Liebert 3000 User Manual

Precision Cooling

For Business-Critical Continuity

Liebert Challenger™ 3000

Operation & Maintenance Manual - 3 & 5 Ton, 50 & 60Hz

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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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 ft2 (m2) for grilles or perforated panels at output velocities

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

v

vi

Introduction

1.0INTRODUCTION

1.1System 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.

1.1.1Compressorized 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

1.1.2GLYCOOL™ (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

1.1.3Chilled 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

Introduction

1.2Start-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.

! 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

2.0OPERATION WITH ADVANCED MICROPROCESSOR CONTROLS

The advanced microprocessor (A) control for your Liebert Challenger 3000 unit features an easy-to- use 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 Microprocessor Controls, and for more alarm information, refer to 5.0 - Alarm Descriptions.

2.1Basics

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

Normal Display

72°F 50%RH

Status/Alarm Data

Cooling

Setpoints/Setup

Dehumidifying

Date and Time

No Alarms Present

Status Display

Status Alarm Data

Setpoints/Setup

Date and Time

Status Display

Active Alarms

View Setpoints

15-APR-2004 09:30:00

75°F 59%RH

Operating Status

Setup System

Cooling

Alarm History Log

Run Diagnostics

ENTER to change

Dehumidifying

Run Hours Log

Change Passwords

ESCape to exit

No Alarms Present

Active	Operating		Alarm	Run	Analog		View	Setup	Run	Change
Alarms	Status	History Log		Hours Log	Sensors	Setpoints		System	Diagnostics	Password
No Alarms Present		Alarm History Log		Analog Sensors				Run Diagnostics
OR		Alarm 01 of 03		Analog in 1 (2,3,4):xx				Show Inputs
Alarm 01 of 01		15-APR 09:20:45						Test Outputs
				AD #1 (2,3,4)
High Head PR		High Humidity		Use /	to Scroll			Test Control Board
Use / to Scroll		Use /	to Scroll	ESCape to exit
								Setup System
	Operating Status		Run Hours Log				Setup Operation		Change Password
	DX Cool	%	Comp				Cold Start TD		Setpoint Password
							Restart TD
	Heat	%	GLYCOOL** or CW Coil**						Setup Password
							IR Fill Rate
	Econo Cool	%	Fan
							F/C Degrees
	CW Valve	%	Hum
	DX Deh / Hum		RH1				Min CW Temp**
			RH2				CW/HW Flush**
							Select Options
					View Setpoints		Heating
	Alarms Available						Humidifier
					Temp Setpoint		Dehumidifier
							Heat Stages
Standard Alarms					Sensitivity
							Calibrate Sensors
					Hum Setpoint
Humidifier Problems
					Sensitivity		Show DIP Switches (1-7)
High Head Pressures
					High Temp		Select Control Type
Change Filter
					Alarm		Intelligent
Loss of Air Flow
					Lo Temp Alarm		Proportional
	High Temperature
	Low Temperature				High Hum Alarm		Tunable PID
					Lo Hum Alarm
	High Humidity							Proportional Gain
	Low Humidity							Derivative Gain
	Short Cycle							Integral Gain
	Low Suction Pressure						Setup Alarms
	Compressor Overload						Set Time Delays
	Loss of Power
							Enable Alarms
Custom Alarms 1 to 4
							Enable Common Alarm
Programmed Alarm Messages
							Set Custom Alarm
	Water Under Floor
								Select Alarm
	Smoke Detected
	Standby GC Pump On							Change Custom TXT 1,2
	Loss of Water Flow						Hum Control Method
	Standby Unit On						Relative
User Customized Alarm Messages							Absolute
Available for Custom Alarms							Analog Setup
* Some alarms require optional equipment							A/D Input 1 (2,3,4)
							Slope
** Optional							Text
							Intercept
							Set Status Display
							Calibrate Actuator

4

Operation with Advanced Microprocessor Controls

2.2Status 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.

2.3Main 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

2.4Status/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

2.4.1Active 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.

2.4.2Operating 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).

2.4.3Alarm 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

Operation with Advanced Microprocessor Controls

2.4.4Run 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.

2.4.5Analog 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.

2.5Setpoints/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.

2.5.1View 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°F	1 to 9.9°F (0.6 to 5.6°C)
Humidity Setpoint	50%	20 to 80% RH
Humidity Sensitivity	5%	1 to 30% RH
High Temperature Alarm	80°F	35 to 95°F (2 to 35°C)
Low Temperature Alarm	65°F	35 to 95°F (2 to 35°C)
High Humidity Alarm	60%	15 to 85% RH
Low Humidity Alarm	40%	15 to 85% RH

6

Operation with Advanced Microprocessor Controls

2.5.2Setup System

The Setup System menu includes the following selections:

•SETUP OPERATION

•SELECT OPTIONS

•CALIBRATE SENSORS

•SHOW DIP SWITCHES

•SELECT CONTROL TYPE (Chilled Water or SCR Reheats only)

•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.

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).

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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
Heating1		Yes or No
Humidifier		Yes or No
Dehumidifier		Yes or No
Hot Gas Reheat2		Yes or No
Heat Stages3		2

1Heating cannot be disabled on units with SCR reheats. 2Hot gas reheat not available on units with SCR reheats. 3Heat stages not selectable on units with SCR reheats.

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
7a		Tight Control	Standard Control

a SCR reheats only (with special software); otherwise, not used.

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.

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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	Delay (seconds)
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

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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. With absolute humidity 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.

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.

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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.

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Operation with Advanced Microprocessor Controls

2.5.3Run 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

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.

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Operation with Advanced Microprocessor Controls

2.5.4Change 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.

2.6Date 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.

2.7Status 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.

NOTE

The system automatically returns to the Status Display in five minutes if no control keys are pressed.

2.8Control 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 Sensors for other configurations

P51—removed

2.8.1LCD 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.

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Operation with Advanced Microprocessor Controls

2.8.2Non-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.

2.8.3DIP 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).

2.8.4Control 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

14

Operation with Advanced Microprocessor with Graphics Control

3.0OPERATION 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 Performance with Advanced Microprocessor Controls; for details on the alarms refer to 5.0 - Alarm Descriptions.

3.1Basics

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