCOM control, A-frame coil (V-frame on upflows), infrared humidifier, finned tubular stainless
steel electric reheat, 2" filter, individual high voltage fused protection and fan assembly.
1.1.1 Self-Contained Systems
Air-Cooled Models
Complete refrigeration system including hot gas bypass and crankcase heater with standard scroll
compressor, standard condenser and fan speed control for 95°F (35°C) ambient at sea level. Optional
Digital scroll compressor with unloading solenoid valve is also available. Digital scroll compressor
systems do not include hot gas bypass.
Introduction
Water-Cooled Models
Compete refrigeration system including hot gas bypass with standard scroll compressor, water/glycolcooled condenser and two-way water regulating valve with bypass. Optional digital scroll compressor
with unloading solenoid valve is also available. Digital scroll compressor systems use a 2-way motorized ball valve in lieu of the regulating valve; they do not include hot gas bypass.
Glycol-Cooled Models
The water-cooled model as described above plus pump package and 95°F (35°C) design ambient drycooler.
GLYCOOL Models (5-Ton Only)
Complete refrigeration system including hot gas bypass with standard scroll compressor, glycol condenser and three-way water regulating valve plus an integrally piped Econ-O-Coil with three-way modulating control valve. Optional digital scroll compressor with unloading solenoid valve is also available.
Digital scroll compressor systems use a 3-way motorized ball valve in lieu of the regulating valve; they
do not include hot gas bypass.
1.1.2 Chilled Water Models
Chilled Water models include chilled water piping, three-way modulating valve, and actuator assembly.
3
1.1.3 Split Systems
Each air-cooled split system consists of an evaporator section and one of the following condensing
units.
Prop Fan Air-Cooled
Prop Fan units include scroll compressor, condenser coil, prop fan, high pressure switch, hot gas
bypass and Liebert Lee-Temp head pressure control. Unit is designed for outdoor location.
Centrifugal Fan Air-Cooled
Centrifugal Fan units include scroll compressor, condenser coil, centrifugal blower assembly,
high-pressure switch, hot gas bypass and Liebert Lee-Temp head pressure control. Unit must be
mounted indoors. Duct flanges are optional.
Water-Cooled
Each water-cooled split system consists of an evaporator section and a water/glycol condensing unit,
which includes scroll compressor, coaxial condenser, water regulating valve, hot gas bypass and
high-pressure switch. Design pressure is 150 psi (1034 kPa) as standard and 350 psi (2413 kPa) as
optional.
Glycol-Cooled
Each glycol-cooled split system consists of an evaporator section, a water/glycol condensing unit (as
described above), a pump package, and a 95°F (35°C) design ambient drycooler.
Introduction
4
2.0 INSTALLATION (APPLICABLE TO ALL MODELS)
!
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 grilles in them.
Outside (or fresh) air should be kept to an absolute minimum. Outside air adds to the heating, cooling, humidifying and dehumidifying loads of the site. It is recommended that outside air be kept
below 5% of the total air circulated in the room and be preconditioned.
2.2 Equipment Inspection
Upon arrival of the unit, inspect all items for visible and concealed damage. Damage should be immediately reported to the carrier and a damage claim filed with a copy sent to Liebert or to your sales
representative.
2.3 Location Considerations
The unit can sit on top of an accessible elevated flooring system. It may be necessary to furnish additional pedestal support below the unit to ensure maximum structural support (see Table 1). A separate floor stand for the unit may be used as support, independent of the elevated floor and installed
prior to the flooring system.
Installation (Applicable to all Models)
Provide approximately 34" (864 mm) service clearance on the front of the unit.
NOTE
GLYCOOL units require 34" (864 mm) service clearance on the right side of the unit in
addition to front service clearance.
Avoid placing units in an alcove or at the extreme end of a room that has a high aspect ratio (long,
narrow room). Ducted units can be placed in room corners or ends as long as front access is maintained. Placing units too close together will reduce the effectiveness of the air distribution.
NOTE
Locate and remove shipping screw on fan motor base.
2.4 Equipment Handling
WARNING
Risk of top-heavy unit falling over. Improper handling can cause equipment damage, injury or
death.
Read all of the following instructions before attempting to move, lift, remove packaging from
or preparing unit for installation.
The instructions below are to be adhered to when handling this unit with or without the skid.
There is the potential for this unit to tip over if it is handled improperly.
5
2.4.1 Handling With Skid
Remove plywood skirting holding
unit and skid in place.
Raise unit with fork lift
or similar machine.
• Always keep the unit upright, indoors and protected from damage.
• If possible, transport the unit using a fork lift; otherwise, use a crane with belts or cables, avoiding pressing on the top edges of the packaging.
• If using a fork lift, make sure the forks, if adjustable, are spread to the widest allowable distance
to still fit under the skid.
NOTICE
Risk of overhead interference. Can cause unit and/or structure damage. Refer to the
installation plans prior to moving the unit to verify clearances.
While on the skid, the unit is too tall to fit through a standard height doorway (83 inches or
2108 mm tall). Any attempt to move the unit, while on the skid, through a standard doorway
will cause damage to the unit.
2.4.2 Removal of Skid
• Remove the plywood skirting that keeps the skid and unit in place.
• Raise the Challenger 3000 off the skid. Liebert recommends using a fork lift (see Figure 1)
or similar machine to ensure that the unit is lifted properly.
• Once the unit is raised, the skid can be removed.
Figure 1 Removing Challenger from skid
Installation (Applicable to all Models)
Table 1 Unit net weight
Model Lb (kg)
036E/035E 535 (243)
060E/059E 545 (247)
042A/040A 615 (279)
067A/065A 670 (304)
046WG/045WG 700 (318)
071WG/070WG 750 (340)
061G/058G 785 (356)
068C/072C 545 (247)
102C/101C 555 (252)
6
Figure 2 Upflow (BU) cabinet dimensions
A
Shaded area indicates a recommended
clearance of 34" (864mm) for component
access. Right side access s uggested for
GLYCOO L units.
DPN000350
Rev. 01
FRONT VIEW
(front return configuration)
32-1/2"
(826mm)
Overall
Dimension
32-1/2"
(826mm)
Overal l
Dimension
32-1/2"
(826mm)
32-1/2"
(826mm)
Blow er Outlet with
1" (25.4mm) Flange
7/8" (22.2mm) Flange for
Duct or Plenum Connection
Return Air Louvers
Plenum available w it h:
-2, 3 or 4 grilles.
-Solid sides w ith a 7/8" (22mm)
duct flange on top.
Standard Piping Location
Standard Elec trical Outlet
Location Through Unit
Standard Elec trical Outlet
Location Through Plenum
29-3/4"
(756mm)
1-5/8"
(41mm)
9-5/8"
(244mm)
30-1/2"
(775mm)
30-1/2"
(775mm)
1-7/8"
(48mm)
12-1/2"
(318mm)
5-1/2" (140mm)
8-1/2"
(216mm)
Filter Access
Through Top
7-1/2"
(191mm)
29"
(737mm)
2-1/2"
(67mm)
1-3/4 "
(44mm)
REAR VIEW
(rear return configuration)
94"
(2388mm)
76"
(1930mm)
6-7/8" (175mm)
10-1/4"
(260mm)
18"
(457mm)
Projec tion of D isplay
Bezel 5/8" (16mm)
Air Discharge Grille
1" (25mm)
FRONT &
SIDES
3/4" (19mm)
REAR
13"
(330mm)
UNIT
TOP VIEW
A
STD 3 & 5T 11-3/4 (299mm)
Hi Static 3T 8 5/8 (219mm)
Hi Static 5T 11-3/4 (299mm)
Installation (Applicable to all Models)
7
Figure 3 Downflow (BF) cabinet dimensions
Shaded area indicates
a recommended clearance of
34” (864mm) for component
access. Right side access
suggested for GLYCOOL units
DPN000351
Rev. 01
32-1/2"
(826mm)
Overall
Dimension
32-1/2"
(826mm)
Overall
Dimension
30-1/2"
(775mm)
76"
(1930mm)
30-1/2"
(775mm)
30-1/2"
(775mm)
30-1/2"
(775mm)
30-1/2"
(775mm)
30-1/2"
(775mm)
30-1/2"
(775mm)
30-1/2"
(775mm)
Projection of Display
Bezel 5/8" (16mm)
Optional 1-5/8" (41mm)
Flange for Duct or
Plenum Connection
1"
(25.4mm)
1"
(25.4mm)
1"
(25.4mm)
1"
(25.4mm)
FLOOR CUTOUT DIMENSIONS
8"
(203mm)
9"
(229mm)
OPTIONAL FLOOR STAND DIMENSIONAL DATA
4"
(102mm)
1" (25.4mm)
28-1/2"
(724mm)
12"
(305mm)
Floor
Level
Standard Piping
Location
Standard Electrical Location
See Specification
Sheet for Floor Stand
Height Ordered.
1" (25mm) FRONT & SIDES
3/4" (19mm) REAR
Installation (Applicable to all Models)
8
2.5 Piping Considerations
All piping below the elevated floor must be located so that it offers the least resistance to air flow.
Careful planning of the piping layout under the raised floor is required to prevent the air flow from
being blocked. When installing piping on the subfloor, it is recommended that the pipes be mounted in
a horizontal plane rather than stacked one above the other. Whenever possible, the pipes should be
run parallel to the air flow.
Condensate pumps for downflow units are shipped separately to be field-installed under the raised
floor. Pump height is 11 inches (279 mm).
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 drain line also drains the humidifier, if applicable. The drain line must be located so it will
not be exposed to freezing temperatures. The drain should be at least the full size of the drain connection and pitched a minimum of 1/8" per ft. (11 mm per meter).
NOTE
This line may contain boiling water. Select appropriate drain system materials.
The drain line must include one and only one trap. Units without a condensate pump have a
factory-supplied trap in the unit, so a field trap should not be added. Units with a condensate
pump will require a field-supplied trap downstream from the pump. The drain line must
comply with all applicable codes.
Table 2 Piping connection size
Air-Cooled Unit Connection Sizes—in.
Model No. BF/BU
(50 Hz)
042A (040A) 3/8 5/8
067A (065A) 1/2 7/8
Split System Fan Coil Unit Connection Sizes—in.
Model No. BF/BU (50 Hz) Liquid Line
036E (035E) 5/8 - 18 Female (#6 QC) 1-1/8 - 12 Female (#11 QC)
060E (059E) 1/2 OD Cu 1-1/8 OD Cu
All Units: Connection Sizes—in.
Humidifier Line
OD Copper
H
1/4 3/4 FPT 1/2
Water/Glycol-Cooled Unit Connection Sizes—inches
Model No. BF/BU
(50 Hz)
046WG (045WG) 7/8 7/8
071WG (070WG) 1-1/8 1-1/8
GLYCOOL Unit Connection Sizes —in.
Model No. BE/BK
(50 Hz)
061G (058G) 1-1/8 1-1/8
Chilled Water Unit Connection Sizes—in.
Model No. BF/BU
(50 Hz)
068C (072C) 1-1/8 1-1/8
102C (101C) 1-1/8 1-1/8
Liquid Line O.D. Copper
L
L
Condensate
Drain Line
C
Supply Line
S
Supply Line
S
Supply Line
CWS
Installation (Applicable to all Models)
Hot Gas Line OD Copper
HG
Suction Line
SC
Condensate Pump Line
OD Copper
P
Return Line
Return Line
Return Line
CWR
Hot Water Reheat
Supply
HWS
5/8 5/8
R
R
OD Copper
Return
HWR
9
Figure 4 Piping connections for air-cooled units - Downflow models
PIPING OUTLET LOCATIONS
(See Cabinet and Floor Planning
Dimensional Data for Piping
Opening Sizes.)
Liebert iCOM
Control Panel
Condensate Drain 3/4" FP T
Field-pitch a minimum of 1/8" (3.2mm)
per foot (305mm). The drain line
must comply with all applicable codes.
Humidifier Water Supply Line
1/4" OD CU
Hot Gas Refrigerant Line
5/8" OD CU on Models BF042A/BF040 A
7/8" OD CU on Models BF067A/BF065 A
Hot Water Return
5/8" OD CU (optional)
Liquid Refrigerant Line
3/8" OD CU on Models BF042A/BF040 A
1/2" OD CU on Models BF067A/BF065 A
Hot Water Supply
5/8" OD CU (optional)
DPN000353
Rev. 01
Installation (Applicable to all Models)
10
Figure 5 Piping connections for air-cooled units - Upflow models
Condensate Drain
3/4" FPT
Field pitch a min. of 1/8" (3.2mm) per ft. (305mm). Units without
a condensate pump have a factory-supplied trap in the unit, so a
field trap should not be added. Units with a condensate pump will
require a field-supplied trap downstream from the pump.The
drain line must comply with all applicable codes. (If condensate
pump is ordered piping is out top of unit).
DPN000352
Rev. 01
Piping outlet locations through the plenum
are the same as the unit. See below for
descriptions and connection sizes.
Humidifier Water Supply Line
1/4" OD CU
Condensate Pump Line
1/2" OD CU
Used only if optional condensate
pump is ordered.
Hot Water Return
5/8" OD CU (optional)
Liquid Refrigerant Line
3/8" OD CU on Models BU042A/BU040A
1/2" OD CU on Models BU067A/BU065A
Hot Water Supply
5/8" OD CU (optional)
Liebert iCOM
Control
PIPING OUTLET LOCATIONS
(See Cabinet and Floor Planning
Dimensional Data for Piping
Opening Sizes.)
Installation (Applicable to all Models)
11
Installation (Applicable to all Models)
PIPING OUTLET LOCATIONS
(See Cabinet and Floor
Planning Dimensional Data
for Piping Opening Sizes.)
DPN000376
Rev. 01
Condensate Drain
3/4" FPT
Field pitch a minimum
of 1/8" (3.2mm) per ft. (305mm).
The drainline must comply
with all applicable codes.
HumidifierWater Supply Line
1/4" OD CU
Suction Refrigerant Line
#11 Quick Connect on Models BF036E/BF035E
1-1/8" OD CU on Models BF060E/BF059E
Hot Water Return
5/8" OD CU (optional)
Liquid Refrigerant Line
#6 Quick Connect on Models BF036E/BF035E
1/2" OD CU on Models BF060E/BF059E
Hot Water Supply
5/8" OD CU (optional)
Liebert iCOM
Control
Figure 6 Piping connections for split system fan coil units - Downflow models
12
Installation (Applicable to all Models)
DPN000375
Rev. 01
Piping outlet locations through the
plenum are the same as the unit.
See below for descriptions and
connection sizes.
Humidifier Water Supply Line
1/4" OD CU
Condensate Pump Line
1/2" OD CU; used only
if optional condensate pump is ordered.
Hot Water Return
5/8" OD CU (optional)
Liquid Refrigerant Line
#6 Quick Connect on Models BU036E/BU035E
1/2" OD CU on Models BU060E/BU059E
Hot Water Supply
5/8" OD CU (optional)
iCOM Control
Panel
Condensate Drain; 3/4" FPT
Field-pitch a min. of 1/8" (3.2mm) per ft. (305mm). Units without
a condensate pump have a factory-supplied trap in the unit, so a
field trap should not be added. Units with a condensate pump will
require a field-supplied trap downstream from the pump. The
drain line must comply with all applicable codes. (If condensate
pump is ordered, piping is out top of unit).
PIPING OUTLET LOCATIONS
(See Cabinet and Floor Planning
Dimensional Data for Piping
Opening Sizes.)
Figure 7 Piping connections for split system fan coil units - Upflow models
13
Installation (Applicable to all Models)
DPN000364
Rev. 01
Condensate Drain
3/4" FPT
Field pitch a minimum
of 1/8" (3.2mm) per ft. (305mm).
The drain line must comply with
all applicable codes
Humidifier Water Supply Line
1/4" OD CU
Condenser Return Line
7/8" OD CU on Models BF046WG/BF045WG
1-1/8" OD CU on Models BF071WG/BF070WG
Hot Water Return
5/8" OD CU (optional)
Condenser Supply Line
7/8" OD CU on Models BF046WG/BF045WG
1-1/8" OD CU on Models BF071WG/BF070WG
Hot Water Supply
5/8" OD CU (optional)
PIPING OUTLET LOCATIONS
(See Cabinet and Floor Planning
Dimensional Data for Piping
Opening Sizes.)
iCOM Control
Panel
Figure 8 Piping connections for water/glycol and GLYCOOL units - Downflow models
14
Installation (Applicable to all Models)
Figure 9 Piping connections for water/glycol and GLYCOOL units - Upflow models
Piping outlet locations through the plenum
the same as the unit. See below for
descriptions and connection sizes.
Humidifier Water Supply Line
1/4" OD CU
Condenser Return Line
7/8" OD CU on Models BU046WG/BU045WG
1-1/8" OD CU on Models BU071WG/BU070WG
Condensate Pump Line
1/2" OD CU
Used only if optional condensate
pump is ordered.
Hot Water Return
5/8" OD CU (optional)
Condenser Supply Line
7/8" OD CU on Models BU046WG/BU045WG
1-1/8" OD CU on Models BU071WG/BU070WG
Hot Water Supply
5/8" OD CU (optional)
Liebert iCOM
Control
Condensate Drain
3/4" FPT
Field pitch a min. of 1/8" (3.2mm) per ft. (305mm). Units without
a condensate pump have a factory-supplied trap in the unit, so a
field trap should not be added. Units with a condensate pump will
require a field-supplied trap downstream from the pump. The
drain line must comply with all applicable codes. (If condensate
pump is ordered piping is out top of unit).
15
PIPING OUTLET LOCATIONS
(See Cabinet and Floor Planning
Dimensional Data for Piping
Opening Sizes.)
DPN000363
Rev. 01
Installation (Applicable to all Models)
Figure 10 Piping connections for chilled water self-contained units - Downflow models
Liebert iCOM
Control
Condensate Drain
3/4" FPT
Field pitch a minimum
of 1/8" (3.2mm) per ft. (305mm).
The drain line must comply
with all applicable codes.
Humidifier Water Supply Line
1/4" OD CU
PIPING OUTLET LOCATIONS
(See Cabinet and Floor Planning
Dimensional Data for Piping
Opening Sizes.)
Chilled Water Supply Line
1-1/8" OD CU
Chilled Water Return Line
1-1/8" OD CU
Hot Water Return
5/8" OD CU (optional)
Hot Water Supply
5/8" OD CU (optional)
DPN000371
Rev. 01
16
Installation (Applicable to all Models)
Condensate Drain 3/4" FP T
Field-pitch a min. of 1/8" (3.2mm) per ft. (305mm). Units without
a condensate pump have a factory-supplied trap in the unit, so a
field trap should not be added. Units with a condensate pump will
require a field-supplied trap downstream from the pump. The
drain line must comply with all applicable codes. (If condensate
pump is ordered, piping is out top of unit).
Piping outlet locations through
the plenum are the same as the unit.
See below for descriptions and
connection sizes.
Humidifier Water Supply Line
1/4" OD CU
Chilled Water Supply Line
1-1/8" OD CU
Condensate Pump Line
1/2" OD CU; used only if optional
condensate pump is ordered.
Hot Water Return
5/8" OD CU (optional)
Chilled Water Return Line
1-1/8" OD CU
Hot Water Supply
5/8" OD CU (optional)
iCOM Control
Panel
DPN000370
Rev. 01
PIPING OUTLET LOCATIONS
(See Cabinet and Floor Planning
Dimensional Data for Piping
Opening Sizes.)
Figure 11 Piping connections for chilled water self-contained units - Upflow models
17
2.5.2 Humidifier Supply Water—Optional Infrared
!
• 1/4" supply line; maximum water pressure is 150 psi (1034kPa)
• Size humidifier supply line for 1 gpm (3.8 l/m), with a minimum water pressure of 20 psi (138kPa)
• Do not supply de-ionized water to the humidifier
2.6 Facility Fluid and Piping Maintenance
Facility water and glycol quality remain a requirement throughout the life of the piping system. Fluid
and piping system maintenance schedules must be established and performed. A local fluid maintenance program must be established that will evaluate fluid chemistry and apply necessary treatment.
A periodic leak inspection of facility and unit fluid piping is recommended. Refer to 5.4 - Glycol Pip-
ing.
2.7 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 and circuit protection requirements. Refer to electrical schematic when making connections.
A manual electrical disconnect switch should be installed within 5 feet (1.6 m) of the unit in accordance with codes, or a factory-supplied disconnect switch may be factory mounted within the unit
accessible from the exterior.
Installation (Applicable to all Models)
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.
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 the
compressor is rotating properly.
18
Figure 12 Electrical connections
88
89
84
85
82
83
91 92931234
7877
3738B37B38C37C9796
95
94
7675
565551
50
24
38
Electrical Handy Box
(factory-installed with cover;
inside unit on top for upflow
and on base for downflo w.)
1
2
3
4
5
15
1
6
7
8
DPN000354
Rev. 01
14 14 9 9 10 11 13 12 16 17 18
70
73
72
71
Installation (Applicable to all Models)
1. Electric conduit knockouts on top and bottom of electric box. Knockout size 1-3/4" (44.5mm).
2. Three-phase connection. Electric service connection terminals when factory disconnect is NOT
supplied.
3. Three-phase connection. Electric service connection terminals when factory disconnect switch
is supplied.
4. Factory-installed disconnect switch. (Optional).
5. Three-phase electric service field-supplied.
6. Earth ground connection (50/60Hz). Connection terminal for field-supplied earth grounding
wire.
7. Earth ground bar (50Hz only). Connection terminals with factory ground from each high
voltage component for field supplied earth grounding wire.
8. Control and monitoring section of electric box.
9. Remote unit shutdown. Replace existing jumper between Terminals 37 + 38 with normally
closed switch having a minimum 75VA, 24VAC rating. Use field-supplied Class 1 wiring. Two
additional contact pairs available as an option (labeled as 37B & 38B, 37C & 38C). Replace
existing jumper for appropriate pair as done for 37 & 38.
10. Special alarm connections. Field-supplied 24V Class 1 wiring for special alarm. Connection
made by adding normally open contacts between terminals 24 + 50. Special alarm connections
may be factory-wired or field-wired. See schematic for factory wired special alarms. For
field-wired special alarms, use 24V Class 1 wiring to connect normally open contacts between
Terminals 24 & 50, 24 & 51, 24 & 55, or 24 & 56.
11. SiteScan connection. Terminals 77 (-) and 78 (+) are for connection of a 2-wire, twisted pair,
communication cable (available from Liebert or others) to optional Liebert SiteScan
12. Remote condensing unit connection. Field-supplied 24V Class 1 wiring to remote condensing
unit Terminals 1, 2, 3, & 4 from (R2) relay (split system only).
®
.
13. Smoke detector alarm connections. Field-supplied 24V Class 1 wiring to remote alarm
circuits. Factory-wired contacts from optional smoke detector are #91-comm., #92-NO, and
#93-NC.
14. Common alarm connection. Field-supplied 24V. Class 1 wiring to common alarm Terminals
75 + 76 (and optional 94 + 95, and 96 + 97), which are factory-connected to common alarm relay
(R3).
19
15. Heat rejection connection. Field-supplied 24V Class 1 wiring to interlock heat rejection from
DPN001733
Rev. 0
23
24
22
21
20
19
25
DPN001734
Rev. 0
22
24
23
20
19
25
Upflow Models with Liebert iCOM Downflow Models with Liebert iCOM
pigtails 70 + 71 which are factory-connected to compressor side switch (self-contained units only)
or to GLYCOOL relay (K11, GLYCOOL units only). On Dual Cool units only, pigtails 72 + 73
connect auxiliary cooling source to GLYCOOL relay K11.
16. Reheat and Humidifier Lockout. Optional emergency power lockout of reheat and/or
humidifier: connections provided for remote 24V AC source.
17. Main Fan Auxiliary Switch. Optional main fan auxiliary side switch. Terminals located in field
wiring compartment for remote indication that the evaporator fan motor/unit is on. Field to
connect 24V maximum.
18. Optional Condensate Alarm (Dual Float Condensate Pump only). Relay terminals located in
field wiring compartment for remote indication.
Refer to specification sheet for full load amp. and wire size amp. ratings.
Figure 13 Electrical field connections for Liebert iCOM
Installation (Applicable to all Models)
19. Network Cable “C” Connection. Eight-wire Ethernet cable from U2U networking switch.
20. Network Cable “D” connection. Eight-wire Ethernet cable from U2U networking switch.
Cable “D” connection supplied on units with large Liebert iCOM display only.
21. Opening for Field Wiring. Suggested entry point for all field wiring to unit. Hole size Ø2.5"
(63.5mm)
22. Loose Wire Ties. To secure field-supplied network cables. Tighten after all field-supplied wires
have been installed.
23. Vacant Liebert IntelliSlot
®
. May contain optional Liebert IntelliSlot cards.
24. Populated Liebert IntelliSlot. Optional Liebert IntelliSlot cards may be placed in either of the
two supplied Liebert IntelliSlot locations.
25. Remote Temperature / Humidity Sensor Connection. Six-wire CAN cable supplied with
optional remote T/H sensor
20
2.8 Balancing the Air Distribution
2.8.1 Under-Floor Discharge Systems
The systems are designed for constant air delivery, therefore any unusual restrictions within the air
circuit must be avoided. For under-floor air distribution, observe the following guidelines:
• Select the air supply grilles and perforated panels for the raised floor to ensure minimum loss of
pressure in the circuit. Air volume dampers on grilles, which extend several inches below the surface of the raised floor, are usually detrimental to airflow.
• Consideration of the height of the damper on the grille in conjunction with the floor height will
determine whether this type of grille may be used.
• The grilles used in raised floors vary in size, the largest being approximately 18" x 6"
(457 x 152 mm). A larger grille size would be detrimental to the structural capacity of the raised
floor panel. An 18" x 6" (457 x 152 mm) heavy duty, pencil-proof type grille typically has 56 square
inches (0.036 m
• Perforated panels are available from various manufacturers of raised floors. These panels are
usually 2' x 2' (610 x 610 mm) square and have a nominal free area of approximately 108 to 144
square inches (0.07 to 0.09 m
have only 36 to 40 square inches (0.023 to 0.026 m
panels.
• Avoid floor elevations below 7-1/2" (190.5 mm), loosely installed flooring systems, and below-floor
obstructions such as: electrical wiring chases, unusually long electronic system cables, or piping
clusters.
• Always check specifications of the floor supplier before specifying the total number of perforated
panels and grilles required to handle the air flow. The proper specifications for grilles and perforated panels should indicate the total free area required for air delivery rather than the number
of panels and grilles. (See Table 3 for recommended free area required for each model.) This table
indicates the recommended free area based on having the supply air grilles and perforated panels
sized to handle approximately 75% of the total cubic feet per minute (CFM) of the units at a velocity of 550 to 600 ft./min. (2.8 - 3.1 m/s). The remaining 25% of the air flow in the raised floor
passes through cable cutouts, cracks between the panels, and other leakage areas.
2
) of free area.
2
). Use caution in selecting perforated panels as some manufacturers
Installation (Applicable to all Models)
2
) of free area, requiring four times as many
Table 3 Recommended free area ft
550 and 600 fpm (2.8 and 3.1 m/s)
50 Hz Units 60 Hz Units
550
Model
3-ton 2.5 (0.01) 2.3 (0.01) 3-ton 2.5 (0.01) 2.3 (0.01)
5-ton 3.5 (0.02) 3.3 (0.02) 5-ton 3.8 (0.02) 3.5 (0.02)
FPM
2.8.2 Ducted Applications
For ducted supply applications on upflow units, the duct work should be attached to the blower discharge flanges of the unit. For ducted return air applications, the duct work should be attached to the
filter box flanges on upflow rear return units and on the unit top flange for downflow units. Refer to
Figure 2 for information on upflow units and to Figure 3 for downflow units.
The duct work on upflow units must allow access to the motors/blowers for maintenance. The duct
work on upflow units must be designed within the capacity of the unit, otherwise air flow and performance will be compromised.
2.8.3 Plenum Installation
A solid plenum or plenum with discharge grille(s) may be installed. The plenum and instructions for
its installation ship separately from the unit.
2.8
m/s
600
FPM
2
(m2) for grilles or perforated panels at output velocities of
3.1
m/s Model
550
FPM
2.8
m/s
600
FPM
3.1
m/s
21
Loading...