Liebert 3000 User Manual
Liebert Challenger™ 3000
Operation & Maintenance Manual - 3 & 5 Ton, 50 & 60Hz
Precision Cooling
For Business-Critical Continuity
TABLE OF CONTENTS
1.0 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
1.1 System Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1.1 Compressorized Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1.2 GLYCOOL™ (Chilled Glycol Cooling) Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1.3 Chilled Water Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Start-Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.0 OPERATION WITH ADVANCED MICROPROCESSOR CONTROLS . . . . . . . . . . . . . . . . . . . . . . .3
2.1 Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Status Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.3 Main Menu <MENU/ESC> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4 Status/Alarm Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4.1 Active Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4.2 Operating Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4.3 Alarm History Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4.4 Run Hours Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.4.5 Analog Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.5 Setpoints/Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.5.1 View Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.5.2 Setup System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.5.3 Run Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.5.4 Change Passwords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.6 Date and Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.7 Status Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.8 Control Circuit Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.8.1 LCD Display Contrast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.8.2 Non-Volatile Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.8.3 DIP Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.8.4 Control Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.0 OPERATION WITH ADVANCED MICROPROCESSOR WITH GRAPHICS CONTROL . . . . . . . . . . .15
3.1 Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.2 Status Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.3 Main Menu <MENU/ESC> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.4 View/Set Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.4.1 Active Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.4.2 Alarm History Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.4.3 Setup Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.4.4 Setup Custom Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.4.5 View Water Detect Floor Plan (for Optional LTM1000/LT750). . . . . . . . . . . . . . . . . . . . . . . . 19
3.4.6 Setup Water Detect Floor Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.5 Operating Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.6 View/Set Control Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.7 System Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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3.7.1 Setup Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.7.2 Select Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.7.3 Calibrate Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.7.4 Calibrate Valve Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.7.5 Select Control Algorithm (Chilled Water and SCR Reheats only). . . . . . . . . . . . . . . . . . . . . . 22
3.7.6 Select Humidity Sensing Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.7.7 Set Status Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.7.8 Change Passwords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.8 Run Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.8.1 Show Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.8.2 Test Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.8.3 Test Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.8.4 DIP Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.9 Date and Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.10 Plot Graphs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.10.1 Modify Plot Scales . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.11 Analog/Digital Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.11.1 Read Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.11.2 Setup Analog Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.11.3 Read Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.11.4 Setup Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.12 View Run Hours Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.12.1 View 24 Hour Run Time History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.12.2 View Total Run Hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.13 Control Circuit board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.13.1 LCD Contrast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.13.2 Nonvolatile Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.13.3 DIP Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.13.4 Control Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.0 SYSTEM PERFORMANCE WITH ADVANCED MICROPROCESSOR CONTROLS . . . . . . . . . . . . . 29
4.1 Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.1.1 Cooling/Heating Required, in Percent (%) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.1.2 Response to Control Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.1.3 Cooling Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.1.4 Heating Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.2 Humidity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.2.1 Dehumidification/Humidification Required, in Percent. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.2.2 Response to Control Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.2.3 Dehumidification Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.2.4 Humidification Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.3 Control Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.3.1 Proportional Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.3.2 PID Control (Chilled Water or SCR Reheats only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.3.3 Intelligent Control (Chilled Water only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.4 Load Control Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.4.1 Short Cycle Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
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4.4.2 Sequential Load Activation Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.5 Additional Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.5.1 Connecting the Analog Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.5.2 Water Detection Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.6 Communications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.0 ALARM DESCRIPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
5.1 Standard Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.1.1 Change Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.1.2 Compressor Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.1.3 Custom Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.1.4 High Head Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.1.5 High Humidity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.1.6 High Humidity and Low Humidity (Simultaneously) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.1.7 High Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.1.8 High Temperature and Low Temperature (Simultaneously) . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.1.9 Humidifier Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.1.10 Loss of Air Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.1.11 Loss of Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.1.12 Low Humidity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.1.13 Low Suction Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.1.14 Low Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.1.15 Main Fan Overload. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.1.16 Short Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.2 Optional/Custom Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.2.1 Loss of Water Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.2.2 Smoke Detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.2.3 Standby GC Pump On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.2.4 Standby Unit On. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.2.5 Water Under Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.0 COMPONENT OPERATION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
6.1 System Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6.1.1 Environmental Control Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6.2 Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6.3 Blower Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.3.1 Fan Impellers and Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.3.2 Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.3.3 Air Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.4 Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
6.4.1 Suction Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
6.4.2 Discharge Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
6.4.3 Superheat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
6.4.4 Thermostatic Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.4.5 Hot Gas Bypass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.4.6 Air Cooled Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6.4.7 Water/Glycol Cooled Condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.4.8 Compressor Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.4.9 Compressor Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
iii
6.5 Humidifier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6.5.1 Infrared Humidifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6.5.2 Steam Generating Humidifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
7.0 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
8.0 MONTHLY MAINTENANCE INSPECTION CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
9.0 SEMIANNUAL MAINTENANCE INSPECTION CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
iv
FIGURES
Figure 1 Advanced microprocessor control panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Figure 2 Advanced microprocessor (A) control for Challenger 3000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Figure 3 Advanced microprocessor with graphics (G) control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Figure 4 Advanced microprocessor with graphics control menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Figure 5 Analog input jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Figure 6 Connecting the LT750. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Figure 7 Liebert leak detection units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Figure 8 Recommended liquid sensor locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Figure 9 Outdoor fan/condenser configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Figure 10 Johnson Controls valve adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Figure 11 Metrex valve adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Figure 12 Infrared humidifier lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Figure 13 Steam generating humidifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Figure 14 Canister replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
TABLES
Table 1 Default setpoints and ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Table 2 Setup functions, default values and ranges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Table 3 Unit options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Table 4 DIP switch settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Table 5 Alarm default time delays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Table 6 Control output LEDs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Table 7 Alarm default time delays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Table 8 Default setpoints and ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Table 9 Setup functions, default values and ranges. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Table 10 Unit options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Table 11 Setting options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Table 12 Control output LEDs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Table 13 Cooling/dehumidification load status response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Table 14 Analog input terminals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Table 15 Additional connections available after unit delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Table 16 Zone leak detection kit installation scenarios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Table 17 Recommended free area ft
of 550 and 600 fpm (2.8 and 3.1 m/s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Table 18 Suction pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Table 19 Discharge pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Table 20 Humidifier canister part numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Table 21 Blower troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Table 22 Chilled water troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Table 23 Compressor and refrigeration system troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Table 24 Dehumidification troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Table 25 Glycol pump troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Table 26 Infrared humidifier troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Table 27 Steam generating humidifier troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Table 28 Reheat troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2
(m2) for grilles or perforated panels at output velocities
v
vi
1.0 INTRODUCTION
1.1 System Descriptions
Challenger 3000™ Liebert environmental control systems are available in several configurations.
Each configuration can operate with either Advanced Microprocessor Controls (A), or Advanced
Microprocessor Controls with Graphics (G). A brief description of each, including operational differences, are listed below. Check model numbers to see what is supplied with your unit.
1.1.1 Compressorized Systems
NOTE
Compressorized systems may be a self-contained system – with the compressor in the
Challenger 3000 unit, or a split system – with the compressor in the separate condensing unit.
These systems may be air, water, or glycol cooled, depending on the heat rejection method selected.
Cooling—One stage standard; two stages of mechanical refrigeration with optional split coil.
Heating—Two stages of electric reheat standard; SCR controlled electric reheat, hot water reheat,
hot gas reheat on water and glycol cooled systems optional.
Humidification—Infrared standard; steam generating optional.
Dehumidification—Hot gas bypass locked out standard; part coil operation optional
Introduction
1.1.2 GLYCOOL™ (Chilled Glycol Cooling) Systems
GLYCOOL™ systems have all of the features of a compressorized water or glycol system, plus a second cooling coil that is connected into the water circuit. When fluid temperature is sufficiently low
(below room temperature), cooling is provided by circulating the fluid through the second cooling coil
(flow is controlled by a motorized valve.) This is then the primary cooling source and it greatly
reduces the compressor operation.
Cooling—Modulated cooling valve opens proportionally to match room needs (primary), one or two
stages of mechanical refrigeration (secondary)
Heating—Two stages of electric reheat standard
Humidification—Infrared standard; steam generating optional
Dehumidification—Hot gas bypass locked out standard
1.1.3 Chilled Water Systems
These systems utilize a central chiller and control cooling by modulating a control valve in the chilled
water line.
Cooling—Proportional in response to room needs
Heating—Two stages of electric reheat standard
Humidification—Infrared standard; steam generating optional
Dehumidification—Chilled water valve opens proportionally in response to room needs
1
1.2 Start-Up Procedure
Before beginning start-up, make certain that unit was installed according to the instructions in the
Installation Manual. Verify that the fan shipping bolt has been removed, the check valve has been
installed (on air cooled units), and that the scroll compressor is rotating in the proper direction. All
exterior panels must be in place with the front panel open.
Locate the start-up form supplied with your unit documents. Complete the form during your start-up
and mail it to Liebert when start-up is completed. Contact your Liebert supplier if you have any questions or problems during your unit installation, start-up, or operation.
WARNING
!
Potentially lethal voltages exist within this equipment during operation. Observe all cautions
and warnings on unit and in this manual. Failure to do so could result in serious injury or
death. Only qualified service and maintenance personnel should work with this equipment.
1. Disconnect all power to the environmental control unit.
2. Tighten all electrical wiring connections that may have loosened during shipping (on electric
panel and at all major components, such as compressor, reheats, humidifier and motor).
3. Remove all line voltage fuses except the main fan fuses at the far right of the electric panel and
the Control Voltage fuses at the far left of the electric panel. For units supplied with circuit
breakers, open them instead of removing fuses.
4. Turn on power and check line voltage on main unit disconnect switch. Line voltage must be
within 10% of nameplate voltage.
5. Turn ON main unit disconnect switch and check secondary voltage at transformer T1. Voltage at
T1 must be 24 VAC ±2.5 VAC (check at TB1-1 and TB1-8). T1 voltage must not exceed 28 VAC.
Change primary tap if necessary.
6. Push ON button. Blower will start.
7. If you do not want your unit to operate at factory default settings, set temperature and humidity
setpoints and sensitivity, alarms, and other control functions. Refer to 2.0 - Operation with
Advanced Microprocessor Controls or 3.0 - Operation with Advanced Microprocessor
with Graphics Control.
8. Stop unit by depressing ON/OFF button on the front display. Turn OFF main unit disconnect and
main breaker.
9. Replace all fuses (or reset circuit breakers) that were removed in Step 3.
10. Restore power to unit; turn ON the main unit disconnect switch.
11. Push ON button - putting the unit into operation.
12. Check the current draw on all line voltage components and match with serial tag.
13. Verify that the scroll compressor is rotating in the proper direction.
Introduction
CAUTION
!
The scroll compressor must rotate in the proper direction. Rotation in the wrong direction
will result in poor performance and compressor damage.
14. Check for unusual noises and vibration.
15. Check all refrigerant and fluid lines for leaks.
16. Test all functions of your unit for proper operation.
17. Close high voltage dead front cover and latch.
18. Close front accent panel and latch.
Return completed start-up form to:
Liebert Corporation
Warranty Registration
1050 Dearborn Drive
P.O. Box 29186
Columbus, OH 43229
2
Operation with Advanced Microprocessor Controls
2.0 OPERATION WITH ADVANCED MICROPROCESSOR CONTROLS
The advanced microprocessor (A) control for your Liebert Challenger 3000 unit features an easy-touse menu driven LCD display. The menus, control features, and circuit board details are described in
this section. For more control details, refer to 4.0 - System Performance with Advanced Micro-
processor Controls, and for more alarm information, refer to 5.0 - Alarm Descriptions.
2.1 Basics
Control keys include ON/OFF, Menu/ESCape, Enter, Increase (UP) arrow, and Decrease (DOWN)
arrow. Refer to Figure 1. These keys are used to move through the menus as prompted on the LCD
display (refer to Figure 2).
To turn the unit ON, press the ON/OFF key after power is applied. To turn the unit OFF, press the
ON/OFF key before power is disconnected.
Active alarms are displayed on the LCD screen. Alarms are also annunciated by an audible beeper. To
silence an alarm, press the ENTER key as prompted on the display. The unit stores the 10 most
recent alarms for review.
Setpoints, DIP switch settings, and other selections were made on your unit before testing at the factory. Setpoints were chosen based on typical operating experience. Other selections were made based
on options included with your unit. Make adjustments to the factory default selections ONLY if they
do not meet your specifications. When entering setpoints, time delays, etc., the allowable ranges are
displayed and may require a password, if enabled.
Figure 1 Advanced microprocessor control panel
3
Operation with Advanced Microprocessor Controls
Figure 2 Advanced microprocessor (A) control for Challenger 3000
Main Menu
Status/Alarm Data
Setpoints/Setup
Date and Time
Status Display
Normal Display
72°F 50%RH
Cooling
Dehumidifying
No Alarms Present
Status Alarm Data
Active Alarms
Operating Status
Alarm History Log
Run Hours Log
Active
Alarms
No Alarms Present
Alarm 01 of 01
High Head PR
Use / to Scroll
Standard Alarms
Custom Alarms 1 to 4
* Some alarms require optional equipment
** Optional
Operating
Status
OR
Operating Status
DX Cool %
Heat %
Econo Cool %
CW Valve %
DX Deh / Hum
Alarms Available
Humidifier Problems
High Head Pressures
Change Filter
Loss of Air Flow
High Temperature
Low Temperature
High Humidity
Low Humidity
Short Cycle
Low Suction Pressure
Compressor Overload
Loss of Power
Programmed Alarm Messages
Water Under Floor
Smoke Detected
Standby GC Pump On
Loss of Water Flow
Standby Unit On
User Customized Alarm Messages
Available for Custom Alarms
Alarm
History Log
Alarm History Log
Alarm 01 of 03
15-APR 09:20:45
High Humidity
Use / to Scroll
Run
Hours Log
Analog Sensors
Analog in 1 (2,3,4):xx
AD #1 (2,3,4)
Use / to Scroll
ESCape to exit
Run Hours Log
Comp
GLYCOOL** or CW Coil**
Fan
Hum
RH1
RH2
Setpoints/Setup
View Setpoints
Setup System
Run Diagnostics
Change Passwords
Analog
Sensors
View Setpoints
Temp Setpoint
Sensitivity
Hum Setpoint
Sensitivity
High Temp
Alarm
Lo Temp Alarm
High Hum Alarm
Lo Hum Alarm
15-APR-2004 09:30:00
ENTER to change
ESCape to exit
View
Setpoints
Setup Operation
Select Options
Calibrate Sensors
Show DIP Switches (1-7)
Select Control Type
Setup Alarms
Hum Control Method
Analog Setup
Set Status Display
Calibrate Actuator
Setup
System
Setup System
Cold Start TD
Restart TD
IR Fill Rate
F/C Degrees
Min CW Temp**
CW/HW Flush**
Heating
Humidifier
Dehumidifier
Heat Stages
Intelligent
Proportional
Tunable PID
Proportional Gain
Derivative Gain
Integral Gain
Set Time Delays
Enable Alarms
Enable Common Alarm
Set Custom Alarm
Select Alarm
Change Custom TXT 1,2
Relative
Absolute
A/D Input 1 (2,3,4)
Slope
Text
Intercept
Date and Time
Diagnostics
Run Diagnostics
Show Inputs
Test Outputs
Test Control Board
Status Display
75°F 59%RH
Cooling
Dehumidifying
No Alarms Present
Run
Change Password
Setpoint Password
Setup Password
Change
Password
4
2.2 Status Display
The display normally shown includes the present room temperature, humidity, active status functions (cooling, heating, dehumidifying, humidifying), and active alarms. If no keys are pressed within
5 minutes, the system automatically returns to the Status Display. The Status Display may also be
selected from the Main Menu.
2.3 Main Menu <MENU/ESC>
Press the MENU/ESC key to display the Main Menu. The Menu selections include:
• Status/alarm data
•Setpoints/setup
• Date and time
• Status display
2.4 Status/Alarm Data
Selecting STATUS/ALARM DATA from the Main Menu will display the following selections:
• Active alarms
• Operating status
• Alarm history log
• Run hours log
• Analog sensors
Operation with Advanced Microprocessor Controls
2.4.1 Active Alarms
This screen displays any active alarm. The alarms are numbered, #1 being the most recent. If there
are no active alarms, then “NO ALARMS PRESENT” will be displayed.
2.4.2 Operating Status
The Operating Status is intended to provide the user with displayed information concerning what the
control is calling for the system to do.
NOTE
There may be some time lapse before a specific component matches the displayed number.
For example: The display indicates the chilled water valve is 68% open. On a new call for cooling, it
takes several seconds for the valve to travel from fully closed to 68% open. So, when the display reads
68%, it may take a few seconds for the valve to actually open 68%. Also, if the display indicates a compressor is operating but the compressor has not yet turned on, it may be off because of the short cycle
control (see 4.4.1 - Short Cycle Control).
2.4.3 Alarm History Log
A history of the 10 most recent alarms is kept in nonvolatile memory complete with the date and time
that the alarms occurred. The first alarm in the history is the most recent and the 10th is the oldest.
If the alarm history is full (10 alarms) and a new alarm occurs, the oldest is lost and the newest is
saved in alarm history location 1. The rest are moved down the list by 1. Alarm history on new units
may show the results of factory testing.
5
2.4.4 Run Hours Log
The total operating hours of all major components in the unit can be monitored from the display and
are retained in nonvolatile memory. Run times are available for the following:
• Compressor
• GLYCOOL Coil (or CW Coil as used on Dual Cooling Unit)
•Fan
• (HUM) humidifier
• (RH1) reheat 1 (or Hot Water or SCR Reheat)
• (RH2) reheat 2
The component run hours for each individual component can be reset by selecting the run hours display screen for the desired component, then pressing ENTER within 5 minutes of applying power to
the control. The user will then be prompted to press ENTER to clear the selected component's run
hours.
NOTE
Run hours for a component should be reset ONLY when the component has been replaced.
2.4.5 Analog Sensors
The four (4) analog sensor inputs can be monitored from the display. The inputs are filtered, then displayed along with the text label assigned during setup. See Analog Setup on page 11.
Operation with Advanced Microprocessor Controls
2.5 Setpoints/Setup
Selecting Setpoints/Setup from the Main Menu will display the following selections:
• View setpoints
• Setup system
• Run diagnostics
• Change passwords
NOTE
Setpoints and system setup parameters are kept in nonvolatile memory.
2.5.1 View Setpoints
Control and alarm setpoints can be reviewed and/or changed through the display. The following table
lists the default setpoints and their allowable ranges.
Table 1 Default setpoints and ranges
Setpoint Default Range
Temperature Setpoint 72°F 40 to 90°F (5 to 32°C)
Temperature Sensitivity 2.0
Humidity Setpoint 50% 20 to 80% RH
Humidity Sensitivity 5% 1 to 30% RH
High Temperature Alarm 80
Low Temperature Alarm 65
High Humidity Alarm 60% 15 to 85% RH
Low Humidity Alarm 40% 15 to 85% RH
°F 1 to 9.9°F (0.6 to 5.6°C)
°F 35 to 95°F (2 to 35°C)
°F 35 to 95°F (2 to 35°C)
6
2.5.2 Setup System
The Setup System menu includes the following selections:
• SETUP OPERATION
• SELECT OPTIONS
• CALIBRATE SENSORS
• SHOW DIP SWITCHES
• SELECT CONTROL TYPE
• SETUP ALARMS
• HUM CONTROL METHOD
• ANALOG SETUP
• SET STATUS DISPLAY
• CALIBRATE ACTUATOR
Setup Operation
The Setup Operation menu permits the review and/or adjustment of the unit configuration. This may
include:
Cold Start—This feature, also referred to as Positive Start or Winter Start Kit, allows for the low
pressure switch to be ignored for the programmed time during a cold start of the compressor. Entering a “0” for this time will bypass this feature. A “1” will bypass the low pressure switch for one
minute, a “2” for 2 minutes, etc. The programmed value can be from 0 to 3 minutes. This delay is factory set to 0 for water cooled, glycol cooled, and GLYCOOL units. Typically, only air cooled units need
a “Winter Start” delay time.
Operation with Advanced Microprocessor Controls
(Chilled Water or SCR Reheats only)
Restart—This feature allows for the unit to restart automatically after a loss of power. The programmed value is in 0.1 minute (6 seconds) intervals. A programmed value of zero (0) would require
the user to manually press the ON/OFF key to start the unit, i.e. no auto restart. The purpose of this
feature is to prevent several units from starting at the same time after a loss of power. The message
“Restart Delay -- Please Wait” will be displayed when the system is in the auto restart mode. Liebert
suggests programming multiple unit installations with different auto restart times.
IR Fill Rate (infrared humidifiers only)—An autoflush system automatically controls a water
makeup valve to maintain the proper level in the infrared humidifier water pan during humidifier
operation. If humidification is needed and 15 hours have elapsed since the last time the humidifier
was on, the humidifier is held off until the valve completes an initial fill of the humidifier pan. This
pre-fill is about 30 seconds. The valve continues to fill and flush the pan for about 4 minutes.
During humidifier operation, with the flush rate set at the default of 150%, the valve is opened periodically to add water to the pan (about 40 seconds for every 9-1/2 minutes of humidifier operation).
This adds enough water to the pan to cause about a third of the total water used to be flushed out the
overflow standpipe located in the humidifier pan. This flushing action helps remove solids from the
pan. The flush rate is adjustable from 110% to 500%. If the water quality is poor, it may be desirable
to increase the water flushing action above the normal 150% rate. Also, if the supply water pressure
is low, the flush rate adjustment can be increased so that sufficient water level is maintained during
humidification.
Chilled Water/Hot Water/Econ-O-Coil Flush—This feature will flush the respective coil for
3 minutes after the programmed number of hours of non-use. For example, if the flush time is programmed with 24 hours on a hot water reheat type system and heating is not required for a 24 hour
period, the hot water valve will be open for 3 minutes to allow the coil to be flushed. The programmed
value can be from 0 (no flush) to 99 (99 hours of non-use).
C/F Degrees—The control can be selected to show readings and setpoints in either degrees Fahrenheit (F) or Celsius (C).
7
Operation with Advanced Microprocessor Controls
Table 2 lists the setup functions, their factory default values and the allowable programming ranges.
Table 2 Setup functions, default values and ranges
Function Default Range
Cold Start Time Delay* 3 0 to 3 min (0 = no delay)
Restart Time Delay 0.1 0 to 9.9 min (0 = manual restart)
Infrared Fill Rate 150 110 to 500%
Chilled/Hot Water Coil Flush 24 0 to 99 hrs (also Econ-O-Coil)
C/F Degrees F C or F
*Factory set to 0 for water cooled, glycol, and GLYCOOL units.
Select Options
The following table lists options which should match the options installed with your unit and should
not need to be changed during normal operation.
Table 3 Unit options
Option Selection
Heating
Humidifier Yes or No
Dehumidifier Yes or No
Hot Gas Reheat
Heat Stages
1
2
3
1
3
Heating cannot be disabled on units with SCR reheats.
Hot gas reheat not available on units with SCR reheats.
Heat stages not selectable on units with SCR reheats.
2
Yes or No
Yes or No
2
Calibrate Sensors
The temperature and humidity sensors can be calibrated by selecting this menu item. “SENSOR”
shows the actual sensor reading or raw reading. “CALIBRATED” shows the sensor reading after the
calibration offset has been added. The temperature sensor can be calibrated ±5 degrees Fahrenheit
and the humidity sensor can be calibrated ±10%RH. When calibrating the humidity sensor, the value
shown will always be % RH, even though absolute humidity control may be selected. If absolute
humidity control is selected, the Normal Status Display will display the adjusted reading and may not
agree with the relative humidity reading displayed while in calibration.
Show DIP Switches
The DIP switch settings can be reviewed from the display panel. Changing the DIP switches requires
opening the upper panel for access to the DIP switches on the microprocessor control board.
NOTE
Power MUST be cycled OFF, then ON from the unit disconnect switch for the control
system to update the DIP switch settings (with the exception of switch 8).
Table 4 DIP switch settings
Switch # Off On
1 No Part Coil Part Coil/Chilled Water
2 Electric/Hot Gas Reheat Hot Water Reheat
3 All Not Used
4 No GLYCOOL GLYCOOL
5 No Dual Cooling Dual Cooling
6 Not Used Not Used
a
7
a
SCR reheats only (with special software); otherwise, not used.
Tight Control Standard Control
The selections shown in Table 4 should match options installed on your unit and should not need to
change during normal operation. Switches 1 through 7 are self explanatory. DIP switch 8, not shown in the
table, enables the password feature when set to ON and disables the password feature when set to OFF.
8
Operation with Advanced Microprocessor Controls
Select Control Type
• Intelligent (Chilled Water only)
• Proportional (all unit types)
• Tunable PID (Chilled Water or SCR Reheats only)
The type of system control method used by the microprocessor can be selected from the front panel.
The default setting is Intelligent, which approximates the actions that a human operator would take
to maintain precise, stable control. The control logic uses Artificial Intelligence techniques including
“fuzzy logic” and “expert systems” methods to maintain precise, stable control and increase reliability
by reducing component cycles. Proportional is a standard control method that uses one gain factor
(temperature sensitivity adjustment). Tunable PID (Proportional, Integral, and Derivative) uses
three gain factors selected by the operator. PID allows precision tuning, but requires an experienced
operator and seasonal adjustments. Note that if PID is selected, it is used for temperature control
while humidity will continue to use Proportional control. Refer to 4.0 - System Performance with
Advanced Microprocessor Controls for more detail on types of controls.
Setup Alarms
Selecting SETUP ALARMS will step to the following menu:
•SET TIME DELAYS
• ENABLE ALARMS
• ENABLE COMMON ALARM
• SET CUSTOM ALARMS
Each individual alarm can be programmed with a time delay from 0 to 255 seconds. Each individual
alarm can be ENABLED or DISABLED and each individual alarm can be programmed to energize or
not to energize the Common Alarm Relay.
Set Time Delays—By programming a time delay for an alarm, the system will delay the specified
amount of time before recognizing the alarm. The alarm condition must be present for the amount of
time programmed for that alarm before it will be annunciated. If the alarm condition goes away
before the time delay has timed out, the alarm will not be recognized and the time delay timer will be
reset. For software alarms such as Loss of Power, Short Cycle, and Low Suction Pressure, a time
delay will only delay the annunciation of that alarm. The condition of the alarm is not applicable
because the condition has already occurred. For these alarms the time delay should be left at the factory default of 0. Table 5, below, shows the default time delays for each alarm.
Table 5 Alarm default time delays
Default Time
Alarm
Humidifier Problem 2
High Head Pressure 2
Change Filter 2
Loss of Air flow 3
Custom Alarm #1 0
Custom Alarm #2 0
Custom Alarm #3 0
Custom Alarm #4 6
High Temperature 30
Low Temperature 30
High Humidity 30
Low Humidity 30
Low Suction Pressure 0
Short Cycle 0
Compressor Overload 2
Main Fan Overload 5
Loss of Power 0
Delay (seconds)
9
Operation with Advanced Microprocessor Controls
Enable Alarms—Each individual alarm can be selected to be ENABLED (annunciated audibly, visually, and communicated to a Site Products System) or DISABLED (ignored).
Enable Common Alarm—Each individual alarm can be selected to energize or to not energize the
common alarm relay. If the energize common alarm function is set to YES, the relay is energized
immediately as the alarm is annunciated and de-energized when the alarm condition goes away (only
after the alarm has been recognized). If the function is set to NO, the alarm has no effect on the common alarm relay regardless of whether the alarm is ENABLED or DISABLED.
Set Custom Alarms—The custom alarm messages can be from a list of standard alarm messages or
you can write your own message.
NOTE
A maximum of two of the alarm messages can be your own message.
They can be in any location(s) 1 through 4. The text for custom alarms can be changed at any time by
selecting “SET CUSTOM ALARMS.” To change the text for a custom alarm, select “SELECT
ALARM.” Then, select the alarm you would like to change, 1 through 4. Using the UP/DOWN arrows
will step through the list of five standard alarm messages (see list below) and the two custom alarms.
NOTE
The two custom alarm messages will be shown with what was previously programmed in them
and can be changed.
Press ENTER to make your selection. To modify the two custom alarm messages, go back one screen
and select “CHANGE CUSTOM TXT 1” (or 2). Text can be up to 20 characters in length and can be
any of the following characters (or a blank space):
ABCDEFGHIJKLMNOPQRSTUVWXYZ#%*-0123456789.
Standard Custom Alarm Messages
• WATER UNDER FLOOR
• SMOKE DETECTED
• STANDBY GC PUMP ON
• LOSS OF WATER FLOW
• STANDBY UNIT ON
For more information concerning alarms, see 5.0 - Alarm Descriptions.
Humidity (HUM) Control Method
The user may select between relative (direct) and absolute (predictive) humidity control. If relative is
selected, the RH control is taken directly from the RH sensor. If absolute is selected, the RH control is
automatically adjusted as the return air temperature deviates from the desired temperature setpoint.
This results in a predictive humidity control. The display will indicate % RH for both methods of control, but the adjusted humidity reading will be displayed if absolute is selected
ity control, the humidity control is automatically adjusted approximately 2% RH for each degree
difference between the return air temperature and the temperature setpoint.
With relative humidity control, unnecessary dehumidification can result when overcooling occurs during a dehumidification cycle. This is because a higher than normal RH reading is caused by overcooling the room (about 2% RH for each degree of overcooling). This extends the dehumidification cycle.
Later, when the dehumidification ends and the temperature rises to the setpoint, the RH reading
falls. The final RH reading will then be lower than actually desired. If the overcooling was significant
enough, the RH could be low enough to activate the humidifier.
. With absolute humid-
If absolute humidity control is selected, over-dehumidification is avoided. When overcooling occurs,
causing an increase in the RH reading, the humidity control program “predicts” what the RH will be
when the dehumidification cycle ends and temperature returns to the setpoint. This allows the dehumidification cycle to end at the proper time. The predictive humidity control can reduce energy consumption by minimizing compressor and reheat operation, and eliminating unnecessary humidifier
operation.
10
Operation with Advanced Microprocessor Controls
Analog Setup
For installation of analog sensors, see 4.5.1 - Connecting the Analog Sensors.
After selecting a compatible sensor and properly wiring it to the terminals, set up the control to monitor the sensor as follows:
Slope—The slope is a multiplier used to scale the input signal. The slope can be positive (rising) or
negative (falling) and can range from 0 (resulting in a horizontal line) to ±999. The slope for a 0-5 volt
input is per 1 volt input, for 0-10 volt input is per 2 volt input, and for 4-20 mA is per 4 mA input. For
example, assuming an intercept of 0, for a 0-10 volt sensor input with a slope of 50, an input of 1 volt
would be displayed as 25: 1x(50/2); 2 volts would be 50: 2x(50/2); 3 volts would be 75: 3x(50/2); etc.
Intercept—The intercept is an offset from point 0 corresponding to 0 volts or 0 mA input. The intercept can be positive or negative and can be a point from 0 to ±999.
Adding an intercept of 100 to the slope example above, 1 volt would be 125: 100 + (1x[50/2]); 2 volts
would be 150: 100 + (2x[50/2]); 3 volts would be 175: 100 + (3x[50/2]); etc.
NOTE
For a 4-20 mA input sensor, if the desired reading at 4 mA input is 0, then an intercept of
-1 x slope would be required. For example, assuming a slope of 50, the formula would be
([-1 x 50] + 4 x [50/4]) = 0. The intercept is -50.
Text—You may enter a custom label for each analog input. The text label can be 20 characters in
length including any of the following:
ABCDEFGHIJKLMNOPQRSTUVWXYZ#%*-0123456789, or space.
Set Status Display
The Status Display can be set to display the return air temperature and humidity SENSOR READINGS or the temperature and humidity control SETPOINTS through this selection. When SETPOINTS is selected, the status display indicates so by displaying “SETPTS.” If SENSOR READINGS
is selected, the Status Display will show the return air sensor readings.
Calibrate Actuator
For systems that use a valve actuator for chilled water or GLYCOOL cooling, the actuator timing may
be calibrated or adjusted. This is the time it takes for the valve to travel from full closed to full open.
It is programmable from 0 to 255 seconds. The factory default time is 165 seconds and should not be
changed unless the actual valve travel time is not correct. The full valve travel time is used by the
control to determine the appropriate valve position. For example, if the valve travel time is 165 seconds and 50% cooling is being called for, the valve will open for 83 seconds to acheive 50% open. To
change the valve travel time, first enter the “CALIBRATE ACTUATOR” screen. The display will show
the present period used by the control for valve actuator full travel. Press ENTER and adjust the time
using the UP/DOWN arrows. When the correct time is displayed, press ENTER to store the new time
to memory.
11
2.5.3 Run Diagnostics
By selecting Run Diagnostics, maintenance personnel can check system inputs, outputs, and complete
a test of the microcontroller circuit board, all from the front panel. Review of the system inputs and
the microcontroller test can be done without interrupting normal operation. To test the system outputs, the normal system control is temporarily suspended. DO NOT leave the unit in the diagnostics
mode any longer than is necessary for troubleshooting. The control system will return to normal operation in 5 minutes, automatically, if no key is pressed.
Show Inputs
With the unit on and the fan running, the input state for the following devices may be displayed:
• Air sail switch: normally off unless Loss of Air Alarm is active
• Custom alarm #1: normally off unless this alarm is active
• Custom alarm #2: normally off unless this alarm is active
• Custom alarm #3: normally off unless this alarm is active
• Custom alarm #4: normally off unless this alarm is active
• Humidifier problem: normally on unless this alarm is active
• Filter clog: normally off unless Change Filters Alarm is active
• Main fan overload: normally on unless Main Fan Overload Alarm is active
• Shutdown device: normally on unless unit is off through the Fire Stat or Remote Shutdown
Device
• Low press switch: normally on if compressor circuit is in operation
• Comp overload: normally on unless Compressor Overload Alarm is active
• High head comp: normally off unless High Head Pressure alarm Compressor is active
Operation with Advanced Microprocessor Controls
Test Outputs
When this feature is selected, the unit is effectively turned off. When stepping from one load to the
next, the previous load, if on, is turned off automatically. The loads can also be toggled ON/OFF by
selecting “ENTER.” Once turned on, the output will remain on for 5 minutes unless toggled off or the
Test Outputs function is exited by selecting “MENU/ESC.” (The compressor is limited to 15 seconds
on to prevent damage.) The outputs are as follows:
• Main fan: main fan contactor
• Comp: compressor contactor
• LLSV: liquid line solenoid valve
• HGBP/CUV: hot gas bypass or compressor unloader valve (on certain units)
• Part coil: part coil solenoid valve
• CWV/CGV: chilled water or GLYCOOL valve
• R5 Relay: Relay 5 (heat rejection)
• Reheat 1: Reheat 1 contactor (also energizes fan for safety) or SCR Reheats
• Reheat 2: Reheat 2 contactor (also energizes fan for safety)
• HWR: hot water solenoid valve
• Humidifier: humidifier contactor (also energizes humidifier makeup valve and fan for safety)
• HMV: humidifier makeup valve
• Comm alarm: common alarm relay
CAUTION
!
Do not test a compressor output for more than a few seconds. Compressor damage could
result!
Test Control Board
By selecting this function, the microcontroller will perform a self test lasting approximately 10 seconds. At the end of the test, the ROM checksum, ROM part number and version number will be displayed.
12
2.5.4 Change Passwords
The display prompts you to enter a three digit password when making changes. The system includes
two (2) passwords, one for setpoints and one for setup. The system allows the passwords to be changed
by first entering the present password, factory set as “123” for setpoints and “321” for setup. The password function provides system security, so only personnel authorized to make changes should know
the passwords. If unauthorized changes are being made, the passwords may be compromised and new
ones should be selected. The password function can be disabled by setting DIP switch 8 to OFF.
2.6 Date and Time
The current date and time is available through the display. This feature allows the date and time to
be read or changed and is accessed by selecting “DATE AND TIME” from the Main Menu.
The “DATE AND TIME” is used only by the control for recording the Alarm History.
NOTE
The clock uses the 24 hour system (For example: 17:00 would be 5:00 PM). The date and time
are backed up by battery.
2.7 Status Display
The Status Display selected from the Main Menu is the same Status Display that is normally on the
screen. While the Main Menu is displayed, you can press the MENU/ESC key to return to the Status
Display.
Operation with Advanced Microprocessor Controls
NOTE
The system automatically returns to the Status Display in five minutes if no
control keys are pressed.
2.8 Control Circuit Board
The control circuit board is located inside the unit behind the LCD display and control key panel.
Open the front panel for access to the board.
The control board includes an adjustment for LCD display contrast, nonvolatile memory, DIP
switches (which should not require customer changes), control output LEDs and jumpers for board
configuration. The jumpers should be placed as follows:
P5—removed
P12—removed
P19—installed on Pins 1 and 2
P47—installed on Pins 1 and 2
P48—installed on Pins 1 and 2
P50—all jumpers installed for 4-20 mA analog inputs. See 4.5.1 - Connecting the Analog Sen-
sors for other configurations
P51—removed
2.8.1 LCD Display Contrast
The level of contrast due to viewing angle of the LCD display can be adjusted using a small thumb
wheel at the upper left of the control board just under the cable going to the display. The control is
labeled R6.
NOTE
The LED backlighting on the text (4 x 20) display is always lit.
13
2.8.2 Non-Volatile Memory
All critical information is stored in nonvolatile memory. Setpoints, setup parameters, and component
run hours are kept inside the microcontroller in EEPROM. Information retained for the alarm history
is kept in non-volatile RAM.
2.8.3 DIP Switches
Equipment options are selected and enabled using DIP switches 1 through 7. These are located at the
upper left of the control board and are labeled SW1. Switch 1 is at the top. These switches are factory
set and should not require any user changes. The setting and function of the switches can be read
from the LCD display (see Show DIP Switches on page 8 or the accompanying Table 4).
2.8.4 Control Outputs
Active control outputs are indicated with LEDs on the lower section of the control board. Each LED is
lit if the control output is active (on). The LEDs assist in troubleshooting the system. Refer to the following table.
Table 6 Control output LEDs
LED Control Output
R5 Heat Rejection
LLSV Liquid Line Solenoid Valve
HGBP Hot Gas By-Pass or Compressor Unloader Valve
C1 Compressor
RH1 Reheat Stage 1, Hot Gas, Hot Water Reheat Solenoid or SCR Reheats
RH2 Reheat Stage 2
HUM Humidifier
FAN Main Fan
HMV Humidifier Make-Up Valve
LLSV2 Part Coil Solenoid Valve
Operation with Advanced Microprocessor Controls
14
Operation with Advanced Microprocessor with Graphics Control
3.0 OPERATION WITH ADVANCED MICROPROCESSOR WITH GRAPHICS CONTROL
The advanced microprocessor with graphics (G) control for your Liebert Challenger 3000 unit features
an easy to use, menu driven LCD Graphics Display. The menus, control features, and circuit board
details are described in this section. For more details on the control refer to 4.0 - System Perfor-
mance with Advanced Microprocessor Controls; for details on the alarms refer to 5.0 - Alarm
Descriptions.
3.1 Basics
Control keys include ON/OFF, Menu/ESCape, ENTER, Increase (UP) arrow, and Decrease (DOWN)
arrow. Refer to Figure 3. These keys are used to move through the menus as prompted on the LCD
display (refer to Figure 4).
To turn the unit ON, press the ON/OFF key after power is applied. To turn the unit OFF, press the
ON/OFF key before power is disconnected.
Active alarms are indicated on the LCD screen by a ringing bell. Alarms are also annunciated by an
audible beeper. To silence an alarm, press the ENTER key as prompted on the display. The unit
stores the 60 most recent alarms for review.
Setpoints, DIP switch settings, and other selections were made on your unit before testing at the factory and are kept in nonvolatile memory. Setpoints were chosen based on typical operating experience. Other selections were made based on options included with your unit. Make adjustments to the
factory default selections ONLY if they do not meet your specifications. When entering setpoints, time
delays, etc., the allowable ranges are displayed and may require a password, if enabled.
Figure 3 Advanced microprocessor with graphics (G) control panel
15
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