Emerson WORLD CLASS 3000 User Manual

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Liebert Challenger™ 3000 with iCOM

Installation Manual - 3 & 5 Tons, 50 & 60Hz

Precision Cooling For Business-Critical Continuity™

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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

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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

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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

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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

(m2) for grilles or perforated panels at output velocities of 550

Page 7

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.

Page 8

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.

Page 9

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.

Page 10

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

Page 11

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.

Page 12

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)

Page 13

Figure 2 Upflow (BU) cabinet dimensions

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

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)

Page 14

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

(25.4mm)

FLOOR CUTOUT DIMENSIONS

(203mm)

(229mm)

OPTIONAL FLOOR STAND DIMENSIONAL DATA

(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)

Page 15

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

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

Condensate

Drain Line

Supply Line

CWS

Installation (Applicable to all Models)

Hot Gas Line OD Copper

Suction Line

Condensate Pump Line

OD Copper

Return Line

CWR

Hot Water Reheat

Supply

HWS

5/8 5/8

OD Copper

Return

HWR

Page 16

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)

Page 17

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)

Page 18

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

Page 19

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

Page 20

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

Page 21

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).

PIPING OUTLET LOCATIONS (See Cabinet and Floor Planning Dimensional Data for Piping Opening Sizes.)

DPN000363 Rev. 01

Page 22

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

Page 23

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

Page 24

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.

Page 25

Figure 12 Electrical connections

91 92931234

7877

3738B37B38C37C9796

7675

565551

Electrical Handy Box (factory-installed with cover; inside unit on top for upflow and on base for downflo w.)

DPN000354 Rev. 01

14 14 9 9 10 11 13 12 16 17 18

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).

Page 26

15. Heat rejection connection. Field-supplied 24V Class 1 wiring to interlock heat rejection from

DPN001733 Rev. 0

DPN001734 Rev. 0

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

Page 27

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.

) of free area.

). Use caution in selecting perforated panels as some manufacturers

Installation (Applicable to all Models)

) 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

(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

Page 28

2.9 Checklist for Completed Installation

___ 1. Unpack and check received material.

___ 2. Proper clearance for service access has been maintained around the equipment.

___ 3. Equipment is level and mounting fasteners are tight.

___ 4. Piping completed to refrigerant or coolant loop (if required). Piping has been leak checked,

evacuated and charged (if required).

___ 5. Check piping within the unit & outside of the unit. Remove potential of rub-through or

chaffing.

___ 6. Condensate pump installed (if required).

___ 7. Drain line connected.

___ 8. Water supply line connected to humidifier (if required).

___ 9. Field provided pan with drain installed under all ceiling mounted fluid condensing units (if

installed).

___ 10. Filter box installed (if applicable).

___ 11. Ducting completed (if applicable).

___ 12. Filter(s) installed.

___ 13. Line voltage to power wiring matches equipment serial tag.

___ 14. Power wiring connections completed between disconnect switch, evaporator and condensing

unit, including earth ground.

___ 15. Power line circuit breakers or fuses have proper ratings for equipment installed.

___ 16. Control wiring connections completed to evaporator and condensing unit.

___ 17. Verify water detection is properly installed around all units (if installed).

___ 18. All wiring connections are tight.

___ 19. Control panel DIP switches set based on customer requirements.

___ 20. Foreign materials have been removed from, in and around all equipment installed (literature,

shipping materials, construction materials, tools, etc.).

___ 21. Fans and blowers rotate freely.

___ 22. Inspect all piping connections for leaks during initial operations. Correct as needed.

___ 23. Verify that a blank startup sheet has been sent with the unit(s) and is ready to be completed

by the installer.

Installation (Applicable to all Models)

Page 29

Air-Cooled Models—Self-Contained Compressor

3.0 AIR-COOLED MODELS—SELF-CONTAINED COMPRESSOR

3.1 Condenser Location

The air-cooled condenser should be located for maximum security and maintenance accessibility. Avoid ground level sites with public access or areas that contribute to heavy snow or ice accumulations. Utilize centrifugal condensers whenever interior building locations must by used. To assure adequate air supply, it is recommended that condensers be located in a clean air area, away from loose dirt and foreign matter that may clog the coil. In addition, condensers should not be located in the vicinity of steam, hot air, or fume exhausts. Also, condensers should be located no closer than three feet (1 meter) from a wall, obstruction, or adjacent unit.

NOTE

If the condenser is located below the level of the room unit, the factory should be consulted.

Install condensers in a level position to assure proper refrigerant flow and oil return. For roof installation, mount condensers on steel supports in accordance with local codes. To minimize sound and vibration transmission, mount steel supports across load bearing walls. For ground installation, a concrete pad will provide adequate support. Condenser legs have mounting holes for securing the condenser to the steel supports or concrete pad.

3.2 Electrical Connections

Refer to equipment nameplate regarding wire size and circuit protection requirements. Refer to electrical schematic when making connections. Make all wiring and electrical connection in accordance with local and national codes.

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.

Use voltmeter to make sure power is turned off before making any electrical connections.

3.2.1 Line Voltage

Line voltage electrical service is required for all air-cooled condensers at the location of the condenser. This power supply does not have to be the same voltage as the indoor unit. This separate power source may be 208, 230, 460, or 575 V, 60 Hz; or 200, 230, or 380/415 V, 50 Hz. The disconnect switch may be factory-supplied and mounted in the electrical panel or field-supplied and mounted per local and national codes.

3.2.2 Low Voltage

A control interlock between the condenser and the indoor unit is required and is connected between 70 and 71 in the handy box of the indoor unit and the electric panel of the air-cooled condenser. NEC Class 1 wiring is required.

3.2.3 Liebert Lee-Temp/Flood Back Head Pressure Control Condensers

Liebert Lee-Temp condensers require a separate power supply for the heated receivers. This power supply is connected to the electrical connection box on the end of the receiver.

Page 30

Figure 14 Air-cooled condensers

Secure each leg to condenser frame at all points shown using hardware provided.

Liquid line

* B

TYPICAL FOOTPRINT

Liebert Lee-Temp heater pad connection box

*B - Inverted traps are to be field-supplied and installed (typ). When installing traps, provide clearance for swing end of access door. Traps are to extend above base of coil by a minimum of 7-1/2" (190 mm)

Liquid line

Hot gas line

Electric service supplied by others

Hot gas line

* B

LIEBERT LEE-TEMP CONDENSER

FAN SPEED AND VFD CONDENSER

44"

(1118mm )

18" (457.2mm)

43-9/16"

(1106mm)

51-7/16"

(1306.5mm)

37-7/8"

(962mm)

Common to all models. See Table 4 below for key to “A” dimension.

CONDENSER MOUNTING

(25.4mm)

1-3/4"

(44.5mm)

4-1/4"

(108mm)

4-1/4"

(108mm)

1-3/4"

(44.5mm)

(25.4mm)

1-3/4"

(44.5mm)

1" typ.

(25.4mm)

1-3/4"

(44.5mm)

37-11/16"

(957.3mm)

1-3/4"

(44.5mm)

9/16" (14.3mm) diameter holes 8 places for 1/2" (12.7mm) diameter bolts

43-3/16"

(1097mm)

SINGLE FAN AIR-COOLED CONDENSERS

1" typ.

(25.4mm)

Air-Cooled Models—Self-Contained Compressor

Table 4 Air-cooled condenser statistics

Model

083 1 7/8 5/8 295 (133.8) 42 (1067)

104 1 1-1/8 5/8 315 (142.8) 42 (1067)

165 2 1-1/8 7/8 425 (193) 82 (2083)

Number

of Fans

Connection Sizes

(OD Copper)

Net Weight

lb (kg)

“A” Dimension

in (mm)Hot Gas (in.) Liquid (in.)

Page 31

3.3 Refrigerant Piping

Unit refrigeration components and piping are shipped from the factory with a nitrogen holding charge.

NOTICE

Risk of improper installation. Can cause equipment and property damage. The refrigeration piping should be isolated from the building by the use of vibration isolating

supports. When installing field piping, care must be taken to protect all refrigerant lines from the

atmosphere, especially when using refrigerants with POE oils. Do not allow the piping to stand open to air for more than 15 minutes. Units designed for R407C have a compressor that contains POE oil that is very hygroscopic; that is, it quickly absorbs water from the air. The longer the compressor piping is left open to air, the harder it will be to fully evacuate. If left open too long, the POE oil may need to be replaced before achieving the required vacuum level.

Keep the evaporator unit and condenser closed with their factory charge of dry nitrogen while all field piping is installed. Keep the field piping clean and dry during installation, and do not allow it to stand open to the atmosphere. When all the field interconnecting piping is in place, vent the condenser dry nitrogen charge and connect to the field piping. Finally, vent the evaporator unit dry nitrogen charge and make its piping connections last.

Follow all proper brazing practices including a dry nitrogen purge to maintain system cleanliness.

Air-Cooled Models—Self-Contained Compressor

NOTE

Piping, including inverted trap(s), must be routed to allow unobstructed access to the panel per the NEC.

Traps should be installed in the hot gas line on vertical risers at the base and every 25 feet (7.6 meters) in elevation. These traps will collect condensed refrigerant and refrigerant oil during the off cycle of the unit and ensure flow of refrigerant oil during operation.

A check valve is factory-supplied with the unit to be field-installed on the discharge side of the scroll compressor. Be sure to install the check valve with the refrigerant flow in the proper direction. When soldering or brazing the valve, it is very important to protect the internal parts by wrapping the valve with a damp cloth to keep the valve temperature below 250°F (121°C).

Approval is required whenever:

• a refrigerant piping run exceeds 150 ft. (46 m) equivalent length

• an R407C system condenser must be located below the level of the cooling coil.

Total discharge line pressure drop must not exceed 10 PSIG (69 kPa).

Consult your local Liebert representative when considering installations outside these guidelines.

Table 5 Recommended line sizes — OD copper (inches)*

3.5-ton 042A (040A) 5-ton 067A (065A)

Equivalent Length

50 ft. (15 m) 5/8 1/2 7/8 1/2 100 ft. (30 m) 3/4 1/2 7/8 5/8 150 ft. (45 m) 3/4 5/8 7/8 5/8

*Recommended vertical line sizes must be used for proper oil return at all cooling and dehumidification steps.

Hot Gas Line Liquid Line Hot Gas Line Liquid Line

Page 32

Air-Cooled Models—Self-Contained Compressor

Table 6 Equivalent lengths (feet) for various pipe fittings

Copper Pipe

O.D. in.

1/2 0.8 1.3 0.4 2.5 0.26 7.0 4.0

5/8 0.9 1.4 0.5 2.5 0.28 9.5 5.0

3/4 1.0 1.5 0.6 2.5 0.3 12.0 6.5

7/8 1.45 1.8 0.8 3.6 0.36 17.2 9.5

1-1/8 1.85 2.2 1.0 4.6 0.48 22.5 12.0 1-3/8 2.4 2.9 1.3 6.4 0.65 32.0 16.0 1-5/8 2.9 3.5 1.6 7.2 0.72 36.0 19.5

Refrigerant trap = 4 times equivalent length of pipe per this table.

90 Degree

Elbow Copper

90 Degree

Elbow Cast

45 Degree

Elbow Tee

Gate

Valve

Globe

Valve

Table 7 Indoor unit refrigerant charge lb (kg)

R407C

Model

42A/40A 0.9 (0.4)

67A/65A 1.4 (0.6)

Approximate Charge

lb (kg)

Table 8 Line charges - refrigerant per 100 ft. (30 m) of Type “L” copper tube

R407C

Liquid Line

O.D.

1/2" 7.3 (3.3) 1.3 (0.6)

5/8" 11.7 (5.3) 2.1 (1.0)

3/4" 16.6 (7.5) 3.0 (1.4)

7/8" 24.4 (11.1) 4.4 (2.0)

lb (kg)

Hot Gas Line

lb (kg)

Angle

Valve

Table 9 Condenser refrigerant (per serial tag)

R407C

Approximate Charge

lb (kg)

Liebert

Model

083 8 (3) 25 (12)

104 9 (4) 37 (17)

165 15 (6.8) 50 (22.7)

* Charge includes the receiver charge.

Fan Speed

Lee-Temp*

3.4 Fan Speed Control Systems

The Variable Fan Speed Control systems (FSC & VFD) uses pressure-activated electronic fan speed control systems and remotely located thermostat(s) to ensure operation at ambient temperatures as low as 0°F (-18°C). For this ambient temperature range, the VFD Control Condenser must be used with digital scroll indoor units and can be used for energy savings with any Liebert Challenger 3000 unit.

Variable Fan Speed Control Piping

A discharge line and a liquid line must be field-installed between the indoor unit and the outdoor condenser. See Figures 15 and 16 for details.

Page 33

Air-Cooled Models—Self-Contained Compressor

Variable Fan Speed Control Materials Supplied

•Built-in, pre-wired condenser control box

• Air-Cooled condenser

• Piping access cover to be reinstalled when piping is complete

• Bolts—four per leg (3/8" x 5/8")

• Terminal block for two-wire, 24V interlock connection between unit and condenser

• Condenser legs—four with 1-fan, 2-fan and 3-fan models; six with 4-fan models

Variable Fan Speed Control Leak Check and Evacuation Procedure

Proper leak check and evacuation can be accomplished only with all system solenoid valves open and check valves accounted for.

NOTE

Systems with a scroll or digital scroll compressor include a factory-installed check valve and an additional downstream Schrader valve with core in the compressor discharge line. Proper evacuation of the condenser side of the compressor can be accomplished only using the downstream Schrader valve. See piping schematic (Figures 15 and 16).

1. If unit power is available, open the unit liquid line solenoid valves using the evacuation function in the diagnostic section of the Liebert iCOM control (refer to the Liebert iCOM user manual, SL-18835). If unit power is not available, a field-supplied 24VAC / 75VA power source must be directly connected to each of the unit solenoid valves.

2. For scroll and digital scroll compressors, connect refrigerant gauges to the suction rotalock valves and discharge line Schrader valves (see Note above) on the compressor.

3. Open the service valves and place a 150 PSIG (1034 kPa) of dry nitrogen with a tracer of refrigerant. Check system for leaks with a suitable leak detector.

4. After completion of leak testing, release the test pressure (per local code) and pull an initial deep vacuum on the system with a suitable pump.

5. After four hours, check the pressure readings and, if they have not changed, break vacuum with dry nitrogen. Pull a second and third vacuum to 250 microns or less. Recheck the pressure after two hours. After completing this step, proceed to Variable Fan Speed Charging on page 28.

Page 34

Air-Cooled Models—Self-Contained Compressor

Variable Fan Speed Charging

1. Check unit nameplate for refrigerant type to be used. Unit control configurations differ depending on refrigerant type.

2. Refrigerant charging requires unit operation. Refer to 2.9 - Checklist for Completed Installation.

3. Calculate the amount of charge for the system. Refer to the unit, condenser and refrigerant line charge data in Tables 6, 7, 8 and 9.

4. Weigh in as much of the system charge as possible before starting the unit.

CAUTION

Risk of improper refrigerant charging. Can cause equipment damage.

Refrigerant R407C is a blend of three components and must be introduced and charged from the cylinder only as a liquid.

When adding liquid refrigerant to an operating system, it may be necessary to add the refrigerant through the compressor suction service valve. Care must be exercised to avoid damage to the compressor. Emerson recommends connecting a sight glass between the charging hose and the compressor suction service valve. This will permit adjustment of the cylinder hand valve so that liquid can leave the cylinder while allowing vapor to enter the compressor.

5. Turn on unit disconnect switch. Operate the unit for 30 minutes using the charging function for the system in the diagnostic section of the Liebert iCOM control (see Liebert iCOM user manual, SL-18835). The charging function operates the compressor at full capacity and energizes the blower motor and the liquid line solenoid valve. The reheat and humidifier are disabled. A minimum 20psig (138kPa) must be established and maintained for the compressor to operate. The charging function can be reset as many times as required to complete unit charging.

Table 10 Fan speed suction pressure transducer settings

R-407C

Gauge (Sea Level) Absolute

Function

Pump-Down Cutout 20 (138) 35 (241)

Pump-Down Reset 65 (448) 80 (552)

Minimum to Start-Cooling 35 (241) 50 (344)

Low-Pressure Cutout (DX only) 52 (358) 67 (461)

psiG (kPa) psiA (kPa)

6. Charge the unit until the liquid line sight glass becomes clear. Then add one additional pound (2.2kg) of refrigerant.

NOTE

A digital scroll compressor will have a clear sight glass only when operating at 100% capacity. When operating below 100%, the sight glass may show bubbles with each 15-second unloading cycle.

7. As head pressure builds, the variable fan speed controlled condenser fan begins rotating. The fan will run at full speed when sufficient head pressure is developed—fan starts to rotate at 190 psig (1310 kPA) and is full speed at 250 psig (1724 kPA).

Page 35

Air-Cooled Models—Self-Contained Compressor

DPN000349 Rev. 3

Condenser Coil

Schrader Valve

Fusible Plug

Evaporator Coil

Hot Gas Bypass Valve

Traps* every 25 ft. (7.6m) of rise

Solenoid Valves

Sight Glass

Filter Dryer

Liquid Return

Shutoff* Valve

Sensing Bulb

External Equalizers

Scroll Compressor

Service Valves

Hot Gas Bypass

Hot Gas Discharge

Check Valve

FIELD PIPING

FACTORY PIPING

*Components are not supplied by Liebert but are recommended for proper circuit operation and maintenance.

Expansion Valve

Inverted Trap * on discharge line to extend above base of coil by a minimum of 7-1/2" (190mm)

Figure 15 General arrangement—Air-cooled models with fan speed control

Page 36

Air-Cooled Models—Self-Contained Compressor

Inverted Trap * on discharge line to extend above base of coil by a minimum of 7-1/2" (190mm)

Condenser Coil

Schrader Valve

Fusible Plug

Traps* every 25 ft. (7.6m) of rise

Evaporator Coil

Expansion Valve

Solenoid Valve

Sight Glass

Filter Dryer

Liquid Return

Shutoff* Valve

Sensing Bulb

External Equalizer Service Valve s

Hot Gas Discharge

Check Valve

FACTORY PIPING FIELD PIPING

*Components are not supplied by Liebert but are recommended for proper circuit operation and maintenance.

Digital Compressor

Digital Solenoid Valve

DPN001726 Rev. 0

Figure 16 General arrangement—Air-cooled models with digital scroll and fan speed control

Page 37

Air-Cooled Models—Self-Contained Compressor

3.5 Air-Cooled Condenser with Liebert Lee-Temp “Flooded Condenser” Head Pressure Control System

The Liebert Lee-Temp system consists of a modulating type head pressure control valve and insulated receivers with heater pads to ensure operation at ambient temperatures as low as -30°F (-34.4°C). The Liebert Lee-Temp system can be used with any compressor choice.

Liebert Lee-Temp Piping

A discharge line and a liquid line must be field-installed between the indoor unit and the outdoor condenser. See Figures 17 and 18 for details.

Liebert Lee-Temp Controlled Materials Supplied

•Built-in, pre-wired condenser control box

• Air-Cooled condenser

• Piping access cover to be reinstalled when piping is complete (models with one to four fans only)

• Bolts—four per leg (3/8" x 5/8")

• Terminal block for two-wire, 24V interlock connection between unit and condenser

• Condenser legs—four with 1-fan, six on two-, three- and six-fan models and eight on four- and eight-fan models

• Bolts—six per receiver (3/8" x 1")

• Lee-Temp system:

• Insulated storage receiver

• Head pressure control valve with integral check valve

• Service valve

• Pressure relief valve

• Liquid level sight glass

•Check valve

NOTE

Lee-Temp heater pads require a separate, continuous electrical source. See nameplate on unit for proper voltage.

Lee-Temp Leak Check and Evacuation Procedure

Proper leak check and evacuation can be accomplished only with all system solenoid valves open and check valves accounted for.

NOTE

Systems with scroll or digital scroll compressors include a factory-installed check valve and an additional downstream Schrader valve with core in the compressor discharge line. Proper evacuation of the condenser side of the compressor can be accomplished only using the downstream Schrader valve. See piping schematic (Figure 18).

1. If unit power is available, open the unit liquid line solenoid valves using the evacuation function in the diagnostic section of the Liebert iCOM control. If unit power is not available, a fieldsupplied 24VAC / 75VA power source must be directly connected to each of the unit solenoid valves.

2. Attach a jumper hose from the service valve fitting on the outlet of the receiver and the Schrader fitting on the discharge header of the condenser. Front-seat the service valve approximately two (2) turns.

3. For scroll and digital scroll compressors, connect refrigerant gauges to the suction rotalock valves and discharge line Schrader valves (see Note above).

4. Open the service valves and place a 150 PSIG (1034 kPa) of dry nitrogen with a tracer of refrigerant. Check system for leaks with a suitable leak detector.

5. After completion of leak testing, release the test pressure (per local code) and pull an initial deep vacuum on the system with a suitable pump.

Page 38

Air-Cooled Models—Self-Contained Compressor

6. After four hours, check the pressure readings and, if they have not changed, break vacuum with dry nitrogen. Pull a second and third vacuum to 250 microns or less. Recheck the pressure after two hours.

7. Remove the jumper hose installed previously from between the service valve fitting and the condenser. After completing this step, proceed to Lee-Temp Charging.

Lee-Temp Charging

1. Check unit nameplate for refrigerant type to be used. Unit control configurations differ depending on refrigerant type.

2. Refrigerant charging requires unit operation. Refer to 2.9 - Checklist for Completed Installation.

3. Calculate the amount of charge for the system. Refer to the unit, condenser and refrigerant line charge data in Tables 6, 7, 8 and 9.

4. Weigh in as much of the system charge as possible before starting the unit.

CAUTION

Risk of improper refrigerant charging. Can cause equipment damage.

Refrigerant R407C is a blend of three components and must be introduced and charged from the cylinder only as a liquid.

5. Turn on unit disconnect switch. Operate the unit for 30 minutes using the charging function for the system in the diagnostic section of the Liebert iCOM control. The charging function operates the compressor at full capacity and energizes the blower motor and liquid line solenoid valve. The reheat and humidifier are disabled. A minimum 20psig (138kPa) must established and maintained for the compressor to operate. The charging function can be reset as many times as required to complete unit charging.

Table 11 Lee-Temp suction pressure transducer settings

R-407C

Gauge Reading

(Sea Level) Absolute

Function

Pump-Down Cutout 20 (138) 35 (241)

Pump-Down Reset 65 (448) 80 (552)

Minimum to Start-Cooling 50 (345) 65 (448)

Low-Pressure Cutout (DX only) 52 (358) 67 (461)

psiG (kPa) psiA (kPa)

6. Charge the unit until the liquid line sight glass becomes clear. Then add one additional pound (2.2 kg) of refrigerant.

NOTE

A digital scroll compressor will have a clear sight glass only when operating at 100% capacity. When operating below 100%, the sight glass may show bubbles with each 15-second unloading cycle.

Lee-Temp Receiver Refrigerant Level

On each receiver at the condenser are two refrigerant-level sight glasses. Refrigerant level will vary with outside temperature. Check refrigerant level after the unit has been on for at least 15 minutes.

Sight Glass Levels

40°F (4.5°C) and lower—bottom sight glass is 3/4 full 40 to 60°F (4.5 to 15.5°C)—bottom sight glass is full 60°F (15.5°C) and higher—top sight glass is 3/4 full.

Page 39

Figure 17 General arrangement—Air-cooled models with Liebert Lee-Temp

* Components are not supplied by Liebert but are recommended for proper circuit operation and maintenance. * * Components supplied by Liebert and must be field installed.

FACTORY PIPING

FIELD PIPING

Piping Assembly * *

Condenser Coil

Rotalock Valve * *

1/4" ( 6.4mm) Pressure Relief Valve * *

Sight Glass

Liebert Lee-Temp Receiver

Head Pressure Control with Integral Check Valve

Check Valve

Evaporator Coil

Sensing Bulb

Expansion Valve

Hot Gas Bypass Valve

Hot Gas Bypass

Solenoid Valves

Sight Glass

Filter Dryer

Shutoff Valve *

Liquid Return

External Equalizers

Service Valves

Scroll Compressor

Liquid Return from Condenser

Traps * Every 25 Ft. (7.6m) of rise on Hot Gas Line only

Inverted Trap * on discharge line to extend above base of coil by a minimum of 7-1/2" (190mm)

OPTIONAL PIPING

Hot Gas Discharge

Check Valve

DPN000674 Rev. 02

Air-Cooled Models—Self-Contained Compressor

Page 40

Air-Cooled Models—Self-Contained Compressor

Digital Solenoid Valve

DPN001725 Rev. 0

* Components are not supplied by Liebert but are recommended for proper circuit operation and maintenance. * * Components supplied by Liebert and must be field-installed.

OPTIONAL PIPING

FIELD PIPING

FACTORY PIPING

Piping Assembly * *

Condenser Coil

Rotalock Valve * *

1/4" ( 6.4mm) Pressure Relief Valve * *

Sight Glass

Liebert Lee-Temp Receiver

Head Pressure Control with Integral Check Valve

Check Valve

Liquid Return from Condenser

Inverted Trap * on discharge line to extend above base of coil by a minimum of 7-1/2" (190mm)

Traps * Every 25 Ft. (7.6m) of rise on Hot Gas Line only

Evaporator Coil

Sensing Bulb

Expansion Valve

Solenoid Valve

Sight Glass

Filter Dryer

Liquid Return

Shutoff Valve *

External Equalizer

Service Valves

Digital Compressor

Hot Gas Discharge

Check Valve

Figure 18 General arrangement—Air-cooled models with digital scroll and Lee-Temp

Page 41

Water-Cooled Models—Self-Contained Compressor

4.0 WATER-COOLED MODELS—SELF-CONTAINED COMPRESSOR

4.1 Piping Considerations

Manual shutoff valves should be installed at the supply and return lines of each unit. This will provide for routine maintenance or emergency isolation of the unit.

When the water source for the condenser is of poor quality, it is good practice to provide cleanable filters in the supply line. These filters will trap the particles in the water supply and extend the service life of the water-cooled condenser.

To provide for the emergency of water leaks and the consequences of sub-floor flooding, floor drains should be provided with wet traps or a water detection system such as a Liebert Liqui-tect that is installed near the base of the unit or below the elevated floor.

4.2 Condenser

The condenser is designed to operate in conjunction with either a cooling tower or city water. The maximum water pressure is 150 psig (1034 kPa). A high pressure system rated at 350 psig (2413 kPa) is available as an option.

™

sensor

Page 42

Water-Cooled Models—Self-Contained Compressor

Field-Supplied Reducers Required on 3-Ton Units

DPN000359 REV 02

Evaporator Coil

Expansion Valve

Sensing Bulb

External Equalizers

Scroll Compressor

Service Valves

Hot Gas Bypass Solenoid Val v e

Hot Gas Bypass Val v e

Sight Glass

Filter Dryer

Hot Gas Bypass

Tube in Tube Condenser

Bypass Valve

2-Way Water Regulating Val v e

3-Way Water Regulating Valve (optional)

Fluid Return From Unit

Fluid Supply To Unit

Fluid Return From Unit

Fluid Supply To Unit

Shutoff* Valves

Hose Bibs*

FACTORY PIPING

FIELD PIPING

* Components are not supplied by Liebert but are recommended for proper circuit operation and maintenance.

Figure 19 General arrangement—Water-cooled models with scroll compressor

Page 43

Water-Cooled Models—Self-Contained Compressor

DPN001727 Rev. 0

Evaporator Coil

Expansion Valve

Sensing

Bulb External Equalizer

Service Va l v e s

Sight Glass

Filter Dryer

Tube in Tube Condenser

Fluid Return From Unit

Fluid Supply To Unit

Fluid Return From Unit

Fluid Supply To U nit

Shutoff* Valv es

Hose Bibs*

FACTORY PIPING

FIELD PIPING

Digital Compressor

Digital Solenoid Valv e

To Liebert iCOM C ontrol

3-Way Motorized Ball Valve (optional)

2-Way Motorized Ball Valve

*Components are not supplied by Liebert but are recommended for proper circuit operation and maintenance.

Field-Supplied Reducers Required on 3- Ton Units

Figure 20 General arrangement diagram—Water-cooled models with digital scroll

Page 44

Water-Cooled Models—Self-Contained Compressor

Range spring

Valve spring guide

Top retainer

Range adjustment screw

Insert screwdrivers underneath the valve spring guide

4.3 Water Regulating Valve

The water regulating valve automatically regulates the amount of fluid necessary to remove the heat from the refrigeration system, permitting more fluid to flow when load conditions are high and less fluid to flow when load conditions are low. The valve consists of a brass body, balance spring, valve seat, valve disc holders, capillary tube to discharge pressure, and adjusting screw.

4.3.1 Standard Valve - 150psig (1034kPa) System for 3 & 5-Ton Units (Johnson Controls Valve) High Pressure Valve - 350psig (2413kPa) System for 5-Ton Units (Johnson Controls Valve)

Adjustment

The valve may be adjusted with a standard refrigeration service valve wrench or screw driver.

To lower the head pressure setting, turn the square adjusting screw clockwise until the high pressure gauge indicates the desired setting.

To raise the head pressure setting, turn the adjusting screw counterclockwise until the desired setting is obtained.

Figure 21 Johnson Controls valve adjustment

4.3.2 High Pressure Valve - 350 psig (2413 kPa) System for 3-Ton Units (Metrex Valve)

Adjustment

The valve may be adjusted using a 1/8" diameter rod. Turn the adjusting collar nut counterclockwise to raise head pressure; turn it clockwise to lower head pressure. Rotation directions are viewed from top of valve spring housing.

Page 45

Figure 22 Metrex Valve adjustment

Adjusting collar nut

Water-Cooled Models—Self-Contained Compressor

4.4 Motorized Ball Valve—Digital Scroll Compressors

4.4.1 Control

Table 12 Refrigerant control settings psi (kPa)

Low Pressure

Cut Out

20 (137.9) 65 (448.2) 400 (2758)

Low Pressure

Cut In

High Pressure

Cut Out

Manual Flushing

The valve may be flushed by rotating the socket head screw clockwise. This screw must be in the OUT position (counterclockwise) for normal valve operation.

On digital scroll units, discharge pressure is controlled by a motorized ball valve. During unloaded operation, the pressure changes during each digital cycle could cause excessive repositions with a pressure-operated water regulating valve. The control algorithm for the motorized ball valve uses an intelligent sampling rate and adjustable pressure thresholds to reduce valve repositions. The valve assembly consists of the brass valve, linkage and actuator.

The valve actuator operates on 24VAC power and is controlled by a 2-10VDC proportional control signal. The valve will move from fully open to fully closed in 60 seconds. At 2VDC, the valve is closed; at 10VDC, the valve is fully open. There is a 20-second delay to position the motorized ball valve before starting the compressor.

Control Method

The control utilizes an upper and lower pressure threshold with a 35psi (241kPa) deadband to reduce valve movement. If the liquid pressure is between the upper and lower threshold, the valve remains at the current position. If the liquid pressure exceeds the upper threshold the valve opens, and if the pressure falls below the lower threshold the valve closes. There are multiple adjustment bands to ease discharge pressure back into control range.

Page 46

4.4.2 Adjustment

Both pressure thresholds can be shifted simultaneously over a 50psi (345kPa) range (the 35psi [241kPa] differential remains constant). The ball valve setpoint offset parameter in the Liebert iCOM Service menu can be adjusted from 0 to 50 PSI (345 kPa) to raise or lower the control band similar to the pressure adjustment on a water regulating valve. Changing the setpoint offset will adjust the pressure thresholds for both circuits. Units are factory-set at a 30psi (207 kPa) setpoint offset (30psi [207 kPa] above minimum). This results in a 220psiA (1517kPa) lower threshold and a 255psiA (1758kPa) upper threshold pressure.

4.4.3 Startup

The setpoint offset is adjusted to the minimum value during startup, then changes to the set value once the compressor reaches normal operating pressures. Changes in fluid temperature could cause pressure changes that do not result in valve movement within the deadband. Fan cycling stats should be set to prevent continuous fluid temperature swings greater than 10

4.4.4 Location

The motorized ball valve is located in the condenser fluid return line. Three-way valves are piped in a mixing arrangement with the common port at the valve outlet.

4.4.5 Manual Control

The valve can be manually set by disconnecting AC power, depressing the manual override button on the valve actuator and adjusting the valve position with the handle. The motorized ball also can be controlled through the Liebert iCOM’s Service menu using manual mode to override the normal control.

Water-Cooled Models—Self-Contained Compressor

°F (5.6°C).

Page 47

Glycol/GLYCOOL-Cooled Models—Self-Contained Compressor

5.0 GLYCOL/GLYCOOL-COOLED MODELS—SELF-CONTAINED COMPRESSOR

5.1 Drycooler Location

The drycooler should be located for maximum security and maintenance accessibility. Avoid groundlevel sites with public access or areas which contribute to heavy snow or ice accumulations. To assure adequate air supply, it is recommended that drycoolers be located in a clean air area, away from loose dirt and foreign matter that may clog the coil. In addition, drycoolers should not be located in the vicinity of steam, hot air or fume exhausts. Also, drycoolers should not be located closer than 3 feet (1 meter) from a wall, obstruction or adjacent unit.

5.2 Drycooler Installation

For roof installation, mount drycoolers on steel supports in accordance with local codes. To minimize sound and vibration transmission, mount steel supports across load bearing walls. For ground installation, a concrete pad will provide adequate support. Drycooler legs have mounting holes for securing the drycooler to steel supports or concrete pad.

5.3 Electrical Connections

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.

Use voltmeter to make sure power is turned off before making any electrical connections.

5.3.1 Line Voltage

Line voltage electrical service is required for all drycoolers at the location of the drycooler. This power supply does not have to be the same voltage as the indoor unit. This separate power source may be 208, 230, 460, or 575 V, 60 Hz; or 200, 230, or 380/415 V, 50 Hz. The disconnect switch is factory-supplied and mounted in the electric panel.

5.3.2 Low Voltage

A control interlock between the drycooler and the indoor unit is required and is connected between 70 and 71 in the handy box of the indoor unit and the pump and drycooler control box of the drycooler. NEC Class 1 wiring is required.

5.3.3 Pump and Drycooler

All wiring to the pump and drycooler from the control box should be done in accordance with the electrical schematic on the inside lid of the drycooler control box and with local and national codes.

Page 48

5.4 Glycol Piping

These guidelines apply to the field leak checking and fluid requirements for field piping systems.

General Guidelines

• Equipment damage and personal injury can result from improper piping installation, leak checking, fluid chemistry and fluid maintenance.

• Follow local piping codes, safety codes.

• Qualified personnel must install and inspect system piping.

• Contact a local water consultant regarding water quality, corrosion protection and freeze protection requirements.

• Install manual shutoff valves at the supply and return line to each indoor unit and drycooler to permit routine service and emergency isolation of the unit.

CAUTION

Risk of frozen fluids. Can cause equipment damage and building damage. Freezing system fluids can rupture piping. Complete system drain-down cannot be ensured.

When the field piping or unit may be exposed to freezing temperatures, charge the system with the proper percentage of glycol and water for the coldest design ambient.

Automotive antifreeze is unacceptable and must NOT be used in any glycol fluid system.

CAUTION

Risk of corrosion. Can cause equipment damage. Read and follow individual unit installation instructions for precautions regarding fluid

system design, material selection and use of field-provided devices. Liebert systems contain iron and copper alloys that require appropriate corrosion protection.

Contact a local water consultant regarding water quality, corrosion and freeze protection requirements.

Water chemistry varies greatly by location, as do the required additives, called inhibitors, that reduce the corrosive effect of the fluids on the piping systems and components. The chemistry of the water used must be considered, because water from some sources may contain corrosive elements that reduce the effectiveness of the inhibited formulation. Preferably, surface waters that are classified as soft and are low in chloride and sulfate ion content should be employed. Proper inhibitor maintenance must be performed in order to prevent corrosion of the system. Consult glycol manufacturer for testing and maintenance of inhibitors.

Commercial ethylene glycol (Union Carbide Ucartherm, Dow Chemical Dowtherm SR-1 and Texaco E.G. Heat Transfer Fluid 100), when pure, is generally less corrosive to the common metals of construction than water itself. It will, however, assume the corrosivity of the water from which it is prepared and may become increasingly corrosive with use if not properly inhibited.

Glycol/GLYCOOL-Cooled Models—Self-Contained Compressor

CAUTION

Risk of oxide layer formation. Can cause equipment damage.

Idle fluid allows the collection of sediment that prevents the formation of a protective oxide layer on the inside of tubes. Keep unit switched ON and system pump operating.

Page 49

Glycol/GLYCOOL-Cooled Models—Self-Contained Compressor

NOTICE

Risk of debris or precipitate clogging pipes. Can cause equipment damage. Galvanized pipe must not be used in or with systems or units that contain glycol. The

phosphates in the inhibitor can react with the zinc in the galvanized pipe, precipitating an insoluble material that can eventually foul the system.

Fluid-cooled condensers have small internal flow passages. To avoid clogging and other resulting system operation problems, install a 16-20 mesh filter in the fluid supply line to the indoor unit. The filter should be located where it can be easily serviced or replaced.

Do not install unit on open loop systems. Debris carried by the fluid will clog the brazed plate condenser.

NOTICE

Risk of improper installation. Can cause equipment or structural damage. Supply and return lines must be supported in a way that keeps their weight from bearing on

the piping of the unit, drycooler or pumps. Failure to support piping can strain the equipment’s structural integrity.

A relief valve must be installed in the system to avoid the possibility of burst pipes. This valve may be obtained from the supplier as an option or obtained from another vendor.

Emerson recommends installing manual service shut-off valves at the supply and return connections to each unit. This enables routine service and/or emergency isolation of the unit. In addition, multiple pump packages require a check valve at the discharge of each pump to prevent back flow through the standby pump(s).

To facilitate filling, installation of hose bibs at the lowest point of the system is recommended.

Consideration of the minimum glycol temperature to be supplied from the drycooler will determine if the need exists to insulate the glycol supply and return lines. Insulation will prevent condensation on the glycol lines in low ambient conditions.

All fluid piping must comply with local codes. Care in sizing pipes will help reduce pumping power and operating costs.

Table 13 Room dew point temperatures

Dry Bulb

°F (°C)

70 (21.1) 70 (21.1)

72 (22.2) 72 (22.2)

75 (23.8) 75 (23.8)

* Minimum glycol temperature before condensation will occur.

Wet Bulb

°F (°C)

57.2 (14.0)

58.5 (14.7)

58.9 (24.9)

60.0 (15.5)

61.2 (16.2)

62.5 (16.9)

Relative

Humidity

45 50

Dew Point*

°F (°C)

48.0 (8.9)

50.5 (10.3)

50.0 (10.0)

52.4 (11.3)

55.0 (12.7)

Page 50

Glycol/GLYCOOL-Cooled Models—Self-Contained Compressor

5.4.1 Expansion Tanks, Fluid Relief Valves and Other Devices

An expansion tank must be provided for expansion and contraction of the fluid due to temperature change in this closed system. Vents are required at system high points to vent trapped air when filling the system. A relief valve is a also a necessary piping component.

Depending on the complexity of the system, various other devices may be specified. Pressure gauges, flow switches, automatic air separator, tempering valves, standby pumps, sensors for electrical controls, and flow switches are just a few of these devices.

NOTICE

Risk of freezing temperatures. Can cause equipment and piping damage. Immediately following the use of water for leak testing or system cleaning, charge the tested

system with the proper percentage of glycol and water for your coldest design ambient. Complete system drain-down cannot be assured and damage to the system could result from freezing of residual water.

5.5 Filling Instructions

5.5.1 Preparing the System for Filling

It is important to remove any dirt, oil or metal filings that may contaminate the cooling system piping in order to prevent contamination of the fresh glycol solution and fouling of the drycooler piping. The system should be flushed thoroughly using a mild cleaning solution or high-quality water and then completely drained before charging with glycol. Cleaning new systems is just as important as cleaning old ones. New systems can be coated with oil or a protective film; dirt and scale are also common. Any residual contaminants could adversely affect the heat transfer stability and performance of your system. In many cases, in both old and new systems, special cleaners are needed to remove scale, rust and hydrocarbon foulants from pipes, manifolds and passages. Clean heat transfer surfaces are important in maintaining the integrity of the heating/cooling system. For more information on cleaners and degreasers, contact your sales representative. Follow the manufacturer's instructions when using these products.

Calculate the internal volume of the system as closely as possible. See Table 14 and Table 16 for unit volumes. Use volume in Table 15 for glycol piping volumes.

Table 14 Indoor unit glycol volume approximate gallons (liters) max.

Model (50 Hz) Glycol-Cooled GLYCOOL

046WG/(045WG) 1.2 (4.5) —

071WG/(070WG) 2.0 (7.5) —

061G/(058G) — 4.0 (15.1)

Table 15 Volume in standard Type “L” copper piping

Diameter (in.) Volume

Outside Inside Gal/Ft L/M

1/2 0.123 0.008 0.01

5/8 0.555 0.012 0.15

3/4 0.666 0.018 0.22

7/8 0.785 0.025 0.31

1-1/8 1.025 0.043 0.53

Page 51

5.5.2 Glycol Solutions

NOTE

Glycol solutions should be considered for protection of the coil. When it is not used, damage can occur from either freezing or corrosion from water.

When considering the use of any glycol products in a particular application, you should review the latest Material Safety Data Sheets and ensure that the use you intend can be accomplished safely. For Material Safety Data Sheets and other product safety information, contact the supplier nearest you. Before handling any other products mentioned in the text, you should obtain available product safety information and take necessary steps to ensure safety of use.

NOTICE

Risk of improper handling of glycol. Can cause environmental damage and violate national, regional and local laws.

When mishandled, glycol products pose a threat to the environment. Before using any glycol products, review the latest Material Safety Data Sheets and ensure that you can use the product safely.

Glycol manufacturers request that the customer read, understand and comply with the information on the product packaging and in the current Material Safety Data Sheets. Make this information available to anyone responsible for operation, maintenance and repair of the drycooler and related equipment.

No chemical should be used as or in a food, drug, medical device, or cosmetic, or in a product or process in which it may contact a food, drug, medical device, or cosmetic until the user has determined the suitability and legality of the use. Since government regulations and use conditions are subject to change, it is the user's responsibility to determine that this information is appropriate and suitable under current, applicable laws and regulations.

Glycol/GLYCOOL-Cooled Models—Self-Contained Compressor

NOTICE

Risk of using improper cooling agent. Can cause reduced cooling performance and damage to equipment and piping.

Proper formulations of inhibited formula ethylene glycol and propylene glycol must be used in the Challenger 3000 system. Automotive antifreeze is unacceptable and must NOT be used.

Typical inhibited formula ethylene glycol and propylene glycol manufacturers and suppliers are Union Carbide (Ucartherm) or Dow Chemical (Dowtherm SR-1, Dowfrost). These glycols are supplied with corrosion inhibitors and do not contain a silicone anti-leak formula. Commercial ethylene glycol, when pure, is generally less corrosive to the common metals of construction than water itself. Aqueous solutions of these glycols, however, assume the corrosivity of the water from which they are prepared and may become increasingly corrosive with use if not properly inhibited.

There are two basic types of additives: corrosion inhibitors and environmental stabilizers. The corrosion inhibitors function by forming a surface barrier that protects the metals from attack. Environmental stabilizers, while not corrosion inhibitors in the strictest sense of the word, decrease corrosion by stabilizing or favorably altering the overall environment. An alkaline buffer such as borax is a simple example of an environmental stabilizer since its prime purpose is to maintain an alkaline condition (pH above 7).

The percentage of glycol to water must be determined by using the lowest design outdoor temperature in which the system is operating. Table 16 indicates the solution freeze point at several concentration levels of ethylene glycol. Propylene glycol concentrations should be 1% higher than the ethylene glycol table values to find the freeze point. For example, 41% propylene glycol freezes at -10°F.

Page 52

Table 16 Ethylene glycol concentrations

% Glycol by Volume 0 * 10 20 30 40 50 Freezing Point °F (°C) 32 (0) 25 (-3.9) 16 (-8.9) 5 (-15.0) -10 (-23.3) -32 (-35.5) Apparent Specific Gravity

@ 50°F (10°C)

* A minimal amount of glycol should be considered for inhibitive coil protection.

NOTICE

Risk of corrosion from water impurities. Can cause equipment damage. The quality of water used for dilution must be considered because water may contain

corrosive elements which reduce the effectiveness of the inhibited formulation. Water that is classified as soft (low in chloride and sulfate ion content less than 100 parts per million each) should be used.

5.5.3 Filling the System

Installation of hose bibs at the lowest point of the system is recommended. When filling a glycol system keep air to a minimum. Air in glycol turns to foam and is difficult and time-consuming to remove. (Anti-foam additives are available and may be considered.) Open all operating systems to the loop. With the top vent(s) open, fill the system from the bottom of the loop. This will allow the glycol to push the air out of the top of the system, minimizing trapped air. Fill to approximately 80% of calculated capacity. Fill slowly from this point, checking fluid levels until full.

Glycol/GLYCOOL-Cooled Models—Self-Contained Compressor

1 1.014 1.028 1.042 1.057 1.071

NOTE

For glycol solution preparation and periodic testing, follow manufacturer's recommendations. Do not mix products of different manufacturers.

Page 53

Figure 23 Drycoolers and pump packages

Notes

1. Single pump packages are 17-1/4" (438 mm) wide. Dual pump packages ar 32-1/4" (819 mm) wide.

2. Mounting holes are 15-1/4" (387 mm) apart on single pump packages and 301/4" (768 mm) apart on dual pump packages.

3. Connection sizes apply to primary pump supplier.

DRYCOOLER

Provided on

dual pump

package only

30-1/4"

(768mm)

19"

(483mm)

43-3/16"

(1097mm)

43-9/16"

(1105mm)

37-7/8"

(1095mm)

GLYCOL PUMP PACKAGE

See Note 1

3/4"

(19mm)

37-11/16"

(957mm)

1/2" (12.7mm) diameter anchor bolts (typ)

PUMP PACKAGE

MOUNTING ANGLES

TYPICAL

FOOTPRINT

UNIT ANCHOR PLAN

See Table 18 for keys to dimensions “A”, “B” and “C”.

See Table 17 for keys to dimensions “A”, “B” and “C”.

1/2" diameter holes for mounting (4 typ)

Note: Angles located

inside, bottom of pump package. View used for mounting reference.

(25.4mm)

1-3/4"

(25.4mm)

1-3/4"

(25.4mm)

4-1/4"

(25.4mm)

4-1/4"

(25.4mm)

For expansion tank dimensions, see Figure 24 on page -48.

Glycol/GLYCOOL-Cooled Models—Self-Contained Compressor

Page 54

Glycol/GLYCOOL-Cooled Models—Self-Contained Compressor

1/2" FPT

Fitting

1/2" FPT

Fitting

6-13/16"

(173mm)

17-1/4"

(438.2mm)

30-1/2

(774.7mm)

(101.6mm)

2-3/4"

(69.9mm)

SL-10065 Pg. 7B SL-10070 Pg. 6B

O 9"

(228.6mm)

O 1/2" (12.7mm) 8 holes

EXPANSION TANK

8.8 gal. (33.3L)

1-1/2"

(38.1mm)

1-1/2" (38.1mm)

1" (25.4mm)

(25.4mm)

6-1/8"

(155.6mm)

(177.8mm)

(76.2mm)

2-1/2"

(63.5mm)

Figure 24 Pump packages—expansion tank

Table 17 Mounting hole dimensional data

PUMP PACKAGE

SINGLE (0.75 - 7.5 Hp) 15-1/4 (387.4) 2-1/2 (63.5) 22-1/2 (571.5)

DUAL (0.75 - 5 Hp) 30-1/4 (768.4) 2-1/2 (63.5) 22-1/2 (571.5)

in (mm)

Table 18 Drycooler data

Drycooler

Model

-069 1 410 (186) 1-1/4 51-1/2 (1308) 44 (1118) 42 (1067) 2.4 (9.2)

-092 1 430 (195) 1-1/2 51-1/2 (1308) 44 (1118) 42 (1067) 3.7 (13.9)

-109 1 450 (204) 2 51-1/2 (1308) 44 (1118) 42 (1067) 4.9 (18.6)

-112 1 470 (213) 2 51-1/2 (1308) 44 (1118) 42 (1067) 5.8 (22.0)

-139 2 565 (256) 2 91-1/2 (2324) 84 (2134) 82 (2083) 4.8 (18.2)

-197 2 605 (274) 2 91-1/2 (2324) 84 (2134) 82 (2083) 9.0 (34.1)

No.

No. of

Fans

Weight

lb (kg)

Conn. Sizes

(Suct. & Disc.) in.

“A” Dimension

in. (mm)

“B” Dimension

in. (mm)

“C” Dimension

in. (mm)

Table 19 Glycol pump data*

Pump

3/4 60 1-1/4 3/4

1-1/2 60 1-1/4 3/4

260 1-1/4 3/4

360 1-1/2 1

5 60 1-1/2 1-1/4

3/4 50 1-1/4 3/4

150 1-1/4 3/4

1-1/2 50 1-1/4 3/4

250 1-1/4 3/4

3 50 1-1/2 1-1/4

* Connection sizes apply to primary pump supplier

Pump Suction

Connection in.

Pump Discharge

Connection in. Hp Hz

Coil Internal

Volume gal. (l)

Page 55

Glycol/GLYCOOL-Cooled Models—Self-Contained Compressor

Glycol Pump

Pump Housing

Unions*

Isolation Valves*

Expansion Val ve

Drycooler Electric Box

Drycooler Coil

Fluid Return to Pump

Fluid Supply from Pump

Unions*

Field-Supplied Reducers Required on 3-Ton Units

Fill*

Expansion Tank Field-Installed at Highest Point in System

Expansion Port*

Hose Bibs*

Flow Regulating Val ve*

Pressure Port*

Sight Glass

Filter Dryer

Evaporator Coil

Sensing Bulb

External Equalizers

Hot Gas Bypass Valve

Scroll Compressor

Service Valves

Hot Gas Bypass Solenoid Valve

Hot Gas Bypass

Tube in Tube Condenser

Bypass Val ve

2-Way Water Regulating Valve

Fluid Return from Unit

Fluid Supply to Unit

Fluid Return from Unit

Fluid Supply to Unit

Isolation Valves*

Hose Bibs*

3-Way Water Regulating Valve (optional)

FACTORY PIPING

FIELD PIPING

*Components are not supplied by Liebert but are recommended for proper circuit operation and maintenance

DPN000361 Rev. 02

Figure 25 General arrangement—Glycol-cooled models with scroll compressor

Page 56

Glycol/GLYCOOL-Cooled Models—Self-Contained Compressor

Digital Solenoid Valve

Glycol

Pump Housing

Unions*

Isolation Valves*

Expansion Valve

Drycooler Electric Box

Drycooler Coil

Fluid Return to Pump

Fluid Supply from Pump

Unions*

Fill*

Expansion Tank Field-Installed at Highest Point in System.

Expansion Port*

Air Vents* at Top of Risers

Flow Regulating

Valve* Pressure Port*

Sight Glass

Filter Dryer

Evaporator Coil

Sensing Bulb

External Equalizer

Digital Compressor

Service Valves

Tube in Tube Condenser

2-Way Motorized Ball Valve

Fluid Return from Unit

Fluid Supply to Unit

Isolation Val ves*

Hose Bibs*

Fluid Supply to Unit

Fluid Return From Unit

3-Way Motorized Ball Valve (optional)

FACTORY PIPING

*Components are not supplied by Liebert but are recommended for proper circuit operation and maintenance.

FIELD PIPING

DPN001722 Rev. 0

Field-Supplied Reducers Required on 3 Ton Units

To i C OM C o n t ro l

To i C O M C o n tr o l

Pump

Figure 26 General arrangement—Glycol-cooled models with digital scroll

Page 57

Glycol/GLYCOOL-Cooled Models—Self-Contained Compressor

Field-Supplied Reducers Required on 3-Ton Units

Pump Housing

Pump

Unions*

Isolation Valves*

Expansion Valve

Evaporator Coil

Drycooler Coil

Drycooler Electric Box

Pressure Port*

Hose Bib*

Fill*

Fluid Return to Pump

Fluid Supply from Pump

Air Vents* at Top of Risers

Flow Regulating Valve*

Sight Glass

Sensing Bulb

External Equalizers

Hot Gas Bypass Valve

Scroll Compressor

Service Valves

Filter Dryer

Hot Gas Bypass

Econ-O-Coil

3-Way Water Regulating Valve

3-Way Chilled Glycol Valve

Valve Actuator

Econ-O-Cycle Comparator

Econ-O-Coil Circuit

Tube in Tube Condenser

Fluid Supply to Unit

Fluid Return from Unit

Isolation Valves*

Hose Bibs*

FACTORY PIPING

FIELD PIPING

*Components are not supplied by Liebert but are recommended for proper circuit operation and maintenance.

Expansion Tank Field-Installed at Highest Point in System

DPN000379 Rev. 03

Glycol

Figure 27 General arrangement—GLYCOOL models with scroll compressor

Page 58

Glycol/GLYCOOL-Cooled Models—Self-Contained Compressor

Digital Solenoid Val v e

Pu m p Housing

Gl ycol

Pu m p

Unions*

Isolation Val v e s*

Ex p an si on Val v e

Ev a p o r a t o r Co i l

Drycooler Coi l

Drycooler El e c t r i c Bo x

Unions*

Pre ssu re Po r t *

Hose Bi b *

Fill*

Fl u id Re t ur n t o Pu m p

Fl u i d Supply from Pu m p

Flow Regul at ing Valve*

Pr essu re Po r t *

Si g h t Gl a ss

Se n s i n g Bu l b

Ex t e rn al Eq ualizer

Se rv i c e Val v es

Fi l t e r Dryer

Econ-O-Coil

3-Way Chilled Glycol Valve

3-Way Mot ori zed Ba l l Va lv e

Val v e Actu ator

Econ-O-Cycle Comparator

Ec on - O- Co il Ci rcui t

Tu b e in Tu be Cond enser

Flui d Su p p l y t o Unit

Fl u i d Re t u r n from Uni t

Isolati on Val v es*

Hose Bib s*

FA CTORY PIPI N G

FIELD PI PI N G

*Components are not supplied b y Liebert but are recommended for proper circuit o p eration and mai n te nan ce.

Expansion Tank Field-Installed at Highest Point in System

DPN001724 Re v. 0

Field-Supplied Re d u c e r s Required on 3-Ton Units

To iCOM Control

Digital Co mp r esso r

Figure 28 General arrangement—GLYCOOL models with digital scroll compressor

Page 59

Glycol/GLYCOOL-Cooled Models—Self-Contained Compressor

5.5.4 Motor Ball Valve—Digital Scroll Compressors

Refer to 4.4 - Motorized Ball Valve—Digital Scroll Compressors for details on the motorized ball valve.

5.6 Condenser

The condenser is designed to operate in conjunction with a drycooler. The maximum coolant pressure is 350 psig (2413 kPa).

5.7 Glycol Regulating Valve

The glycol regulating valve automatically regulates the amount of coolant necessary to remove the heat from the refrigeration system, permitting more fluid to flow when load conditions are high and less fluid to flow when load conditions are low. The valve consists of a brass body, balance spring, valve seat, valve disc holders, capillary tube to discharge pressure, and adjusting screw.

5.7.1 Standard Valve - 150psig (1034kPa) System for 3 & 5-Ton Units (Johnson Controls Valve) High Pressure Valve - 350psig (2413kPa) System for 5-Ton Units (Johnson Controls Valve)

For details, refer to 4.3.1 - Standard Valve - 150psig (1034kPa) System for 3 & 5-Ton Units (Johnson Controls Valve) High Pressure Valve - 350psig (2413 kPa) System for 5-Ton Units (Johnson Controls Valve).

5.7.2 High Pressure Valve - 350 psig (2413 kPa) System for 3-Ton Units (Metrex Valve)

For details, refer to 4.3.2 - High Pressure Valve - 350 psig (2413 kPa) System for 3-Ton Units (Metrex Valve).

5.7.3 Testing Valve Function

When the refrigeration system has been off for approximately 10-15 minutes, the coolant flow should stop.

Should the coolant continue to flow, the valve is either improperly adjusted (head pressure is too low) or the pressure sensing capillary is not connected properly to the condenser.

Table 20 Refrigerant control settings psi (kPa)

Low Pressure

Cut Out

20 (137.9) 65 (448.2) 400 (2758)

Low Pressure

Cut In

High Pressure

Cut Out

Page 60

6.0 CHILLED WATER MODELS

FACTORY PIPING

SL-11899 Pg. 5

Air

Flow

Air

Flow

Chilled Water Coil

Chilled

Water

Coil

Bleed Val ve

Val ve

Actuator

Val ve

Actuator

Val ve

2-Way

Chilled

Water

Val ve

Flow

Switch

(optional)

Chilled

Water

Supply

Chilled

Water

Supply

Chilled

Water

Return

Chilled

Water

Return

Hose Bibs *

Shutoff

Shutoff Val v e s *

3-WAY VALVE

2-WAY VALVE

*Components are not supplied by Liebert but are recommended for proper circuit operation and maintenance.

FIELD PIPING

3-Way

Chilled

Water

6.1 Piping Considerations

Manual shut-off valves should be installed at the supply and return lines to each unit. This will provide for routine service and emergency isolation of the unit.

Consideration of the minimum water temperature to be supplied from the chiller will determine if the need exists to insulate supply and return lines. Insulation will prevent condensation on the supply and return lines.

To provide for the emergency of water leaks and the consequences of sub-floor flooding, floor drains should be provided with wet traps or a water detection system, such as a Liebert Liqui-tect, that is installed near the base of the unit or below the elevated floor.

Figure 29 Chilled water general arrangement - Upflow (BU)

Chilled Water Models

Page 61

Figure 30 Chilled water general arrangement - Downflow (BF) models

SL-11899 Pg. 6

Flow Switch (optional)

Chilled Water Return

Chilled Water Supply

Chilled Water Return

Chilled Water Coil

2-Way Chilled Water Valve

Chilled Water Supply

Hose Bibs *

3-WAY VALVE

2-WAY VALVE

3-Way Chilled Water Valve

Air Flow

Valve Actuator

Valve Actuator AB

Bleed Valve

Hose Bibs *

Shutoff Valves *

*Components are not supplied by Liebert, but are recommended for proper circuit operation and maintenance.

FACTORY PIPING FIELD PIPING

Chilled Water Models

Page 62

7.0 SPLIT SYSTEM MODELS

Three condensing unit styles are available: two air-cooled and one water/glycol-cooled condensing unit.

7.1 Location Considerations

7.1.1 Air-Cooled Condensing Units

To assure an adequate air supply, it is recommended that all condensing units be located in a clean air area, away from loose dirt and foreign matter that may clog the coil.

The outdoor condensing unit must not be located in the vicinity of steam, hot air, or fume exhausts or closer than 18" from a wall, obstruction, or adjacent unit.

The outdoor condensing unit should be located for maximum security and maintenance accessibility. Avoid ground-level sites with public access or areas that will contribute to heavy snow accumulations. Do not allow the discharge air to blow into another condensing unit.

The outdoor condensing unit must be located at the same level or above the indoor Liebert Challenger 3000 unit. It must NOT be located below the indoor unit.

A solid base, capable of supporting the weight of the condenser and at least 2" (51 mm) higher than the surrounding grade and at least 2" (51 mm) larger than the condensing unit base dimensions, should be installed at the pre-determined location. In snow areas, a base of sufficient height to clear snow accumulation must be installed.

Split System Models

The centrifugal fan air-cooled condensing unit may be located above the dropped ceiling or any remote indoor area. If noise is of concern, the condensing unit should be located away from personnel. Normal operating sound may be objectionable if the condensing unit is placed near quiet work areas.

To mount the unit in the ceiling, refer to 7.5.1 - Installing the Indoor Condensing Unit for hanging guidelines and to Figure 35 - Detail of ceiling hanging bracket for dimensional data.

7.1.2 Water/Glycol-Cooled Condensing Units

The condensing unit may be located above the dropped ceiling or any remote indoor area. If noise is of concern, the condensing unit should be located away from personnel. Normal operating sound may be objectionable if the condensing unit is placed near quiet work areas. To mount the unit the in ceiling, refer to 7.5.1 - Installing the Indoor Condensing Unit.

7.2 Electrical Connections

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.

Use voltmeter to make sure power is turned off before making any electrical connections.

7.2.1 Line Voltage

Line voltage electrical service is required for all condensing units at the location of the condensing unit. This power supply does not have to be the same voltage as the indoor unit. This separate power source may be 208, 230, 460 or 575V, 60 Hz; or 200, 230, or 380/415 V, 50 Hz. A disconnect switch is required and must be mounted per local and national codes to isolate the unit for maintenance.

Page 63

7.2.2 Low Voltage

The control cable between the condensing unit and the evaporator unit is connected between terminals 1,2 and 3 on the terminal strip in the evaporator unit and the condensing unit control box. A fourth wire is required on systems with hot gas bypass. NEC Class 1 wiring is required. Glycol-cooled units also require a two-wire control connection to the drycooler and pump package.

7.3 Piping Considerations

7.3.1 Refrigerant Loop

NOTICE

Risk of improper refrigerant charge. Risk of equipment damage, environmental degradation and violation of national, state and local law.

Follow all applicable codes for handling refrigerant. R22 and R407C are similar in properties—proper safety equipment and proper refrigeration

tools are required on both types. Check unit nameplate for correct refrigerant type before topping off or recharging a system.

R407C refrigerant must be introduced and charged from the cylinder only as a liquid.

NOTICE

Risk of improper piping installation. Can cause contamination of hygroscopic oil with water. When installing field piping, care must be taken to protect all refrigerant lines from the

atmosphere, especially when using refrigerants, such as R407C which requires use of polyol ester oils. Do not allow the piping to stand open to air for more than 15 minutes. Units designed for R407C have a compressor that contains polyol ester oil, which is very hygroscopic; that is, it quickly absorbs water from the air. The longer the compressor piping is left open to air, the harder it will be to fully evacuate. If left open too long, the polyol ester oil may need to be replaced before achieving the required vacuum level.

Split System Models

NOTE

Complete all piping and evacuate lines before connecting quick connects when using an optional sweat adapter kit and field installed hard piping.

Follow all proper brazing practices including a dry nitrogen purge to maintain system cleanliness.

All split systems require two refrigerant lines (an insulated copper suction line and a copper liquid line) between the evaporator and the condensing unit.

Two possible methods exist for installing the copper suction and liquid lines.

1. Using an optional Sweat Adapter Kit and hard piping between the two units.

2. Using optional pre-charged line sets (for 3-ton models only).

All refrigeration piping should be installed with high temperature brazed joints. Prevailing good refrigeration practices should be employed for piping supports, leak testing, evacuation, dehydration, and charging of the refrigeration circuits. The refrigeration piping should be isolated from the building by the use of vibration isolating supports.

It is important to handle the pre-charged lines for 3-ton units with care so they will not get kinked or damaged. Use tube benders and make all bends before making connections to either end. Coil any excess tubing in a horizontal plane with the slope of the tubing toward the condensing unit.

To prevent tube damage when sealing openings in walls and to reduce vibration transmission, use a soft flexible material to pack around the tubes.

When installing remote condensing units mounted above the evaporator, the suction gas line should be trapped at the evaporator. This trap will retain refrigerant oil in the off cycle. When the unit starts, oil in the trap is carried up the vertical riser and returns to the compressor.

Page 64

Split System Models

Refrigerant charge requirements: Total refrigerant charge will be required only if units are evacuated during installation or maintenance. Total refrigerant charge = evaporator + lines + condensing unit.

NOTE

All condensing units and 3-ton evaporator units are fully charged with refrigerant. All 5 ton evaporator units include a nitrogen holding charge only. See Table 21 for field charge required. If field-supplied refrigerant piping is installed, refrigerant must be added to the system.

Once all piping is complete, check for leaks and dehydrate the field piping as follows:

1. Pressurize the field piping to 150 PSIG (1034 kPa) using dry nitrogen with a trace of refrigerant.

Check system for leaks with a suitable leak detector.

2. After completion of leak testing, release the test pressure (per local code) and pull a deep vacuum

on the field piping with a suitable pump.

3. After 15 minutes, check the pressure readings and, if they have not changed, break vacuum with

dry nitrogen. Pull a second vacuum to 250 microns or less. Recheck the pressure after 15 minutes.

Table 21 Unit refrigerant charge

R407C Charge

Model

BF/BU 036E 0.5 (0.2) PF_042A-_H 25.8 (11.7)

BF/BU 035E 0.5 (0.2) PF_041A-_H 25.8 (11.7)

BF/BU 060E 0.8 (0.4) PF_067A-_L 25.8 (11.7)

BF/BU 059E 0.8 (0.4) PF_066A-_L 25.8 (11.7)

MC_40/39A 12.9 (5.8) PF_Z67A-_L 50.1 (22.7)

MC_65/64A 26.1 (11.8) PF_Z66A-_L 50.1 (22.7)

PF_042A-_L 12.9 (5.8) PF_067A-_H 50.1 (22.7)

PF_041A-_L 12.9 (5.8) PF_066A-_H 50.1 (22.7)

PF_Z42A-_L 25.8 (11.7) MC_44/43W 3.4 (1.5)

PF_Z41A-_L 25.8 (11.7) MC_69/68W 5.9 (2.7)

lb (kg) lb (kg)

Model

R407C Charge

Table 22 Line charges - refrigerant per 100 ft. (30 m) of Type “L” copper tube

R407C

Liquid Line

O.D.

1/2" 7.3 (3.3) -

5/8" 11.7 (5.3) 0.4 (0.2)

7/8" 24.4 (11.1) 1.0 (0.4)

1-1/8" 41.6 (18.9) 1.7 (0.7)

1-3/8" 63.3 (28.7) 2.7 (1.1)

lb (kg)

Suction Line

lb (kg)

Table 23 Recommended refrigerant lines (R407C) sizes OD copper

3.5-Ton

036E (035E)

Equivalent Feet (m)

0-50 (0-15) 7/8" 1/2" 1-1/8" 1/2"

51-100 (16-30) 1-1/8" 1/2" 1-1/8" 5/8"

101-150 (31-45) 1-1/8" 5/8" 1-3/8" 5/8"

Suction Liquid Suction Liquid

5-Ton

060E (059E)

Page 65

Table 24 Line coupling sizes

Evaporator

Condensing unit

Suction Line Piping Condensing unit above evaporator Traps recommended at the base of riser and every 25 feet (7.6m) of vertical rise.

Model

(Tons)

33/8 #610-12 5 1/2 & 5/8 #10 35-45 3 7/8 #11 35-45 5 1-1/8 #12 50-65

Line Size

OD Cu, in.

Table 25 Equivalent lengths (feet) for various pipe fittings

Copper Pipe

OD in.

1/2 0.8 1.3 0.4 2.5 0.26 7.0 4.0 5/8 0.9 1.4 0.5 2.5 0.28 9.5 5.0 3/4 1.0 1.5 0.6 2.5 0.3 12.0 6.5

7/8 1.45 1.8 0.8 3.6 0.36 17.2 9.5 1-1/8 1.85 2.2 1.0 4.6 0.48 22.5 12.0 1-3/8 2.4 2.9 1.3 6.4 0.65 32.0 16.0 1-5/8 2.9 3.5 1.6 7.2 0.72 36.0 19.5

Refrigerant trap = 4 times equivalent length of pipe per this table

90 Degree

Elbow Copper

Figure 31 Refrigerant piping diagram

Coupling

Size

90 Degree

Elbow Cast

Torque

lb-ft.

45 Degree

Elbow Tee

Gate

Valve

Globe

Valve

Split System Models

Angle

Valve

7.3.2 Quick Connect Fittings

NOTE

When hard piping is used, complete all piping and evacuate lines before connecting quick connects.

Be especially careful when connecting the quick connect fittings. Read through the following steps before making the connections.

1. Remove protector caps and plugs.

2. Carefully wipe coupling seats and threaded surfaces with a clean cloth.

3. Lubricate the male diaphragm and synthetic rubber seal with refrigerant oil.

4. Thread the coupling halves together by hand to ensure that the threads mate properly.

5. Tighten the coupling body hex nut and union nut with the proper sized wrench until the coupling bodies “bottom out” or until a definite resistance is felt.

6. Using a marker or pen, make a line lengthwise from the coupling union nut to the bulkhead.

7. Tighten the nuts an additional quarter turn; the misalignment of the lines shows how much the coupling has been tightened. This final quarter turn is necessary to ensure that the joint will not leak. Refer to Table 24 for torque requirements.

8. Add charge for the additional piping (refer to Table 22).

Page 66

7.4 Outdoor Air-Cooled Condensing Units

Shaded area indicates

a minimum clearance

of 18" (457mm) for

proper air flow

Shaded area indicates

a minimum clearance

of 18" (457mm) for

proper air flow

Removable (Front) Panel

for access to high-voltage and

low-voltage connections and

refrigeration components

Shaded area indicates

a minimum clearance

of 24" (610mm) for component

access and removal

Removable (Right) Panel for access to refrigeration components

Right Air

Discharge

Left Air

Intake

Fan Rotation

CCW (left side)

SL-11081 Pg. 4

Liquid Line Quick Connect (Male Coupling)

Suction Line Quick Connect (Male Coupling) Except as noted

Electrical Entrance for High-Voltage Connection

Electrical Entrance for Low-Voltage Connection

SL-11081 Pg. 6

UNIT DIMENSIONS (See Table 26)

Figure 32 Outdoor air-cooled condensing unit—horizontal air discharge models

Split System Models

Page 67

Table 26 Horizontal air discharge cabinet and floor planning dimensional data

Model Numbers Dimensional Data in. (mm) Module

Weight

lb (kg) net60 Hz 50 Hz A B C

PFC042A-_L PFC041A-_L

PFH042A-_L —

PFC042A-_H PFC041A-_H

PFH042A-_H —

PFCZ42A-_L PFCZ41A-_L

PFC067A-_L PFC066A-_L

PFH067A-_L —

48 (1219) 31 (787) 18 (457) 241 (109)

53 (1343) 36-1/4 (918) 18 (457) 351 (159)

Table 27 Horizontal air discharge piping and electrical connection data

Model Numbers Dimensional Data in. (mm) Piping Connections in. (mm)

60 Hz 50 Hz A B C D E F G

PFC042A-_L PFC041A-_L

PFH042A-_L —

PFC042A-_H PFC041A-_H

PFH042A-_H PFCZ41A-_L

PFCZ42A-_L —

PFC067A-_L PFC066A-_L

PFH067A-_L —

2 (51) 5-3/4 (146) 8-1/2 (216) 4-3/4 (121) 6-3/4 (171) — 8-1/2 (216)

2 (51) 6 (152) 8-1/2 (216) 4-3/4 (121) 7-3/4 (197) — 8-1/2 (216)

Split System Models

Page 68

Figure 33 Outdoor air-cooled condensing unit—top air discharge models

(51mm)

36-1/8"

(918mm)

25-3/32"

(637mm)

46-7/32"

(1174mm)

4-23/32"

(120mm)

53-3/16"

(1351mm)

4" (typ.)

(102mm)

2" (typ.) (51mm)

(51mm)

32-1/8"

(816mm)

FOOTPRINT

DIMENSIONS

1/2" (13mm) Bolt-Down Holes 6 places

Shaded area indicates

a minimum clearance

of 18" (457mm) for

proper air flow

Shaded area indicates

a minimum clearance

of 18" (457mm) for

proper air flow

Removable (Front) Panel

for access to high-voltage and

low-voltage connections and

refrigeration components

Shaded area indicates

a minimum clearance

of 24" (610mm) for component

access and removal

Right Air

Discharge

Top Air

Discharge

Left Air

Intake

Guard Height

SL-11081 Pg. 5

Suction Line Quick Connect (Male Coupling)

Liquid Line Quick Connect (Male Coupling)

Electrical Entrance for High-Voltage Connection

Electrical Entrance for Low-Voltage Connection

SL-11081 Pg. 7

UNIT DIMENSIONS (see Table 28)

PIPING & ELECTRICAL CONNECTIONS (see Table 29)

Split System Models

Page 69

Split System Models

Table 28 Cabinet and floor planning dimensional data - prop fan condensing modules, top air discharge

Model Numbers Dimensional Data in. (mm) Module

Weight

lb (kg) net60 Hz 50 Hz A B C D

PFC067A-_H PFC066A-_H

53 (1343) 36-1/4 (918) 38-1/2 (978) 5-1/2 (140) 488 (222)PFH067A-_H —

PFCZ67A-_L PFCZ66A-_L

Table 29 Piping and electrical connections - top air discharge

Model Numbers Dimensional Data in. (mm) Piping Connections in. (mm)

60 Hz 50 Hz A B C D E F

PFC067A-_H PFC066A-_H

2 (51) 6 (152) 8-1/2 (216) 4-3/4 (121) 7-3/4 (197) 8-1/2 (216)PFH067A-_H —

PFCZ67A-_L PFCZ66A-_L

Page 70

Figure 34 Electrical field connections, prop fan condensing module

NOTE: Refer to specification sheet for full load amp and wire size amp ratings

SL-11081 Pg. 8

Factory-wired to components on electric panel.

Heat rejection connection. Field supplied 24V NEC class 2 wiring. Wire connections from evaporator module:

1. 24V GND

2. 24V Supply

3. High Pressure Alarm

4. Hot Gas Bypass Connection (only on units with hot gas bypass. If no hot gas bypass, connection is provided in the evaporator module. Connect wire 4 with wire 2 to the 24V supply).

Electric service connection to contactor or terminal block

Single- or 3-phase electric service; not by Liebert

High-voltage electric power supply entrance

Low-voltage electric power supply entrance

Earth ground connection terminal for field wiring.

SL-11081 Pg. 8A

TOP AIR

DISCHARGE MODELS

(5-Ton High Ambient

& 5-Ton Quiet-Line)

HORIZONTAL AIR DISCHARGE MODELS

Single- or 3-phase electric service; not by Liebert

Field-supplied 24V NEC

Class 2 wiring to

evaporator module

Single- or 3-phase electric service; not by Liebert

Field-supplied unit disconnect switch

Field-supplied 24V NEC Class 2 wiring to evaporator module

Split System Models

Page 71

7.5 Centrifugal Air-Cooled Condensing Units

7.5.1 Installing the Indoor Condensing Unit

Refer to drawings for unit dimensions and component locations.

WARNING

Risk of heavy unit falling from supports. Can cause equipment and building damage, injury and death.

Be sure the supporting roof structure is capable of supporting the weight of the unit(s) and the accessories during installation and service. (See Table 30 - Indoor centrifugal condensing unit.)

Be sure to securely anchor the top ends of the suspension rods. Make sure all nuts are tight.

The indoor condensing unit is usually mounted above the ceiling and must be securely mounted to the roof structure. The ceiling and ceiling supports of existing buildings may require reinforcements. Be sure to follow all applicable codes. Use field-supplied threaded suspension rods and 3/8"-16 factory hardware kit.

The indoor condensing unit must be located at the same level or above the Liebert Challenger 3000 unit. It must NOT be located below the Liebert Challenger 3000.

Recommended clearance between ceiling grids and building structural members is unit height plus three inches.

Split System Models

Install the four field-supplied rods by suspending them from suitable building structural members. Locate the rods so that they will align with the four mounting holes in the flanges that are part of the unit base.

Using a suitable lifting device, raise the unit up and pass the threaded rods through the four mounting holes in the flanges that are part of the unit base.

Attach the threaded rods to the unit flanges using the supplied nuts and grommets. (See Figure 35 - Detail of ceiling hanging bracket, Threaded Rod and Hardware Kit Installation). The rubber grommets provide vibration isolation.

1. Use the plain nuts to hold unit in place. Adjust these nuts so that the weight of the unit is supported evenly by the four rods, does not rest on the ceiling grid, and is level.

NOTE

The units must be level in order to operate properly.

2. Use the Nylock nuts to “jam” the plain nuts.

Table 30 Indoor centrifugal condensing unit

Model

MC_40A MC_39A 240 (109)

MC_65A MC_64A 449 (204)

Net Weight

lb (kg)60 Hz 50 Hz

Page 72

Figure 35 Detail of ceiling hanging bracket

3/8" threaded rod (field-supplied)

3/8" hex nut

3/8" washer

Sleeve

Isolator

3/8" fender washer

3/8" hex nut

3/8" hex nut Nylock

Unit base pan (ref)

7.5.2 Ducting

The total external static pressure for the inlet and outlet ducts, including grille, must not exceed

0.5 inches of H

sions.

O. Hood intake dimensions should be the same as the condensing unit duct dimen-

Split System Models

If the condensing unit is located close to the outside of the building, rain hoods must be installed. In addition, install a triple layer bird screen over rain hood openings to eliminate the possibility of insects, birds, water, or debris entering the unit.

Use flexible ductwork or nonflammable cloth collars to attach ductwork to the unit and to control vibration transmission to the building. Attach the ductwork to the unit using the flanges provided. Locate the unit and ductwork so that the return air does not short circuit to the supply air inlet.

Avoid directing the hot exhaust air toward adjacent doors or windows.

Normal operating sound may be objectionable if the condensing unit is placed directly over quiet work areas. Ductwork that runs through a conditioned space or is exposed to areas where condensation may occur must be insulated. Whenever possible, ductwork should be suspended using flexible hangers. Ductwork should not be fastened directly to the building structure. In applications where the ceiling plenum is used as the heat rejection domain, the discharge air must be directed away from the condensing unit air inlet and a screen must be added to the end of the discharge duct to protect service personnel.

For multiple unit installations, space the units so that the hot condensing unit exhaust air is not directed toward the air inlet of an adjacent unit.

Table 31 Airflow CFM (CMH)

3-Ton 5-Ton

60 Hz 2000 (3398) 3500 (5947)

50 Hz 1650 (2800) 3500 (5947)

Page 73

Split System Models

Customer-supplied threaded rods for  module support from ceiling (typ. 4)

SL-11085 Pg. 4

Air Outlet

Duct Connection

Air Outlet

Duct Dimension

Note:Unit is evenly spaced in reference to threaded for centers.

PIPING CONNECTIONS

DIMENSIONAL DATA

Blower Motor Service Access Panel on Bottom of Unit Minimum Clearance 33" (838mm) for Component Access and Removal.

50-1/4" (1276mm)

Overall Dimension

46-1/2" (1181mm)

Cabinet Dimension

48-1/4" (1225mm)

Threaded Rod Centers

21-1/2" (546mm )

Cabinet Dimension

22-1/2"

(572mm)

Cabinet

Dimension

19-1/2" (495mm)

Threaded Rod

Centers

Duct Flange

2-1/4"

(57mm)

(25.4mm)

20-7/16" (519mm) Coil Inlet Duct Conn.

Minimum Clearance 33" (838mm) This End for Component Access and Removal

20-3/4"

(527mm)

1/2" (13mm)

7/8" (22.2mm) Dia. Electrical Entrance for Low-Voltage Connection

30-1/8" (765mm) Coil Inlet

Duct Connection

Liquid Line Male Quick Connect

Suction Line Male Quick Connect

Integral Hanging Bracket

Holes for Module Rigging (typ. 2 each end)

7/8" (22.2mm) Dia. Electrical Entrance for Line-Voltage Connection

22-3/4" (578mm)

Overall Dimension

Figure 36 3-ton centrifugal air-cooled condensing unit dimensional data & piping connections

Page 74

Figure 37 3-ton centrifugal air-cooled condensing unit (con't.)

DPN000207 Rev0

Single- or three-phase electric service not by Liebert

Optional factory-installed disconnect switch

Factory-wired to components on electric panel

Line voltage electric power supply conduit entrance

Field-supplied 24V NEC Class 2 wiring to fan/coil unit

Single- or three-phase electric service not by Liebert

Field-supplied unit disconnect switch when optional disconnect is not provided in unit

Connection terminal for field-supplied grounding wire

Low-voltage electric power supply entrance

Heat rejection connection. Field-supplied 24V NEC Class 2 wiring. See NOTE 2.

NOTES:

1. Refer to specification sheet for full load amp. and wire size amp. ratings.

2. Control voltage wiring must be a minimum of 16 GA (1.6mm) for up to 75' (23m) or not to exceed 1 volt drop in control line.

Wire connections from evaporator mod:

1. 24V ground

2. 24V supply

3. High-pressure alarm (optional)

4. Hot gas bypass connection (only on units with hot gas bypass)

Split System Models

Page 75

Figure 38 5-ton centrifugal air-cooled condensing unit dimensional data

SL-11087 Pg. 4

24"

(610mm)

Cabinet

Dimension

32"

(812.8mm)

Cabinet

Dimension

3-3/8"

(85.7mm)

14-1/2"

(368.3mm)

8-15/16"

(227mm)

15-3/4"

(400mm)

1-5/8"

(41.1mm)

54"

(1371.6mm)

Cabinet

Dimension

1-3/4"

(44.5mm)

51-13/16"

(1316mm)

Threaded Rod

Centers

21-1/4"

(539.8mm)

48"

(1219.2mm)

33-5/8"

(854.1mm)

Threaded Rod

Centers

Hanger Bracket

Shaded area indicates a recommended clearance of 30" (762mm) for component access and removal.

1/2" (12.7mm) dia. holes for threaded rods (typ. 2 each end)

Air Outlet

Air Inlet

7/8" (22.2mm) & 1-1/8" (28.6mm) dia. knockouts electrical entrance for highvoltage connection (Single Point Power Kit)

7/8" (22.2mm) & 1-1/8" (28.6mm) dia. knockouts electrical entrance for high-voltage connection

Suction Line male quick connect location

Liquid Line male quick connect location

Single Point Power Kit connection to Evaporator

NOTE: Unit is spaced evenly in reference to threaded rod centers.

7/8" (22.2mm) dia. electrical entrance for low voltage connection

7/8" (22.2mm) dia. knockout electrical entrance for alternate control panel low-voltage routing

Split System Models

Page 76

Figure 39 5-ton centrifugal air-cooled condensing unit dimensional data (con't.)

DPN000226_Rev0

Field-Supplied Unit Disconnect Switch when Factory Unit Disconnect Switch is not Supplied

Electric service not by Liebert

Optional Factory-Installed Disconnect Switch

AIR COOLED

Line Voltage Electric Power Supply Conduit Voltage

Connection terminal for field-supplied earth grounding wire

Removable Access Panels

Field-Supplied 24V NEC Class 2 wiring between condensing unit and fan/coil unit

Low-voltage electric power supply conduit entrance

Heat rejection connection. Field-supplied 24V NEC Class 2 wiring. See Note 2. Wire connections from evaporator module.

1. 24V GND

2. 24V supply

3. High pressure alarm (optional)

4. Hot gas bypass connection (only on units with hot gas bypass)

NOTES: Refer to specification sheet for full load amp and wire size amp ratings. Control voltage wiring must be a minimum of 16 G A (1.6mm) for up to 75’ (23m) or not to exceed 1 volt drop in control line.

Split System Models

Page 77

Figure 40 Split systems general arrangement

Condenser Coil

1/2" (12.7mm) NPT Pressure Relief Valve

Pressure Balancing Val ve

Sight Glass

Check Val ve

Lee-Temp Receiver

High-Pressure Switch

Scroll Compressor

Head-Pressure Control with Integral Check Val ve

Liquid Line Solenoid Valve

Suction Line Male Quick Connect Coupling*

Liquid Line Male Quick Connect Coupling*

Suction Line Female Quick Connect Coupling*

Liquid Line Female Quick Connect Coupling*

Liquid Line Male Quick Connect Coupling*

Liquid Line Female Quick Connect Coupling*

Filter Dryer

Service Access Ports

Sensing Bulb

Expansion Val ve

External Equalizer

Evaporator Coil

High-Pressure Switch

Tube in Tube Condenser

Water/Glycol Return Line

AIR COOLED

WATER COOLED

GLYCOL COOLED

Liquid Injection Val v e Bulb

Liquid Injection Val ve Bu lb

Hot-Gas Bypass Solenoid Val ve

Hot-Gas Bypass Control Val ve

Receiver Heater Pressure Limiting Switch

Water/Glycol Supply Line

Liquid Injection Val ve

SL-11900 Pg. 5

Fluid Supply to Unit

Shutoff Val ves *

Hose Bibs *

Fluid Return from Unit

Fluid Supply to Unit

3-Way Water Regulating Valve (optional)

2-Way Water Regulating Valve

OPTIONAL PIPING

FACTORY PIPING

* Components are not supplied by Liebert but are recommended for proper circuit operation maintenance.

Split System Models

Page 78

7.6 Water and Glycol-Cooled Condensing Units

For installation guidelines, refer to Installing the Indoor Condensing Unit on page 65.

7.6.1 Piping Considerations

It is recommended that manual service shut-off valves be installed at the supply and return line to each unit. This will provide for routine service or emergency isolation of the unit.

3-Ton Connection Sizes

Condenser Water Inlet 7/8" OD Cu

Condenser Water Outlet 7/8" OD Cu

Suction Line 1-1/8 - 12 male #11 quick connect

Liquid Line: 5/8 - 18 male #6 quick connect

5-Ton Connection Sizes

Condenser Water Inlet 1-1/8" OD Cu

Condenser Water Outlet 1-1/8" OD Cu

Suction Line 1-7/16" - 16 male #12 quick connect

Liquid Line 1-1/16" - 12 male #10 quick connect

Split System Models

Table 32 Water and glycol-cooled condensing unit data

Model

MC_44W MC_43W

MC_69W MC_68W

Net Weight,

lb (kg)

200 (91) 1.7 (6.4)

282 (128) 2.0 (7.6)

Glycol Volume,

gal (l)

7.6.2 Condenser Water Requirements

The standard maximum water pressure is 150 psig (1034 kPa). For applications above this pressure, consult the factory about high pressure systems.

The system will operate in conjunction with a cooling tower, city water, or drycooler.

7.6.3 Regulating Valve

For details, refer to sections 4.3.1 - Standard Valve - 150psig (1034kPa) System for 3 & 5-Ton Units (Johnson Controls Valve) High Pressure Valve - 350psig (2413 kPa) System for 5-Ton Units (Johnson Controls Valve) and 4.3.2 - High Pressure Valve - 350 psig (2413 kPa) System for 3-Ton Units (Metrex Valve).

Page 79

7.6.4 Glycol Systems

Suction Line Male Quick Connect

20-3/4"

(527mm)

46-1/2" (1181mm)

Minimum Clearance 33" (838mm) This side for component access and removal

Customer-Supplied Threaded Rods for Module Support from Ceiling (typ. 4)

Outlet

Inlet

DIMENSIONAL DATA

3/4" (19mm) NPT Female

Water/Glycol Outlet Connection

Integral Hanging Bracket

22-1/2"

(572mm)

SL-11085 Pg. 6

PIPING CONNECTIONS

12" (305mm)

Threaded Rod

Centers

14" (356mm)

Overall Cabinet

Dimension

Holes for Module Rigging (typ. 2 each end)

3/4" (19mm) NP T Female

Water/Glycol Inlet Connection

7/8" (22mm) Dia. Electrical Entrance for Low-Voltage Connection

7/8" (22mm) Dia. Electrical Entrance for High-Voltage Connection

Liquid Line Male Quick Connect

Cabinet

Dimension

Cabinet Dimension

8-7/16" (214mm)

8-7/8" (225mm)

50-1/4" (1276mm) Overall Dimension

48-1/4" (1225mm) Threaded Rod Centers

3-7/8" (98mm)

For split system glycol systems, use drycooler and pump data found in 5.0 - Glycol/GLYCOOLCooled Models—Self-Contained Compressor. See Table 18 - Drycooler data.

Electrical control interconnect to drycooler is wired from water/glycol condensing unit.

Figure 41 3-ton water/glycol-cooled condensing unit

Split System Models

Page 80

Figure 42 3-ton water/glycol-cooled condensing unit (con't.)

DPN000209_Rev0

Single- or three-phase electric service not by Liebert

Field-supplied unit disconnect switch when optional disconnect is not provided in unit

Field-supplied 24V NEC Class 1 wiring to fan/coil unit

Field-supplied 24V NEC Class 1 wiring to drycooler (glycol-cooled units only)

Earth/ground connection Connection terminal for field-supplied earth-grounding wire

Line-voltage electric power supply entrance

Factory-wired components on electric panel

Optional factory-installed disconnect switch

Low-voltage electric power supply entrance

Remote drycooler connection Terminals 70 & 71 supplied for connection to remote drycooler Use field-supplied 24V NEC Class 1 wiring (glycol-cooled units only)

Heat rejection connection. Field-supplied 24V NEC Class 2 wiring. Wire connections from evaporator mod:

1. 24V GND

2. 24V supply

3. High-pressure alarm (optional)

4. Hot gas bypass connection (only on units with hot-gas bypass)

NOTES

1. Refer to specification sheet for full load amp and wire size amp ratings.

2. Control voltage wiring must be a minimum of 16 GA (1.6mm) for up to 75' (23m) or not to exceed 1 volt drop in control line.

Split System Models

Page 81

Figure 43 5-ton water/glycol-cooled condensing unit dimensional data

7/8" (22.2mm) & 1-1/8" (28.6mm) dia. knockouts electrical entrance for line voltage connection (Single Point Power Kit)

Removable Access Panel

1/2" (12.7mm) dia. holes for module rigging (typ. 2 each end)

Customer-supplied threaded rods for module support from ceiling (typ. 4).

NOTE: Unit is evenly spaced in reference to threaded rod centers.

1" (25.4mm) NPT Female Water/Glycol Outlet Connection

1" (25.4mm) NPT Female Water/Glycol Inlet Connection

7/8" (22.2mm) dia. knockout electrical entrance for alternate control panel low-voltage routing

7/8" (22.2mm) dia. electrical entrance for low-voltage connection

Suction Line male quick connect location

Liquid Line male quick connect location

7/8" (22.2mm) & 1-1/8" (28.6mm) dia. knockouts electrical entrance for line voltage connection

32"

(812.8mm)

Cabinet

Dimension

32"

(812.8mm)

Cabinet

Dimension

24 "

(610mm)

Cabinet

Dimension

33-5/8"

(854.1mm)

Threaded Rod

Centers

29-13/16 "

(757.2mm)

Threaded Rod

Centers

(177.8mm)

SL-11087 Pg. 6

Hanger Bracket

Shaded area indicates a recommended clearance of 30" (762mm) for component access and removal.

8-7/16"

(214.4mm)

3-3/4" (95.2mm)

Split System Models

Page 82

Figure 44 5-ton water/glycol-cooled condensing unit (con't.)

DPN000228_Rev0

Field-supplied unit disconnect switch when factory unit disconnect switch is not suplied

Electric service; not by Liebert

WATER/GLYCOL

Optional factory-installed disconnect switch

Field-supplied 24V NEC Class 1 wiring to fan/coil unit

Field-supplied 24V NEC Class 1 wiring to drycooler (glycol-cooled units only)

Line voltage electric power supply conduit voltage

Removable Access Panel

Heat rejection connection. Field-supplied 24V NEC Class 2 wiring. Wire connections from evaporator mod:

1. 24V ground

2. 24V supply

3. High pressure alarm (optional)

4. Hot gas bypass connection (only on units with hot gas bypass)

Remote drycooler connection; field-supplied 24V NEC Class 1 wiring (glycol-cooled units only)

Connection terminal for field-supplied earth grounding wire

Low-voltage electric power supply conduit entrance

Field-supplied 24V NEC Class 1 wiring between glycol condensing unit and drycooler

NOTES

1. Refer to specification sheet for full load amp. and wire size amp. ratings.

2. Control voltage wiring must be a minimum of 16 G A (1.6mm) for up to 75' (23m) or not to exceed 1 volt drop in control line.

Split System Models

Page 83

R407C Refrigerant

8.0 R407C REFRIGERANT

Table 33 R407C pressure/temperature chart for operation and superheat (discharge/hot gas and suction

gas)

Temperature Gauge Pressure Temperature Gauge Pressure Temperature Gauge Pressure

°F °C Psig kPa °F °C Psig kPa °F °C Psig kPa

0.0 -17.8 18.9 130 35.0 1.7 54.8 378 70.0 21.1 114.9 792

1.0 -17.2 19.6 135 36.0 2.2 56.1 387 72.0 22.2 119.3 822

2.0 -16.7 20.4 141 37.0 2.8 57.5 396 74.0 23.3 124 853

3.0 -16.1 21.2 146 38.0 3.3 58.9 406 76.0 24.4 128 885

4.0 -15.6 22.0 152 39.0 3.9 60.3 415 78.0 25.6 133 917

5.0 -15.0 22.8 157 40.0 4.4 62.2 429 80.0 26.7 138 950

6.0 -14.4 23.6 163 41.0 5.0 63.1 435 82.0 27.8 143 984

7.0 -13.9 24.5 169 42.0 5.6 64.6 445 84.0 28.9 148 1019

8.0 -13.3 25.4 175 43.0 6.1 66.1 456 86.0 30.0 153 1054

9.0 -12.8 26.2 181 44.0 6.7 67.6 466 88.0 31.1 158 1091

10.0 -12.2 27.1 187 45.0 7.2 69.1 476 90.0 32.2 164 1128

11.0 -11.7 28.0 193 46.0 7.8 70.7 487 92.0 33.3 169 1167

12.0 -11.1 28.9 200 47.0 8.3 72.2 498 94.0 34.4 175 1206

13.0 -10.6 29.9 206 48.0 8.9 73.8 509 96.0 35.6 181 1246

14.0 -10.0 30.8 213 49.0 9.4 75.4 520 98.0 36.7 187 1287

15.0 -9.4 31.8 219 50.0 10.0 77.1 531 100.0 37.8 193 1329

16.0 -8.9 32.8 226 51.0 10.6 78.7 543 102.0 38.9 199 1372

17.0 -8.3 33.8 233 52.0 11.1 80.4 554 104.0 40.0 205 1416

18.0 -7.8 34.8 240 53.0 11.7 82.1 566 106.0 41.1 212 1461

19.0 -7.2 35.8 247 54.0 12.2 83.9 578 108.0 42.2 219 1507

20.0 -6.7 36.9 254 55.0 12.8 85.6 590 110.0 43.3 225 1553

21.0 -6.1 38.0 262 56.0 13.3 87.4 603 112.0 44.4 232 1601

22.0 -5.6 39.0 269 57.0 13.9 89.2 615 114.0 45.6 239 1650

23.0 -5.0 40.1 277 58.0 14.4 91.0 628 116.0 46.7 247 1701

24.0 -4.4 41.3 284 59.0 15.0 92.9 640 118.0 47.8 254 1752

25.0 -3.9 42.4 292 60.0 15.6 94.8 653 120.0 48.9 262 1804

26.0 -3.3 43.6 300 61.0 16.1 96.7 666 122.0 50.0 269 1858

27.0 -2.8 44.7 308 62.0 16.7 98.6 680 124.0 51.1 277 1912

28.0 -2.2 45.9 317 63.0 17.2 100.5 693 126.0 52.2 285 1968

29.0 -1.7 47.1 325 64.0 17.8 102.5 707 128.0 53.3 294 2025

30.0 -1.1 48.4 333 65.0 18.3 104.5 721 130.0 54.4 302 2083

31.0 -0.6 49.6 342 66.0 18.9 106.5 735 132.0 55.6 311 2143

32.0 0.0 50.9 351 67.0 19.4 108.6 749 134.0 56.7 320 2203

33.0 0.6 52.1 359 68.0 20.0 110.7 763 136.0 57.8 329 2265

34.0 1.1 53.5 369 69.0 20.6 112.8 778 138.0 58.9 338 2329

- - - - - - - - 140.0 60.0 347 2393

NOTE

Use this table for superheat and for control adjustment (e.g., pressure switches). See Table 34 for subcooling.

Page 84

R407C Refrigerant

Table 34 R407C pressure/temperature chart for subcooling only (liquid measurements)

Temperature Pressure Gauge Temperature Pressure Gauge Temperature Pressure Gauge

°F °C Psig kPa °F °C Psig kPa °F °C Psig kPa

36.0 2.2 73 500 59.0 15.0 114 786 94.0 34.4 203 1402

37.0 2.8 74 511 60.0 15.6 116 801 96.0 35.6 209 1444

38.0 3.3 76 522 61.0 16.1 118 815 98.0 36.7 216 1488

39.0 3.9 77 533 62.0 16.7 120 830 100.0 37.8 222 1532

40.0 4.4 79 544 63.0 17.2 123 845 102.0 38.9 229 1578

41.0 5.0 81 556 64.0 17.8 125 860 104.0 40.0 236 1624

42.0 5.6 82 567 65.0 18.3 127 875 106.0 41.1 242 1671

43.0 6.1 84 579 66.0 18.9 129 891 108.0 42.2 249 1720

44.0 6.7 86 591 67.0 19.4 131 906 110.0 43.3 257 1769

45.0 7.2 87 602 68.0 20.0 134 922 112.0 44.4 264 1819

46.0 7.8 89 615 69.0 20.6 136 938 114.0 45.6 271 1870

47.0 8.3 91 627 70.0 21.1 138 954 116.0 46.7 279 1922

48.0 8.9 93 639 72.0 22.2 143 987 118.0 47.8 287 1975

49.0 9.4 95 652 74.0 23.3 148 1021 120.0 48.9 294 2029

50.0 10.0 96 664 76.0 24.4 153 1055 122.0 50.0 302 2085

51.0 10.6 98 677 78.0 25.6 158 1090 124.0 51.1 310 2141

52.0 11.1 100 690 80.0 26.7 163 1126 126.0 52.2 319 2198

53.0 11.7 102 704 82.0 27.8 169 1163 128.0 53.3 327 2256

54.0 12.2 104 717 84.0 28.9 174 1201 130.0 54.4 336 2315

55.0 12.8 106 730 86.0 30.0 180 1239 132.0 55.6 345 2376

56.0 13.3 108 744 88.0 31.1 185 1279 134.0 56.7 354 2437

57.0 13.9 110 758 90.0 32.2 191 1319 136.0 57.8 363 2500

58.0 14.4 112 772 92.0 33.3 197 1360 138.0 58.9 372 2563

--------140.0 60.0 381 2628

NOTE

Use this table for subcooling calculation ONLY. See Table 33 for superheat or control adjustment.

8.1 Calculating Subcooling

Example

Measure the liquid pressure (e.g., 200 psig). Find the liquid saturation temperature at that pressure on Table 34 (e.g., 93°F). Measure the temperature of the liquid line (e.g., 90°F). Subtract the actual temperature from the liquid saturation temperature to obtain the subcooling (e.g., 93 – 90 = 3°F). If the actual temperature is greater than the liquid saturation temperature, then there is no subcooling, and the fluid may be a mixture of liquid and vapor.

Why There Are Two R407C Temperature and Pressure Tables

R407C is a blend of refrigerants that exhibits a temperature “glide” of approximately 8 to 12°F (4 to 7°C). This “glide” is the difference between the liquid and vapor saturation temperatures at a given pressure. Use the correct table for the saturation temperature you need. Table 33 is for superheat or operating controls. Table 34 is for subcooling only.

Page 85

NOTES

R407C Refrigerant

Page 86

R407C Refrigerant

Page 87

Page 88

Ensuring The High Availability Of Mission-Critical Data And Applications.

Emerson Network Power, the global leader in enabling business-critical continuity, ensures network resiliency and adaptability through a family of technologies—including Liebert power and cooling technologies—that protect and support business-critical systems. Liebert solutions employ an adaptive architecture that responds to changes in criticality, density and capacity. Enterprises benefit from greater IT system availability, operational flexibility and reduced capital equipment and operating costs.

While every precaution has been taken to ensure the accuracy and completeness of this literature, Liebert Corporation assumes no responsibility and disclaims all liability for damages resulting from use of this information or for any errors or omissions. © 2008 Liebert Corporation All rights reserved throughout the world. Specifications subject to change without notice. ® Liebert is a registered trademark of Liebert Corporation. All names referred to are trademarks or registered trademarks of their respective owners.

SL-11962_REV0_09-09

Technical Support / Service

Web Site

www.liebert.com

Monitoring

[email protected]

800-222-5877

Outside North America: +00800 1155 4499

Single-Phase UPS & Server Cabinets

[email protected]

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800-543-2378

Outside North America: 614-841-6598

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800-543-2778

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