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Emerson 3000 Furnace User Manual

1. 21 22 23 24 25 DPN001734 Rev 0 DPN001733 il j E Rev 0 Upflow Models with Liebert COM Downflow Models with Liebert iCOM 19 20 Network Cable C Connection Eight wire Ethernet cable from U2U networking switch Network Cable D connection Eight wire Ethernet cable from U2U networking switch Cable D connection supplied on units with large Liebert iCOM display only Opening for Field Wiring Suggested entry point for all field wiring to unit Hole size 2 5 63 5mm Loose Wire Ties To secure field supplied network cables Tighten after all field supplied wires have been installed Vacant Liebert IntelliSlot May contain optional Liebert IntelliSlot cards Populated Liebert IntelliSlot Optional Liebert IntelliSlot cards may be placed in either of the two supplied Liebert IntelliSlot locations Remote Temperature Humidity Sensor Connection Six wire CAN cable supplied with optional remote T H sensor 20 Installation Applicable to all Models 2 8 2 8 1 2 8 2 2 8 3 Balancing the Air Distribution Under Floor Discharge Systems The systems are designed for constant air delivery therefore any unusual restrictions within the air circuit must be avoided For under floor air distribution observe the following guidelines Select the air
2. J ilr Liquid Refrigerant Line 11 Quick Connect on Models BU036E BU035E 6 Quick Connect on Models BUO36E BU035E 1 1 8 OD CU on Models BUO60E BU059E Condensate Pump Line 1 2 OD CU used only 5 8 OD CU optional if optional condensate pump is ordered 1 2 OD CU on Models BUO60E BU059E iCOM Control Panel AM SS N AMM Vy 90 G QU LLL QQ gt gt PIPING OUTLET LOCATIONS T See Cabinet and Floor Planning Condensate Drain 3 4 FPT Dimensional Data for Piping Field pitch a min of 1 8 3 2mm per ft 305mm Units without Opening Sizes a condensate pump have a factory supplied trap in the unit so a field trap should not be added Units with a condensate pump will require a field supplied trap downstream from the pump The drain line must comply with all applicable codes If condensate pump is ordered piping is out top of unit DPN000375 Rev 01 13 Installation Applicable to all Models Figure 8 Piping connections for water glycol and GLYCOOL units Downflow models COM Control Panel Condenser Supply Line 7 8 OD CU on Models BFO46WG BF045WG 1 1 8 OD CU on Models BF071WG BF070WG Condenser Return Line 7 8 OD CU on Models BFO46WG BF045WG 1 1 8 OD CU on Models BF071WG BF070WG Hot Water Return 5 8 OD CU optional Condensate Drain 3 4 FPT
3. 7 8 22 2mm Dia Electrical Entrance for Low Voltage Connection Suction Line Male Quick Connect Liquid Line Male Quick Connect PIPING CONNECTIONS SL 11085 Pg 4 67 Split System Models Figure 37 3 ton centrifugal air cooled condensing unit con t Field supplied unit disconnect switch when optional disconnect is not provided in unit Single or three phase electric service not by Liebert Field su NEC Class 2 wiring to fan coil unit Factory wired to components on electric panel Optional factory installed Line voltage electric power disconnect switch supply conduit entrance Single or three phase electric service not by Liebert Connection terminal for field supplied grounding wire Low voltage electric power supply entrance Heat rejection connection Field supplied 24V NEC Class 2 wiring See NOTE 2 Wire connections from evaporator mo Revo 1 24V ground 2 24V supply 3 High pressure alarm optional NOTES OR ne 4 Hot gas bypass connection 1 Refer to specification sheet for full load amp and wire size amp ratings only on units with hot gas 2 Control voltage wiring must be a minimum of 16 GA 1 6mm for up to 75 23m bypass or not to exceed 1 volt drop in control line 68 Split System Models Figure 38 5 ton centrifugal air cooled condensing unit dimensional data 32 812 8mm 2 Cabinet MAS 2 Dimension Cabinet 1 5 8 D
4. Components are not supplied by Liebert but are recommended for proper circuit operation and maintenance Check Val ar en Components supplied by Liebert Hot Gas Discharge and must be field installed a FACTORY PIPING Deal Rev 0 OPTIONAL PIPING Z FIELD PIPING 34 Water Cooled Models Self Contained Compressor 4 0 WATER COOLED MODELS SELF CONTAINED COMPRESSOR 4 1 Piping Considerations Manual shutoff valves should be installed at the supply and return lines of each unit This will pro vide for routine maintenance or emergency isolation of the unit When the water source for the condenser is of poor quality it is good practice to provide cleanable fil ters in the supply line These filters will trap the particles in the water supply and extend the service life of the water cooled condenser To provide for the emergency of water leaks and the consequences of sub floor flooding floor drains should be provided with wet traps or a water detection system such as a Liebert Liqui tect sensor that is installed near the base of the unit or below the elevated floor 4 2 Condenser The condenser is designed to operate in conjunction with either a cooling tower or city water The maximum water pressure is 150 psig 1034 kPa A high pressure system rated at 350 psig 2413 kPa is available as an option 35 Water Cooled Models Self Contained Compressor Figure 19 General arrangement Water cool
5. Field pitch a minimum of 1 8 3 2mm per ft 305mm The drain line must comply with all applicable codes Humidifier Water Supply Line Y 1 4 OD CU Hot Water Supply 5 8 OD CU optional PIPING OUTLET LOCATIONS See Cabinet and Floor Planning DPN000364 Dimensional Data for Piping Rev 01 Opening Sizes 14 Installation Applicable to all Models Figure 9 Piping connections for water glycol and GLYCOOL units Upflow models mmi Piping outlet locations through the plenum Humidifier Water Supply Line 4 1 4 OD CU Condenser Return Line 7 r 7 8 OD CU on Models BU046WG BU045WG 1 1 8 OD CU on Models BU071WG BU070WG Condensate Pump Line 1 2 OD CU Used only if optional condensate pump is ordered ANNL Condensate Drain a 3 4 FPT Field pitch a min of 1 8 3 2mm per ft 305mm Units without a condensate pump have a factory supplied trap in the unit so a field trap should not be added Units with a condensate pump will require a field supplied trap downstream from the pump The drain line must comply with all applicable codes If condensate pump is ordered piping is out top of unit Tr TLL ANANN the same as the unit See below for descriptions and connection sizes Hot Water Return 5 8 OD CU optional Condenser Supply Line 7
6. WARNING Risk of electric shock Can cause injury or death Disconnect local and remote power supplies before working within Before proceeding with installation read all instructions verify that all the parts are included and check the nameplate to be sure the voltage matches available utility power The Liebert iCOM microprocessor does not isolate power from the unit even in the unit off mode Some internal components require and receive power even during the unit off mode of Liebert iCOM control The factory supplied optional disconnect switch is inside the unit The line side of this switch contains live high voltage The only way to ensure that there is NO voltage inside the unit is to install and open a remote disconnect switch Refer to unit electrical schematic Follow all local codes WARNING Risk of explosive discharge from high pressure refrigerant Can cause injury or death This unit contains fluids and gases under high pressure Relieve pressure before working with piping WARNING Risk of refrigerant system rupture or explosion from overpressurization Can cause equipment damage injury or death If a pressure relief device is not provided with the condenser unit the system installer must provide and install a discharge pressure relief valve rated for a maximum of 500 psig 34bar in the high side refrigerant circuit Do not install a shutoff valve between the compressor and the field installed
7. oooooooooooo 29 General arrangement Air cooled models with digital scroll and fan speed control 30 General arrangement Air cooled models with Liebert Lee Temp o oooooooooooo 33 General arrangement Air cooled models with digital scroll and Lee Temp 34 General arrangement Water cooled models with scroll compressor ooooooooo 36 General arrangement diagram Water cooled models with digital scroll 37 Johnson Controls valve adjustment 38 Metrex Valve adjustment 39 Drycoolers and pump packages oooooorrr essen eeeeeeeeeneeenene 47 Pump packages expansion tank 1 1 0 0 ccc eee teen nee ens 48 General arrangement Glycol cooled models with scroll compressor 222222222 49 General arrangement Glycol cooled models with digital scroll o o oooooo o 50 General arrangement GLYCOOL models with scroll compressor 0 00 0c ee eae 51 General arrangement GLYCOOL models with digital scroll compressor 52 Chilled water general arrangement Upflow BU 22222 ccc cence 54 Chilled water general arrangement Downflow BF models 22222 ces 55 Refrigerant piping diagram eee nent ee eee ene ees 59 Outdoor air cooled condensing unit horizontal air discharge models 60 Outdoor air cooled condensing unit top air discharge models 0000 eee oo 62
8. 77 R407C Refrigerant Table 34 R407C pressure temperature chart for subcooling only liquid measurements Temperature Pressure Gauge Temperature Pressure Gauge Temperature Pressure Gauge F C Psig kPa F C Psig kPa F C Psig kPa 36 0 2 2 73 500 59 0 15 0 114 786 94 0 34 4 203 1402 37 0 2 8 74 511 60 0 15 6 116 801 96 0 35 6 209 1444 38 0 3 3 76 522 98 0 36 7 216 1488 39 0 3 9 77 533 100 0 37 8 222 1532 40 0 4 4 79 544 102 0 38 9 229 1578 41 0 5 0 81 556 104 0 40 0 236 1624 42 0 5 6 82 567 106 0 41 1 242 1671 43 0 6 1 84 579 108 0 42 2 249 1720 44 0 6 7 86 591 110 0 43 3 257 1769 45 0 72 87 602 112 0 44 4 264 1819 46 0 7 8 89 615 69 0 20 6 136 938 114 0 45 6 271 1870 47 0 8 3 91 627 70 0 21 1 138 954 116 0 46 7 279 1922 48 0 8 9 93 639 72 0 22 2 143 987 118 0 47 8 287 1975 49 0 9 4 95 652 74 0 23 3 148 1021 120 0 48 9 294 2029 50 0 10 0 96 664 122 0 50 0 302 2085 51 0 10 6 98 677 124 0 51 1 310 2141 52 0 11 1 100 690 126 0 52 2 319 2198 53 0 11 7 102 704 128 0 53 3 327 2256 54 0 12 2 104 717 130 0 54 4 336 2315 55 0 12 8 106 730 132 0 55 6 345 2376 56 0 13 3 108 744 134 0 56 7 354 2437 57 0 13 9 110 758 136 0 57 8 363 2500 58 0 14 4 112 772 138 0 58 9 372 2563 140 0 60 0 381 2628 NOTE Use this table for subcooling calculation ONLY See Table 33 for superheat or control adjustment 8 1 Calculating Subcooling
9. See Table 21 for field charge required If field supplied refrigerant piping is installed refrigerant must be added to the system Once all piping is complete check for leaks and dehydrate the field piping as follows 1 Pressurize the field piping to 150 PSIG 1034 kPa using dry nitrogen with a trace of refrigerant Check system for leaks with a suitable leak detector 2 After completion of leak testing release the test pressure per local code and pull a deep vacuum on the field piping with a suitable pump 3 After 15 minutes check the pressure readings and if they have not changed break vacuum with dry nitrogen Pull a second vacuum to 250 microns or less Recheck the pressure after 15 minutes Table 21 Unit refrigerant charge R407C Charge R407C Charge Model Ib kg Model Ib kg BF BU 036E 0 5 0 2 PF_042A H 25 8 11 7 BF BU 035E 0 5 0 2 PF_041A H 25 8 11 7 BF BU 060E 0 8 0 4 PF_067A L 25 8 11 7 BF BU 059E 0 8 0 4 PF_066A L 25 8 11 7 MC_40 39A 12 9 5 8 PF_Z67A L 50 1 22 7 MC_65 64A 26 1 11 8 PF_Z66A L 50 1 22 7 PF_042A L 12 9 5 8 PF_067A _H 50 1 22 7 PF_041A L 12 9 5 8 PF_066A _H 50 1 22 7 PF_Z42A L 25 8 11 7 MC_44 43W 3 4 1 5 PF_Z41A L 25 8 11 7 MC_69 68W 5 9 2 7 Table 22 Line charges refrigerant per 100 ft 30 m of Type L copper tube R407C Liquid Line Suction Line O D Ib kg Ib kg 1 2 7
10. These traps will collect condensed refrigerant and refrigerant oil during the off cycle of the unit and ensure flow of refrigerant oil during operation A check valve is factory supplied with the unit to be field installed on the discharge side of the scroll compressor Be sure to install the check valve with the refrigerant flow in the proper direction When soldering or brazing the valve 1t is very important to protect the internal parts by wrapping the valve with a damp cloth to keep the valve temperature below 250 F 121 C Approval is required whenever a refrigerant piping run exceeds 150 ft 46 m equivalent length an R407C system condenser must be located below the level of the cooling coil Total discharge line pressure drop must not exceed 10 PSIG 69 kPa Consult your local Liebert representative when considering installations outside these guidelines Table 5 Recommended line sizes OD copper inches 3 5 ton 042A 040A 5 ton 067A 065A Equivalent Length Hot Gas Line Liquid Line Hot Gas Line Liquid Line 50 ft 15 m 5 8 1 2 718 1 2 100 ft 30 m 3 4 1 2 718 5 8 150 ft 45 m 3 4 5 8 718 5 8 Recommended vertical line sizes must be used for proper oil return at all cooling and dehumidification steps 25 Air Cooled Models Self Contained Compressor Table 6 Equivalent lengths feet for various pipe fittings Copper Pipe 90 Degree 90 Degree 45
11. 119 3 822 2 0 16 7 20 4 141 74 0 23 3 124 853 3 0 16 1 21 2 146 76 0 24 4 128 885 4 0 15 6 22 0 152 78 0 25 6 133 917 5 0 15 0 22 8 157 80 0 26 7 138 950 6 0 14 4 23 6 163 82 0 27 8 143 984 7 0 13 9 24 5 169 84 0 28 9 148 1019 8 0 13 3 25 4 175 86 0 30 0 153 1054 9 0 12 8 26 2 181 88 0 31 1 158 1091 10 0 12 2 27 1 187 90 0 32 2 164 1128 11 0 11 7 28 0 193 92 0 33 3 169 1167 12 0 11 1 28 9 200 94 0 34 4 175 1206 13 0 10 6 29 9 206 96 0 35 6 181 1246 14 0 10 0 30 8 213 98 0 36 7 187 1287 15 0 9 4 31 8 219 100 0 37 8 193 1329 16 0 8 9 32 8 226 102 0 38 9 199 1372 17 0 8 3 33 8 233 104 0 40 0 205 1416 18 0 7 8 34 8 240 106 0 41 1 212 1461 19 0 7 2 35 8 247 108 0 42 2 219 1507 20 0 6 7 36 9 254 110 0 43 3 225 1553 21 0 6 1 38 0 262 112 0 44 4 232 1601 22 0 5 6 39 0 269 114 0 45 6 239 1650 23 0 5 0 40 1 277 116 0 46 7 247 1701 24 0 4 4 41 3 284 118 0 47 8 254 1752 25 0 3 9 42 4 292 120 0 48 9 262 1804 26 0 3 3 43 6 300 122 0 50 0 269 1858 27 0 2 8 44 7 308 124 0 51 1 277 1912 28 0 2 2 45 9 317 126 0 52 2 285 1968 29 0 1 7 47 1 325 128 0 53 3 294 2025 30 0 1 1 48 4 333 130 0 54 4 302 2083 31 0 0 6 49 6 342 132 0 55 6 311 2143 32 0 0 0 50 9 351 134 0 56 7 320 2203 33 0 0 6 52 1 359 136 0 57 8 329 2265 34 0 1 1 53 5 369 69 0 20 6 112 8 778 138 0 58 9 338 2329 140 0 60 0 347 2393 NOTE Use this table for superheat and for control adjustment e g pressure switches See Table 34 for subcooling
12. 4 121 7 3 4 197 8 1 2 216 PFCO67A _L PFCO66A _L PFHO67A _L 61 Split System Models Figure 33 Outdoor air cooled condensing unit top air discharge models Guard Height Top Air Discharge Right Air UNIT DIMENSIONS Discharge see Table 28 i Shaded area indicates o o 0 a minimum clearance of 18 457mm for proper air flow Left Air Intake Shaded area indicates a minimum clearance of 18 457mm for proper air flow Shaded area indicates a minimum clearance of 24 610mm for component access and removal Removable Front Panel for access to high voltage and low voltage connections and refrigeration components 36 1 8 918mm 2 typ a 66 102mm 1351mm DIMENSIONS 2 ye 112 13mm 51mm Bolt Down Holes 6 places 4 23 32 120mm TA aaor 637mm 16mm 3 6 7159 51mm ieee 1174mm Pg 5 Electrical Entrance A for High Voltage Connection PIPING amp ELECTRICAL CONNECTIONS see Table 29 Electrical Entrance for Low Voltage Connection Liquid Line Quick Connect Male Coupling D Suction Line Quick Connect SL 11081 Male Coupling Pg 7 62 Split System Models Table 28 Cabinet and floor planning dimensional data prop fan condensing modules top air discharge Model Numbers Dimensional Data in mm 60 Hz 50 Hz PFCO67A
13. 8 fender washer 3 8 hex nut 3 8 hex nut Nylock ake Unit base pan ref The total external static pressure for the inlet and outlet ducts including grille must not exceed 0 5 inches of H20 Hood intake dimensions should be the same as the condensing unit duct dimen sions Ducting If the condensing unit is located close to the outside of the building rain hoods must be installed In addition install a triple layer bird screen over rain hood openings to eliminate the possibility of insects birds water or debris entering the unit Use flexible ductwork or nonflammable cloth collars to attach ductwork to the unit and to control vibration transmission to the building Attach the ductwork to the unit using the flanges provided Locate the unit and ductwork so that the return air does not short circuit to the supply air inlet Avoid directing the hot exhaust air toward adjacent doors or windows Normal operating sound may be objectionable if the condensing unit is placed directly over quiet work areas Ductwork that runs through a conditioned space or is exposed to areas where condensation may occur must be insulated Whenever possible ductwork should be suspended using flexible hang ers Ductwork should not be fastened directly to the building structure In applications where the ceil ing plenum is used as the heat rejection domain the discharge air must be directed away from the condensing unit air inlet and a screen must be
14. 95 F 85 C ambient at sea level Optional Digital scroll compressor with unloading solenoid valve is also available Digital scroll compressor systems do not include hot gas bypass Water Cooled Models Compete refrigeration system including hot gas bypass with standard scroll compressor water glycol cooled condenser and two way water regulating valve with bypass Optional digital scroll compressor with unloading solenoid valve is also available Digital scroll compressor systems use a 2 way motor ized ball valve in lieu of the regulating valve they do not include hot gas bypass Glycol Cooled Models The water cooled model as described above plus pump package and 95 F 35 C design ambient dry cooler GLYCOOL Models 5 Ton Only Complete refrigeration system including hot gas bypass with standard scroll compressor glycol con denser and three way water regulating valve plus an integrally piped Econ O Coil with three way mod ulating control valve Optional digital scroll compressor with unloading solenoid valve is also available Digital scroll compressor systems use a 3 way motorized ball valve in lieu of the regulating valve they do not include hot gas bypass Chilled Water Models Chilled Water models include chilled water piping three way modulating valve and actuator assem bly Introduction 1 1 3 Split Systems Each air cooled split system consists of an evaporator section and one of the following condensing
15. A a ESA SRS ee Tee 40 44 38 ar LUD Eee Ed NM i oa ely ee Ws 40 AAA Locations aeeie r ne as ne Bee AR 40 SAS Manual Controla a Ad eii a 40 5 0 5 1 5 2 5 3 5 4 5 5 5 6 5 7 6 0 6 1 7 0 7 1 1 2 1 3 7 4 1 5 7 6 8 0 8 1 GLYCOL GLYCOOL COOLED MODELS SELF CONTAINED COMPRESSOR Drycooler OCACIONES N a EPI O Be Le Drycooler Installation ate rdi mt as 2a ea es a Electrical Connections instand He ds ee ia bd dr 5 3 1 RA A Eier er Seas ws ee a nee 5 3 2 Bow Voltage ii ee ne ee Re se ea te 9 3 3 Pump and Drycooler ne 2 2 A ERBE as ee ne ie ne e ee bach Glycol Biping 2 2 2 242 Mar othe age a set ab ar thts Ra EA 5 4 1 Expansion Tanks Fluid Relief Valves and Other Devices o ooooooooooooo o o Filling Instructions u a Rn PEE el E A ri 5 5 1 Preparing the System for Filling ce eee eee A A Solutions a8 8 ce es E Ae Seb ee ath ace ed 5 09 93 Fla the Systemi rss ne SA ow nee a OSI BD be wht a node A 5 5 4 Motor Ball Valve Digital Scroll Compressors 0 0 ccc eee eens Condenser ss palcos rs A ae he da ees ew Lio Glycol R sulating Valve nv bles oh ak 02 mer a eh hea Ran 5 7 1 Standard Valve 150psig 1034kPa System for 3 5 Ton Units Johnson Controls Valve High Pressure Valve 350psig 2413kPa System for 5 Ton Units Johnson Controls Valve a Se ee a As 5 7 2 High Pressure Valve 350 psig 2413 kPa System for 3 Ton Units Metrex Valv
16. Figure 16 Figure 17 Figure 18 Figure 19 Figure 20 Figure 21 Figure 22 Figure 23 Figure 24 Figure 25 Figure 26 Figure 27 Figure 28 Figure 29 Figure 30 Figure 31 Figure 32 Figure 33 Figure 34 Figure 35 Figure 36 Figure 37 Figure 38 Figure 39 Figure 40 Figure 41 Figure 42 Figure 43 Figure 44 FIGURES Removing Challenger from skid c oo anane eere 6 Upflow BU cabinet dimensions 7 Downflow BF cabinet dimensions 8 Piping connections for air cooled units Downflow models 00 cece eens 10 Piping connections for air cooled units Upflow models ooooocooooorooooo oo 11 Piping connections for split system fan coil units Downflow models 12 Piping connections for split system fan coil units Upflow models o oooooooo 13 Piping connections for water glycol and GLYCOOL units Downflow models 14 Piping connections for water glycol and GLYCOOL units Upflow models 15 Piping connections for chilled water self contained units Downflow models 16 Piping connections for chilled water self contained units Upflow models 17 Electrical connections sig ne ee Bees ED Bee Sara a wh a 19 Electrical field connections for Liebert iCOM 0 cee eee nes 20 Air cooled Condensers seis re dee a ea er Lana aan ae ae ee ish 24 General arrangement Air cooled models with fan speed control
17. _H PFCO66A _H PFHO67A _H PFCZ67A _L PFCZ66A _L A 53 1343 B 36 1 4 918 38 1 2 978 Cc 5 1 2 140 Module Weight Ib kg net 488 222 Table 29 Piping and electrical connections top air discharge Model Numbers Dimensional Data in mm Piping Connections in mm 60 Hz 50 Hz PFCO67A _H PFCO66A _H PFHO67A _H PFCZ67A _L PFCZ66A _L A 2 51 B Cc 6 152 8 1 2 216 D 4 3 4 121 E 7 3 4 197 F 8 1 2 216 63 Split System Models Figure 34 Electrical field connections prop fan condensing module Field supplied unit disconnect switch HORIZONTAL AIR DISCHARGE MODELS Field supplied 24V NEC Class 2 wiring to evaporator module RN I i LS Mo j i lin O U N x Single or en 3 phase electric service not by WA Liebert Electric service connection to contactor or terminal block Single or 3 phase electric service not by Liebert High voltage electric power supply entrance Low voltage electric power supply entrance Earth ground connection terminal for field wiring NOTE Refer to specification sheet for full load amp SL 11081 Pg 8 and wire size amp ratings TOP AIR DISCHARGE MODELS 5 Ton High Ambient amp 5 Ton Quiet Line A l l SL 11081 Pg 8A Field supplied 24V Single or NEC Class 2 w
18. air adds to the heating cool ing humidifying and dehumidifying loads of the site It is recommended that outside air be kept below 5 of the total air circulated in the room and be preconditioned Equipment Inspection Upon arrival of the unit inspect all items for visible and concealed damage Damage should be imme diately reported to the carrier and a damage claim filed with a copy sent to Liebert or to your sales representative Location Considerations The unit can sit on top of an accessible elevated flooring system It may be necessary to furnish addi tional pedestal support below the unit to ensure maximum structural support see Table 1 A sepa rate floor stand for the unit may be used as support independent of the elevated floor and installed prior to the flooring system Provide approximately 34 864 mm service clearance on the front of the unit NOTE GLYCOOL units require 34 864 mm service clearance on the right side of the unit in addition to front service clearance Avoid placing units in an alcove or at the extreme end of a room that has a high aspect ratio long narrow room Ducted units can be placed in room corners or ends as long as front access is main tained Placing units too close together will reduce the effectiveness of the air distribution NOTE Locate and remove shipping screw on fan motor base Equipment Handling WARNING A Risk of top heavy unit falling over Improper handling can cause
19. and open a remote disconnect switch Refer to unit electrical schematic Use voltmeter to make sure power is turned off before making any electrical connections Line Voltage Line voltage electrical service is required for all condensing units at the location of the condensing unit This power supply does not have to be the same voltage as the indoor unit This separate power source may be 208 230 460 or 575V 60 Hz or 200 230 or 380 415V 50 Hz A disconnect switch is required and must be mounted per local and national codes to isolate the unit for maintenance 56 Split System Models 7 2 2 Low Voltage 7 3 7 3 1 The control cable between the condensing unit and the evaporator unit is connected between termi nals 1 2 and 3 on the terminal strip in the evaporator unit and the condensing unit control box A fourth wire is required on systems with hot gas bypass NEC Class 1 wiring is required Glycol cooled units also require a two wire control connection to the drycooler and pump package Piping Considerations Refrigerant Loop NOTICE Risk of improper refrigerant charge Risk of equipment damage environmental degradation and violation of national state and local law Follow all applicable codes for handling refrigerant R22 and R407C are similar in properties proper safety equipment and proper refrigeration tools are required on both types Check unit nameplate for correct refrigerant type before topping off or
20. be considered Open all operating systems to the loop With the top vent s open fill the system from the bottom of the loop This will allow the glycol to push the air out of the top of the system minimizing trapped air Fill to approximately 80 of calcu lated capacity Fill slowly from this point checking fluid levels until full NOTE For glycol solution preparation and periodic testing follow manufacturer s recommendations Do not mix products of different manufacturers 46 Glycol GLYCOOL Cooled Models Self Contained Compressor Figure 23 Drycoolers and pump packages DRYCOOLER PS 43 9 16 P 1105mm GLYCOL PUMP PACKAGE gt See Note 1 Sn 19 483mm O NS B 1097mm De Provided on See Table 18 for keys to dual pump dimensions A B and C package only 37 718 1095mm PUMP PACKAGE 1 2 diameter holes MOUNTING ANGLES for mounting 4 typ Notes 1 Single pump packages are 17 1 4 438 mm wide Dual pump packages ar 32 1 4 819 mm wide 2 Mounting holes are 15 1 4 387 mm apart on single pump packages and 30 1 4 768 mm apart on dual pump Note Angles located 2 inside bottom of pump package View used for mounting reference 3 4 19mm a S packages IK 3 Connection sizes apply to primary pumz Ro me supplier See Table 17 for keys to dimensions A B and C For expansion tank dimensions see Fig
21. box Air Cooled condenser Piping access cover to be reinstalled when piping is complete models with one to four fans only Bolts four per leg 3 8 x 5 8 Terminal block for two wire 24V interlock connection between unit and condenser Condenser legs four with 1 fan six on two three and six fan models and eight on four and eight fan models Bolts six per receiver 3 8 x 1 Lee Temp system Insulated storage receiver Head pressure control valve with integral check valve Service valve Pressure relief valve Liquid level sight glass Check valve NOTE Lee Temp heater pads require a separate continuous electrical source See nameplate on unit for proper voltage Lee Temp Leak Check and Evacuation Procedure Proper leak check and evacuation can be accomplished only with all system solenoid valves open and check valves accounted for NOTE Q Systems with scroll or digital scroll compressors include a factory installed check valve and an additional downstream Schrader valve with core in the compressor discharge line Proper evacuation of the condenser side of the compressor can be accomplished only using the downstream Schrader valve See piping schematic Figure 18 1 If unit power is available open the unit liquid line solenoid valves using the evacuation function in the diagnostic section of the Liebert COM control If unit power is not available a field supplied 24VAC 75VA power source must be
22. equipment damage injury or death Read all of the following instructions before attempting to move lift remove packaging from or preparing unit for installation The instructions below are to be adhered to when handling this unit with or without the skid There is the potential for this unit to tip over if it is handled improperly Installation Applicable to all Models 2 4 1 Handling With Skid Always keep the unit upright indoors and protected from damage If possible transport the unit using a fork lift otherwise use a crane with belts or cables avoid ing pressing on the top edges of the packaging If using a fork lift make sure the forks if adjustable are spread to the widest allowable distance to still fit under the skid NOTICE Risk of overhead interference Can cause unit and or structure damage Refer to the installation plans prior to moving the unit to verify clearances While on the skid the unit is too tall to fit through a standard height doorway 83 inches or 2108 mm tall Any attempt to move the unit while on the skid through a standard doorway will cause damage to the unit 2 4 2 Removal of Skid Remove the plywood skirting that keeps the skid and unit in place Raise the Challenger 3000 off the skid Liebert recommends using a fork lift see Figure 1 or similar machine to ensure that the unit is lifted properly Once the unit is raised the skid can be removed Figure 1 Removing Ch
23. located above the dropped ceiling or any remote indoor area If noise is of concern the condensing unit should be located away from personnel Normal operating sound may be objectionable if the condensing unit is placed near quiet work areas To mount the unit in the ceiling refer to 7 5 1 Installing the Indoor Condensing Unit for hang ing guidelines and to Figure 35 Detail of ceiling hanging bracket for dimensional data Water Glycol Cooled Condensing Units The condensing unit may be located above the dropped ceiling or any remote indoor area If noise is of concern the condensing unit should be located away from personnel Normal operating sound may be objectionable if the condensing unit is placed near quiet work areas To mount the unit the in ceiling refer to 7 5 1 Installing the Indoor Condensing Unit Electrical Connections Refer to equipment nameplate regarding wire size and circuit protection requirements Refer to elec trical schematic when making connections Make all wiring and electrical connections in accordance with local and national codes A WARNING Risk of electric shock Can cause injury or death Potentially lethal voltages exist within this equipment during operation Observe all cautions and warnings on unit and in this manual The Liebert iCOM microprocessor does not isolate power from the unit even in the Unit Off mode The only way to ensure that there is NO voltage inside the unit is to install
24. must be installed in the system to avoid the possibility of burst pipes This valve may be obtained from the supplier as an option or obtained from another vendor Emerson recommends installing manual service shut off valves at the supply and return connections to each unit This enables routine service and or emergency isolation of the unit In addition multiple pump packages require a check valve at the discharge of each pump to prevent back flow through the standby pump s To facilitate filling installation of hose bibs at the lowest point of the system is recommended Consideration of the minimum glycol temperature to be supplied from the drycooler will determine if the need exists to insulate the glycol supply and return lines Insulation will prevent condensation on the glycol lines in low ambient conditions All fluid piping must comply with local codes Care in sizing pipes will help reduce pumping power and operating costs Table 13 Room dew point temperatures Dry Bulb Wet Bulb Relative Dew Point F C F C Humidity F C 70 21 1 57 2 14 0 45 48 0 8 9 70 21 1 58 5 14 7 50 50 5 10 3 72 22 2 58 9 24 9 45 50 0 10 0 72 22 2 60 0 15 5 50 52 4 11 3 75 23 8 61 2 16 2 45 52 4 11 3 75 23 8 62 5 16 9 50 55 0 12 7 Minimum glycol temperature before condensation will occur 43 Glycol GLYCOOL Cooled Models Self Contained Compressor 5 4 1 5 5
25. property damage The refrigeration piping should be isolated from the building by the use of vibration isolating supports When installing field piping care must be taken to protect all refrigerant lines from the atmosphere especially when using refrigerants with POE oils Do not allow the piping to stand open to air for more than 15 minutes Units designed for R407C have a compressor that contains POE oil that is very hygroscopic that is it quickly absorbs water from the air The longer the compressor piping is left open to air the harder it will be to fully evacuate If left open too long the POE oil may need to be replaced before achieving the required vacuum level Keep the evaporator unit and condenser closed with their factory charge of dry nitrogen while all field piping is installed Keep the field piping clean and dry during installation and do not allow it to stand open to the atmosphere When all the field interconnecting piping is in place vent the condenser dry nitrogen charge and connect to the field piping Finally vent the evaporator unit dry nitrogen charge and make its piping connections last Follow all proper brazing practices including a dry nitrogen purge to maintain system cleanliness NOTE Piping including inverted trap s must be routed to allow unobstructed access to the panel per the NEC Traps should be installed in the hot gas line on vertical risers at the base and every 25 feet 7 6 meters in elevation
26. resistance to air flow Careful planning of the piping layout under the raised floor is required to prevent the air flow from being blocked When installing piping on the subfloor it is recommended that the pipes be mounted in a horizontal plane rather than stacked one above the other Whenever possible the pipes should be run parallel to the air flow Condensate pumps for downflow units are shipped separately to be field installed under the raised floor Pump height is 11 inches 279 mm Drain Line A 3 4 19 1 mm female pipe thread FPT connection is provided for the evaporator coil condensate drain This drain line also drains the humidifier if applicable The drain line must be located so it will not be exposed to freezing temperatures The drain should be at least the full size of the drain connec tion and pitched a minimum of 1 8 per ft 11 mm per meter Q NOTE This line may contain boiling water Select appropriate drain system materials The drain line must include one and only one trap Units without a condensate pump have a factory supplied trap in the unit so a field trap should not be added Units with a condensate pump will require a field supplied trap downstream from the pump The drain line must comply with all applicable codes Table 2 Piping connection size Air Cooled Unit Connection Sizes in Model No BF BU Liquid Line O D Copper Hot Gas
27. supply grilles and perforated panels for the raised floor to ensure minimum loss of pressure in the circuit Air volume dampers on grilles which extend several inches below the sur face of the raised floor are usually detrimental to airflow Consideration of the height of the damper on the grille in conjunction with the floor height will determine whether this type of grille may be used The grilles used in raised floors vary in size the largest being approximately 18 x 6 457 x 152 mm A larger grille size would be detrimental to the structural capacity of the raised floor panel An 18 x 6 457 x 152 mm heavy duty pencil proof type grille typically has 56 square inches 0 036 m of free area Perforated panels are available from various manufacturers of raised floors These panels are usually 2 x 2 610 x 610 mm square and have a nominal free area of approximately 108 to 144 square inches 0 07 to 0 09 m Use caution in selecting perforated panels as some manufacturers have only 36 to 40 square inches 0 023 to 0 026 m of free area requiring four times as many panels Avoid floor elevations below 7 1 2 190 5 mm loosely installed flooring systems and below floor obstructions such as electrical wiring chases unusually long electronic system cables or piping clusters Always check specifications of the floor supplier before specifying the total number of perforated panels and grilles required to handle the air flow The prop
28. units Prop Fan Air Cooled Prop Fan units include scroll compressor condenser coil prop fan high pressure switch hot gas bypass and Liebert Lee Temp head pressure control Unit is designed for outdoor location Centrifugal Fan Air Cooled Centrifugal Fan units include scroll compressor condenser coil centrifugal blower assembly high pressure switch hot gas bypass and Liebert Lee Temp head pressure control Unit must be mounted indoors Duct flanges are optional Water Cooled Each water cooled split system consists of an evaporator section and a water glycol condensing unit which includes scroll compressor coaxial condenser water regulating valve hot gas bypass and high pressure switch Design pressure is 150 psi 1034 kPa as standard and 350 psi 2413 kPa as optional Glycol Cooled Each glycol cooled split system consists of an evaporator section a water glycol condensing unit as described above a pump package and a 95 F 35 C design ambient drycooler Installation Applicable to all Models 2 0 INSTALLATION APPLICABLE TO ALL MODELS 2 1 2 2 2 3 2 4 Room Preparation The room should be well insulated and must have a sealed vapor barrier The vapor barrier in the ceiling can be a polyethylene film type Use a rubber or plastic base paint on concrete walls and floors Doors should not be undercut or have grilles in them Outside or fresh air should be kept to an absolute minimum Outside
29. when factory disconnect switch 1s supplied Factory installed disconnect switch Optional Three phase electric service field supplied Earth ground connection 50 60Hz Connection terminal for field supplied earth grounding wire Earth ground bar 50Hz only Connection terminals with factory ground from each high voltage component for field supplied earth grounding wire Control and monitoring section of electric box Remote unit shutdown Replace existing jumper between Terminals 37 38 with normally closed switch having a minimum 75VA 24VAC rating Use field supplied Class 1 wiring Two additional contact pairs available as an option labeled as 37B amp 38B 37C amp 38C Replace existing jumper for appropriate pair as done for 37 38 Special alarm connections Field supplied 24V Class 1 wiring for special alarm Connection made by adding normally open contacts between terminals 24 50 Special alarm connections may be factory wired or field wired See schematic for factory wired special alarms For field wired special alarms use 24V Class 1 wiring to connect normally open contacts between Terminals 24 amp 50 24 amp 51 24 amp 55 or 24 amp 56 SiteScan connection Terminals 77 and 78 are for connection of a 2 wire twisted pair communication cable available from Liebert or others to optional Liebert SiteScan Remote condensing unit connection Field supplied 24V Class 1 wiring to remote condensing unit
30. with oil or a protective film dirt and scale are also common Any residual contaminants could adversely affect the heat transfer stability and performance of your system In many cases in both old and new systems special cleaners are needed to remove scale rust and hydrocarbon foulants from pipes manifolds and passages Clean heat transfer surfaces are important in maintaining the integrity of the heating cooling system For more information on clean ers and degreasers contact your sales representative Follow the manufacturer s instructions when using these products Calculate the internal volume of the system as closely as possible See Table 14 and Table 16 for unit volumes Use volume in Table 15 for glycol piping volumes Table 14 Indoor unit glycol volume approximate gallons liters max Model 50 Hz Glycol Cooled GLYCOOL 046WG 045WG 1 2 4 5 071WG 070WG 2 0 7 5 061G 058G 4 0 15 1 Table 15 Volume in standard Type L copper piping Diameter in Volume Outside Inside Gal Ft L M 1 2 0 123 0 008 0 01 5 8 0 555 0 012 0 15 3 4 0 666 0 018 0 22 7 8 0 785 0 025 0 31 1 1 8 1 025 0 043 0 53 44 Glycol GLYCOOL Cooled Models Self Contained Compressor 5 5 2 Glycol Solutions NOTE Glycol solutions should be considered for protection of the coil When it is not used damage can occur from either freezing or corrosion from water When considering th
31. 1 1 2 2324 84 2134 82 2083 4 8 18 2 197 2 605 274 2 91 1 2 2324 84 2134 82 2083 9 0 34 1 Table 19 Glycol pump data Pump Pump Suction Pump Discharge Hp Hz Connection in Connection in 3 4 60 1 1 4 3 4 1 1 2 60 1 1 4 3 4 2 60 1 1 4 3 4 3 60 1 1 2 1 5 60 1 1 2 1 1 4 3 4 50 1 1 4 3 4 1 50 1 1 4 3 4 1 1 2 50 1 1 4 3 4 2 50 1 1 4 3 4 3 50 1 1 2 1 1 4 Connection sizes apply to primary pump supplier 48 Glycol GLYCOOL Cooled Models Self Contained Compressor Figure 25 General arrangement Glycol cooled models with scroll compressor Expansion Tank Field Installed at Highest Point in System qe Fi Pump Housing Drycooler Electric Box olation Expansion A K Evaporator Port 2 5 to Pump a Valves Coil Yesa i Fluid A Sees ser Suppl alve Es A 2 upply es A a rom Hose L 7 SA uy Sensing Air Vents Bibs Flow Regulating Sight at Top of e Valve Risers 7 Pressure Glass Port External pte Equalizers alve Solenoid Valve Hot Gas Tube in Tube Condenser Tube 1 in Tube Fluid Condenser Supply to Unit Return dl gt Ka SR Isolation ah Valves A 3 Way Water ER Regulating Valve a 4 optional MS MS amp fi id LY T Fluid gt A A Components are not EA Supply 4 supplied by Liebert but Hose LY to Unit K are recommended for Bibs Y Fluid PA proper cir
32. 3 3 3 5 8 11 7 5 3 0 4 0 2 7 8 24 4 11 1 1 0 0 4 1 1 8 41 6 18 9 1 7 0 7 1 3 8 63 3 28 7 2 7 1 1 Table 23 Recommended refrigerant lines R407C sizes OD copper 3 5 Ton 5 Ton 036E 035E 060E 059E Equivalent Feet m Suction Liquid Suction Liquid 0 50 0 15 7 8 1 2 1 1 8 1 2 51 100 16 30 1 1 8 1 2 1 1 8 5 8 101 150 31 45 1 1 8 5 8 1 3 8 5 8 58 Split System Models Table 24 Line coupling sizes Model Line Size Coupling Torque Tons OD Cu in Size Ib ft 3 3 8 6 10 12 5 1 2 amp 5 8 10 35 45 3 718 11 35 45 5 1 1 8 12 50 65 Table 25 Equivalent lengths feet for various pipe fittings Copper Pipe 90 Degree 90 Degree 45 Degree Gate Globe Angle OD in Elbow Copper Elbow Cast Elbow Tee Valve Valve Valve 1 2 0 8 1 3 0 4 2 5 0 26 7 0 4 0 5 8 0 9 1 4 0 5 2 5 0 28 9 5 5 0 3 4 1 0 1 5 0 6 2 5 0 3 12 0 6 5 7 8 1 45 1 8 0 8 3 6 0 36 17 2 9 5 1 1 8 1 85 2 2 1 0 4 6 0 48 22 5 12 0 1 3 8 2 4 2 9 1 3 6 4 0 65 32 0 16 0 1 5 8 2 9 3 5 1 6 7 2 0 72 36 0 19 5 Refrigerant trap 4 times equivalent length of pipe per this table Figure 31 Refrigerant piping diagram Evaporator Condensing unit Suction Line Piping Condensing unit above evaporator Traps recommended at the base of riser and every 25 feet 7 6m of vertical rise 7 3 2 Quick Connect Fitti
33. 34kPa System for 3 amp 5 Ton Units Johnson Controls Valve High Pressure Valve 350 psig 2413kPa System for 5 Ton Units Johnson Controls Valve For details refer to 4 3 1 Standard Valve 150 psig 1034kPa System for 3 amp 5 Ton Units Johnson Controls Valve High Pressure Valve 350 psig 2413kPa System for 5 Ton Units Johnson Controls Valve High Pressure Valve 350 psig 2413 kPa System for 3 Ton Units Metrex Valve For details refer to 4 3 2 High Pressure Valve 350 psig 2413 kPa System for 3 Ton Units Metrex Valve Testing Valve Function When the refrigeration system has been off for approximately 10 15 minutes the coolant flow should stop Should the coolant continue to flow the valve is either improperly adjusted head pressure is too low or the pressure sensing capillary is not connected properly to the condenser Table 20 Refrigerant control settings psi kPa Low Pressure Low Pressure High Pressure Cut Out Cut In Cut Out 20 137 9 65 448 2 400 2758 53 Chilled Water Models 6 0 CHILLED WATER MODELS 6 1 Piping Considerations Manual shut off valves should be installed at the supply and return lines to each unit This will pro vide for routine service and emergency isolation of the unit Consideration of the minimum water temperature to be supplied from the chiller will determine if the need exists to insulate supply and return lines Insulation will prevent condensati
34. 5 5 1 Expansion Tanks Fluid Relief Valves and Other Devices An expansion tank must be provided for expansion and contraction of the fluid due to temperature change in this closed system Vents are required at system high points to vent trapped air when fill ing the system A relief valve is a also a necessary piping component Depending on the complexity of the system various other devices may be specified Pressure gauges flow switches automatic air separator tempering valves standby pumps sensors for electrical con trols and flow switches are just a few of these devices NOTICE Risk of freezing temperatures Can cause equipment and piping damage Immediately following the use of water for leak testing or system cleaning charge the tested system with the proper percentage of glycol and water for your coldest design ambient Complete system drain down cannot be assured and damage to the system could result from freezing of residual water Filling Instructions Preparing the System for Filling It is important to remove any dirt oil or metal filings that may contaminate the cooling system piping in order to prevent contamination of the fresh glycol solution and fouling of the drycooler piping The system should be flushed thoroughly using a mild cleaning solution or high quality water and then completely drained before charging with glycol Cleaning new systems is just as important as clean ing old ones New systems can be coated
35. 5 Duct or Plenum Connection A GREHA 5 F Z REAR VIEW 1 3 4 Z Z Return Air Louvers rear return configuration 44mm Z A SY ZW G DIGG p 7 A Shaded area indicates a recommended ZY clearance of 34 864mm for component access Right side access suggested for GLYCOOL units DPN000350 FRONT VIEW Rev 01 front return configuration Installation Applicable to all Models Figure 3 Downflow BF cabinet dimensions 32 1 2 32 1 2 826mm 826mm Overall Overall Dimension Dimension Projection of Display Bezel 5 8 16mm 30 1 2 30 1 2 775 srpom 775mm Optional 1 5 8 41mm Flange for Duct or Plenum Connection 76 1930mm 1 25mm FRONT amp SIDES 3 4 19mm REAR Shaded area indicates a recommended clearance of 4 34 864mm for component 25 4mm 4 access Right side access 30 1 2 39 479 suggested for GLYCOOL units 775mm 775mm 25 4mm 12 P 4 305mm 30 1 2 1 25 4mm Standard Electrical Location ik Standard Piping SV mm 30 1 2 Location Floor 8 775mm 203mm Level FLOOR CUTOUT DIMENSIONS qa TE 25 4mm 30 1 2 dm gt S See Specification Sheet for Floor Stand Height Ordered DPN000351 OPTIONAL FLOOR STAND DIMENSIONAL DATA Rev 01 Installation Applicable to all Models 2 5 2 5 1 Piping Considerations All piping below the elevated floor must be located so that it offers the least
36. 8 457mm for proper air flow Shaded area indicates a minimum clearance of 24 610mm for component Shaded area indicates a minimum clearance Removable Front Panel of 18 457mm for for access to high voltage and access and removal proper air flow low voltage connections and SL 11081 refrigeration components Pg 4 Liquid Line Suction Line Quick Connect Male Coupling Except as noted Quick Connect Male Coupling Electrical Entrance for High Voltage Connection Electrical Entrance for Low Voltage Connection SL 11081 Pg 6 60 Split System Models Table 26 Horizontal air discharge cabinet and floor planning dimensional data Model Numbers Dimensional Data in mm Module Weight 60 Hz 50 Hz A B C Ib kg net PFCO42A L PFCO41A _L 48 1219 31 787 18 457 241 109 PFHO42A _L PFC042A _H PFC041A _H PFH042A _H PFCZ42A L PFCZ41A _L 53 1343 36 1 4 918 18 457 351 159 PFCO67A _L PFCO66A _L PFHO67A _L Table 27 Horizontal air discharge piping and electrical connection data Model Numbers Dimensional Data in mm Piping Connections in mm 60 Hz 50 Hz A B Cc D E F G PFCO42A L PFCO41A _L 2 51 5 3 4 146 8 1 2 216 4 3 4 121 6 3 4 171 8 1 2 216 PFHO42A _L PFC042A _H PFCO41A _H PFHO42A _H PFCZ41A _L PFCZ42A _L os 2 51 6 152 8 1 2 216 4 3
37. 8 OD CU on Models BU046WG BU045WG 1 1 8 OD CU on Models BU071WG BU070WG Hot Water Supply 5 8 OD CU optional Liebert COM Control IN QQ in PIPING OUTLET LOCATIONS See Cabinet and Floor Planning Dimensional Data for Piping Opening Sizes DPNO000363 Rev 01 15 Installation Applicable to all Models Figure 10 Piping connections for chilled water self contained units Downflow models Condensate Drain al 3 4 FPT Field pitch a minimum of 1 8 3 2mm per ft 305mm The drain line must comply with all applicable codes Humidifier Water Supply Line 1 4 OD CU Liebert iCOM Control PIPING OUTLET LOCATIONS See Cabinet and Floor Planning Dimensional Data for Piping Opening Sizes u L Chilled Water Supply Line 1 1 8 OD CU L Chilled Water Return Line 1 1 8 OD CU L Hot Water Return 5 8 OD CU optional Hot Water Supply 5 8 OD CU optional r DPN000371 Rev 01 16 Installation Applicable to all Models Figure 11 Piping connections for chilled water self contained units Upflow models Mt I Piping outlet locations through the plenum are the same as the unit See below for descriptions and connection sizes gt Humidifier Water Supply Line 3 Hot Water Retu
38. A AAA NEC Class 1 wiring a to drycooler glycol cooled units only Line voltage electric power supply conduit voltage Removable Access Panel Heat rejection connection Field supplied 24V NEC Class 2 wiring Wire connections from evaporator mod 1 24V ground 2 24V supply 3 High pressure alarm optional 4 Hot gas bypass connection only on units with hot gas bypass Connection terminal for field supplied earth grounding wire IE Low voltage electric power supply conduit entrance Field supplied 24V NEC Class 1 wiring between glycol condensing unit DAA and drycooler DPN000228_RevO Remote drycooler connection field supplied 24V NEC Class 1 wiring glycol cooled units only I un ES NOTES 1 Refer to specification sheet for full load amp and wire size amp ratings 2 Control voltage wiring must be a minimum of 16 GA 1 6mm for up to 75 23m or not to exceed 1 volt drop in control line 76 R407C Refrigerant 8 0 R407C REFRIGERANT Table 33 R407C pressure temperature chart for operation and superheat discharge hot gas and suction gas Temperature Gauge Pressure Temperature Gauge Pressure Temperature Gauge Pressure F C Psig kPa F C Psig kPa F C Psig kPa 0 0 17 8 18 9 130 70 0 21 1 114 9 792 1 0 17 2 19 6 135 72 0 22 2
39. Degree Gate Globe Angle O D in Elbow Copper Elbow Cast Elbow Tee Valve Valve Valve 1 2 0 8 1 3 0 4 25 0 26 7 0 4 0 5 8 0 9 1 4 0 5 25 0 28 9 5 5 0 3 4 1 0 1 5 0 6 2 5 0 3 12 0 6 5 718 1 45 1 8 0 8 3 6 0 36 17 2 9 5 1 1 8 1 85 2 2 1 0 4 6 0 48 22 5 12 0 1 3 8 2 4 2 9 1 3 6 4 0 65 32 0 16 0 1 5 8 2 9 3 5 1 6 7 2 0 72 36 0 19 5 Refrigerant trap 4 times equivalent length of pipe per this table Table 7 Indoor unit refrigerant charge Ib kg R407C Approximate Charge Model Ib kg 42A 40A 0 9 0 4 67A 65A 1 4 0 6 Table 8 Line charges refrigerant per 100 ft 30 m of Type L copper tube R407C Liquid Line Hot Gas Line O D Ib kg Ib kg 1 2 7 3 3 3 1 3 0 6 5 8 11 7 5 3 2 1 1 0 3 4 16 6 7 5 3 0 1 4 718 24 4 11 1 4 4 2 0 Table 9 Condenser refrigerant per serial tag R407C Approximate Charge Ib kg Liebert Model Fan Speed Lee Temp 083 8 3 25 12 104 9 4 37 17 165 15 6 8 50 22 7 Charge includes the receiver charge Fan Speed Control Systems The Variable Fan Speed Control systems FSC amp VFD uses pressure activated electronic fan speed control systems and remotely located thermostat s to ensure operation at ambient temperatures as low as 0 F 18 C For this ambient temperature range the VFD Control Condenser must be used with digital scroll indoor units and ca
40. Electrical field connections prop fan condensing module 0 c eee eee eee nes 64 Detail of ceiling hanging bracket ence ene nnn ees 66 3 ton centrifugal air cooled condensing unit dimensional data amp piping connections 67 3 ton centrifugal air cooled condensing unit con t 2 0 eee 68 5 ton centrifugal air cooled condensing unit dimensional data ooooooooooooo 69 5 ton centrifugal air cooled condensing unit dimensional data con t o oooooo o 70 Split systems general arrangement 0 eee e eee e enn 71 3 ton water glycol cooled condensing unit suussaan anean cee eee een nee 73 3 ton water glycol cooled condensing unit con t 0 0 0 eens 74 5 ton water glycol cooled condensing unit dimensional data 0 0c cece eee o 75 5 ton water glycol cooled condensing unit con t 0 0 eens 76 iii Table 1 Table 2 Table 3 Table 4 Table 5 Table 6 Table 7 Table 8 Table 9 Table 10 Table 11 Table 12 Table 13 Table 14 Table 15 Table 16 Table 17 Table 18 Table 19 Table 20 Table 21 Table 22 Table 23 Table 24 Table 25 Table 26 Table 27 Table 28 Table 29 Table 30 Table 31 Table 32 Table 33 Table 34 TABLES Un tnet weisht ii Bee Denn ae ee de TEA Ree has 6 Piping CONNECT ee ne ea aes ee ea 9 Recommended free area ft m for grilles or perforated panels at output velocities of 550 and 600 fpm 2 8 and AS ee re beit
41. Example Measure the liquid pressure e g 200 psig Find the liquid saturation temperature at that pressure on Table 34 e g 93 F Measure the temperature of the liquid line e g 90 F Subtract the actual temperature from the liquid saturation temperature to obtain the subcooling e g 93 90 3 F If the actual temperature is greater than the liquid saturation temperature then there is no subcooling and the fluid may be a mixture of liquid and vapor Why There Are Two R407C Temperature and Pressure Tables R407C is a blend of refrigerants that exhibits a temperature glide of approximately 8 to 12 F 4 to 7 C This glide is the difference between the liquid and vapor saturation temperatures at a given pressure Use the correct table for the saturation temperature you need Table 33 is for super heat or operating controls Table 34 is for subcooling only 78 R407C Refrigerant NOTES 79 R407C Refrigerant 80 Ensuring The High Availability Of Mission Critical Data And Applications Emerson Network Power the global leader in enabling business critical Technical Support Service continuity ensures network resiliency and adaptability through Web Site a family of technologies including Liebert power and cooling www liebert com technologies that protect and support business critical systems Monitoring Liebert solutions employ an adaptive architecture that responds liebert monitorin
42. General arrangement Air cooled models with digital scroll and fan speed control Condenser Coil Inverted Trap on discharge line to Schrader extend above base Valve of coil by a minimum Y of 7 1 2 190mm 7 Y 2 Fusible ye JJ wn Plug Aa Aa 74 A IA AA Z 2 a 7 li if Evaporator Traps every Il A 25 ft 7 6m Yj of rise De FRI Liquid Return Il Solenoid Shutoff Valve Sensing Filter Dryer xternal Equalizer Service Valves Digital Solenoid Valve Digital Compressor Components are not supplied by Liebert but are recommended for proper circuit operation I Check Valve and maintenance 17 Hot Gas Discharge Z J FACTORY PIPING pide 2 gt FIELD PIPING Edo 30 Air Cooled Models Self Contained Compressor 3 5 Air Cooled Condenser with Liebert Lee Temp Flooded Condenser Head Pressure Control System The Liebert Lee Temp system consists of a modulating type head pressure control valve and insulated receivers with heater pads to ensure operation at ambient temperatures as low as 30 F 34 4 C The Liebert Lee Temp system can be used with any compressor choice Liebert Lee Temp Piping A discharge line and a liquid line must be field installed between the indoor unit and the outdoor con denser See Figures 17 and 18 for details Liebert Lee Temp Controlled Materials Supplied e Built in pre wired condenser control
43. H Precision Cooling For Business Critical Continuity Liebert Challenger 3000 with iCOM Installation Manual 3 amp 5 Tons 50 amp 60Hz ZAE FS we gt 1 2 20 1 09 En Mn IT 4 EMERSON Network Power TABLE OF CONTENTS IMPORTANT SAFETY INSTRUCTIONS 00 0c ee eee ee ee eee nn 1 1 0 INTRODUCTION See 8 ces os a Be A Se ee eS at 3 1 1 System Descriptions slats aa wed tal acl tdt ee R E 3 1 1 1 Self Contained Systems 3 11 2 Chilled Water Models cito fg a ler an A a IA ed pha 3 1 18 SPSS EMS enri e ea Re nan A eas a ee ne isos 4 2 0 INSTALLATION APPLICABLE TO ALL MODELS 0000cceeecceeeeeeeeceee 5 2 1 Room Preparation s are rs an sans ee nen rs Dineen hae ie 5 2 2 Equipment Inspection 53 2 8242 20 awe ae uam nen lesen 5 2 3 Location Considerations ara Sao ewe N BR A eee II 5 2 4 Equipment Handle seen een Pre nl a 5 2 4 1 Handling WithcSkid ss ive st een tele 6 2 42 Removal ob Skid aria dt ai hc Oe Raia kes an 6 2 5 Piping Considerations old a il OSA an ande 9 205l SN ae Rn ee De 9 2 5 2 Humidifier Supply Water Optional Infrared 0 0 00 ooo 18 2 6 Facility Fluid and Piping Maintenance oooocoooorcrrn eens 18 2 7 Electrical Connections nises AA A pen a ee 18 2 8 Balancing the Air Distribution a aa ar a O A AS 21 2 8 1 Under Floor Discharge Systems 21 2 8 2 Ducted Applications u NEE ne a Rs ed 21 2 8 3 Plenum Installation o oooooo
44. Line OD Copper 50 Hz L HG 042A 040A 3 8 5 8 067A 065A 1 2 7 8 Split System Fan Coil Unit Connection Sizes in Model No BF BU 50 Hz Liquid Line Suction Line L 036E 035E 5 8 18 Female 6 QC 1 1 8 12 Female 11 QC O60E 059E 1 2 OD Cu 1 1 8 OD Cu All Units Connection Sizes in Humidifier Line Condensate Condensate Pump Line Hot Water Reheat OD Copper Drain Line OD Copper OD Copper H P Supply Return 1 4 3 4 FPT 1 2 HWS HWR 5 8 5 8 Water Glycol Cooled Unit Connection Sizes inches Model No BF BU Supply Line Return Line 50 Hz S 046WG 045WG 718 718 071WG 070WG 1 1 8 1 1 8 GLYCOOL Unit Connection Sizes in Model No BE BK Supply Line Return Line 50 Hz S R 061G 058G 1 1 8 1 1 8 Chilled Water Unit Connection Sizes in Model No BF BU Supply Line Return Line 50 Hz CWS CWR 068C 072C 1 1 8 1 1 8 102C 101C 1 1 8 1 1 8 Installation Applicable to all Models Figure 4 Piping connections for air cooled units Downflow models E Condensate Drain 3 4 FPT J Field pitch a minimum of 1 8 3 2mm per foot 305mm The drain line must comply with all applicable codes Humidifier Water Supply Line I 1 4 OD CU PIPING OUTLET LOCATIONS Liebert COM Control Panel L Liquid Refrigerant Line 3 8 OD CU on Models BF042A BF040A 1 2 OD CU on Models BFO67A BFO65A L _ Hot Gas Refrigerant Line 5 8 OD CU on Mo
45. OOLERICONDENSERS 51 7 16 _y 43 9 16 1306 5mm 1106mm Sie er Liquid line en t AK 18 457 2mm 37 718 962mm eo da CONDENSER MOUNTING i tops gt e 25 4mm Y 1 3 4 pi 16 44 44 5mm 1097mm la 1118mm y E 9 16 14 3mm t t diameter holes 25 PH 8 places for 25 4mm 37 11 16 1 2 12 7mm q 4 3 4 4 1 4 957 3mm diameter bolts 25 4mm 44 5mm 108mm 1 3 4 4 IR er 44 5mm 1 3 4 1 3 4 44 5mm gt gt 44 5mm 4 1 4 108mm a 25 4mm A _______ Common to all models See Table 4 below for key to A dimension TYPICAL FOOTPRINT Table 4 Air cooled condenser statistics Connection Sizes Number OD Copper Net Weight A Dimension Model ofFans Hot Gas in Liquid in Ib kg in mm 083 1 7 8 5 8 295 133 8 42 1067 104 1 1 1 8 5 8 315 142 8 42 1067 165 2 1 1 8 718 425 193 82 2083 24 Air Cooled Models Self Contained Compressor 3 3 Refrigerant Piping All refrigeration piping should be installed with high temperature brazed joints Prevailing good refrigeration practices should be employed for piping supports leak testing dehydration and charg ing of the refrigeration circuits Unit refrigeration components and piping are shipped from the factory with a nitrogen holding charge NOTICE Risk of improper installation Can cause equipment and
46. Pump Ga Isolation AR Valves Air Vents at Top of Risers Digital Solenoid 2 No Valve Auid er y Actuator ui Return from Econ O Cycle Unit ge Comparator pls lI BH Isolation AY P3 Way Chilled Y 3 Way Motorized Pee Val ves we IT Ball Valve Nett f A ee 1 8 PRE EE A Econ O Coi 6 Circuit Thea 3 Y f L Field Supplied Componentsare not supplied by Liebert but Y Ed oe are recommended for proper circuit operation TA y he Required on 3 Ton Units ad Matan ose Y BOSAL ys A __ FACTORY PIPING Zo DPN001724 eS ee AELD PIPING Rev 0 52 Glycol GLYCOOL Cooled Models Self Contained Compressor 5 5 4 5 6 5 7 5 7 1 5 7 2 5 7 3 Motor Ball Valve Digital Scroll Compressors Refer to 4 4 Motorized Ball Valve Digital Scroll Compressors for details on the motorized ball valve Condenser The condenser is designed to operate in conjunction with a drycooler The maximum coolant pressure 1s 350 psig 2413 kPa Glycol Regulating Valve The glycol regulating valve automatically regulates the amount of coolant necessary to remove the heat from the refrigeration system permitting more fluid to flow when load conditions are high and less fluid to flow when load conditions are low The valve consists of a brass body balance spring valve seat valve disc holders capillary tube to discharge pressure and adjusting screw Standard Valve 150 psig 10
47. TORY PIPING and maintenance ae a A DPN001727 E TE en FIELD PIPING Rev 0 37 Water Cooled Models Self Contained Compressor 4 3 4 3 1 Water Regulating Valve The water regulating valve automatically regulates the amount of fluid necessary to remove the heat from the refrigeration system permitting more fluid to flow when load conditions are high and less fluid to flow when load conditions are low The valve consists of a brass body balance spring valve seat valve disc holders capillary tube to discharge pressure and adjusting screw Standard Valve 150 psig 1034kPa System for 3 amp 5 Ton Units Johnson Controls Valve High Pressure Valve 350 psig 2413kPa System for 5 Ton Units Johnson Controls Valve Adjustment The valve may be adjusted with a standard refrigeration service valve wrench or screw driver To lower the head pressure setting turn the square adjusting screw clockwise until the high pressure gauge indicates the desired setting To raise the head pressure setting turn the adjusting screw counterclockwise until the desired set ting is obtained Figure 21 Johnson Controls valve adjustment Range spring Valve spring Range adjustment screw Insert screwdrivers underneath the valve spring guide 4 3 2 High Pressure Valve 350 psig 2413 kPa System for 3 Ton Units Metrex Valve Adjustment The valve may be adjusted using a 1 8 diameter rod Turn the adjusting collar nu
48. Terminals 1 2 3 amp 4 from R2 relay split system only Smoke detector alarm connections Field supplied 24V Class 1 wiring to remote alarm circuits Factory wired contacts from optional smoke detector are 91 comm 92 NO and 93 NC Common alarm connection Field supplied 24V Class 1 wiring to common alarm Terminals 75 76 and optional 94 95 and 96 97 which are factory connected to common alarm relay R3 19 Installation Applicable to all Models 15 16 17 18 Heat rejection connection Field supplied 24V Class 1 wiring to interlock heat rejection from pigtails 70 71 which are factory connected to compressor side switch self contained units only or to GLYCOOL relay K11 GLYCOOL units only On Dual Cool units only pigtails 72 73 connect auxiliary cooling source to GLYCOOL relay K11 Reheat and Humidifier Lockout Optional emergency power lockout of reheat and or humidifier connections provided for remote 24V AC source Main Fan Auxiliary Switch Optional main fan auxiliary side switch Terminals located in field wiring compartment for remote indication that the evaporator fan motor unit is on Field to connect 24V maximum Optional Condensate Alarm Dual Float Condensate Pump only Relay terminals located in field wiring compartment for remote indication Refer to specification sheet for full load amp and wire size amp ratings Figure 13 Electrical field connections for Liebert COM
49. a field supplied 24VAC 75VA power source must be directly connected to each of the unit solenoid valves For scroll and digital scroll compressors connect refrigerant gauges to the suction rotalock valves and discharge line Schrader valves see Note above on the compressor Open the service valves and place a 150 PSIG 1034 kPa of dry nitrogen with a tracer of refrigerant Check system for leaks with a suitable leak detector After completion of leak testing release the test pressure per local code and pull an initial deep vacuum on the system with a suitable pump After four hours check the pressure readings and if they have not changed break vacuum with dry nitrogen Pull a second and third vacuum to 250 microns or less Recheck the pressure after two hours After completing this step proceed to Variable Fan Speed Charging on page 28 27 Air Cooled Models Self Contained Compressor Variable Fan Speed Charging 1 2 4 Check unit nameplate for refrigerant type to be used Unit control configurations differ depending on refrigerant type Refrigerant charging requires unit operation Refer to 2 9 Checklist for Completed Installation Calculate the amount of charge for the system Refer to the unit condenser and refrigerant line charge data in Tables 6 7 8 and 9 Weigh in as much of the system charge as possible before starting the unit CAUTION Risk of improper refrigerant charging Can cause equipment
50. added to the end of the discharge duct to protect ser vice personnel For multiple unit installations space the units so that the hot condensing unit exhaust air is not directed toward the air inlet of an adjacent unit Table 31 Airflow CFM CMH 3 Ton 5 Ton 60Hz 2000 3398 3500 5947 50 Hz 1650 2800 3500 5947 66 Split System Models Figure 36 3 ton centrifugal air cooled condensing unit dimensional data amp piping connections Customer supplied 50 1 4 1276mm 22 34 578mm threaded rods for 5 i Overall Dimension Overall Dimension module support 21 1 2 546mm Br 46 1 2 1181mm Cabinet Dimension from ceiling typ 4 Cabinet Dimension woo i c 48 1 4 1225mm Paca Threaded Rod Center Air Outlet Duct Connection 22 1 2 20 7 16 gt 572mm 519mm e Cabinet Coil Inlet gt Air Outlet Dimension q Duct B Duct Dimension F 30 118 A 765mm Blower Motor Service Access Holes for Module NM Coil Inlet Panel on Bottom of Unit Rigging typ 2 each end gt Duct Connection Minimum Clearance 33 838mm for ComponentAccess and Removal Integral Hanging 1 S Duct Flange 25 4mm Bracket Y 2 1 4 Note Unit is evenly spaced in Minimum Clearance 33 838mm 57 mm reference to threaded for centers This End for ComponentAccess and Removal DIMENSIONAL DATA 7 8 22 2mm Dia Electrical Entrance for Line Voltage Connection
51. ainte nance program must be established that will evaluate fluid chemistry and apply necessary treatment A periodic leak inspection of facility and unit fluid piping is recommended Refer to 5 4 Glycol Pip ing Electrical Connections Three phase electrical service is required for all models in either 208 230 460 or 575 V 60 Hz or 200 230 or 380 415 V 50 Hz Electrical service shall conform to national and local electrical codes Refer to equipment nameplate regarding wire size and circuit protection requirements Refer to elec trical schematic when making connections A manual electrical disconnect switch should be installed within 5 feet 1 6 m of the unit in accor dance with codes or a factory supplied disconnect switch may be factory mounted within the unit accessible from the exterior A WARNING Risk of electric shock Can cause injury or death Potentially lethal voltages exist within this equipment during operation Observe all cautions and warnings on unit and in this manual The Liebert COM microprocessor does not isolate power from the unit even in the Unit Off mode The only way to ensure that there is NO voltage inside the unit is to install and open a remote disconnect switch Refer to unit electrical schematic NOTICE Risk of improper scroll compressor installation Could cause poor performance and compressor damage Three phase power must be connected to the unit line voltage terminals in the prop
52. allenger from skid Raise unit with fork lift Remove plywood skirting holding or similar machine unit and skid in place Table 1 Unit net weight Model Lb kg 036E 035E 535 243 060E 059E 545 247 042A 040A 615 279 067A 065A 670 304 046WG 045WG 700 318 071WG 070WG 750 340 061G 058G 785 356 068C 072C 545 247 102C 101C 555 252 Installation Applicable to all Models Figure 2 Upflow BU cabinet dimensions 32 1 2 7 1 2 191mm 29 3 4 756mm A 826mm 30 1 2 ml UNIT STD 38 5T 11 3 4 299mm 775mm TOP VIEW Hi Static 3T 8 5 8 219mm A 9 5 8 Hi Static 5T 11 3 4 299mm 8 1 2 m 216mm 244mm roe mm 330mm 41mm 30 1 2 Standard Piping Location HT an ve 826mm Projection of Display Bezel 5 8 16mm a 5 1 2 140mm Standard Electrical Outlet 32 1 2 32 1 2 Location Through Unit 826mm 826mm Overall Overall i Dimension Dimension 6 7 8 175mm Standard Electrical Outlet Location Through Plenum Filter Access Through Top Air Discharge Grille Plenum available with 1 25mm 2 3 or 4 grilles a Solid sides with a 7 8 22mm 3 4 19mm duct flange on top REAR A 94 mm ower Outlet wi 2388 Bl Outlet with 1 25 4mm Flange 29 2 1 2 737mm 67mm 76 ie 7 8 22 2mm Flange for e 1930mm
53. anel Low Voltage A control interlock between the drycooler and the indoor unit is required and is connected between 70 and 71 in the handy box of the indoor unit and the pump and drycooler control box of the drycooler NEC Class 1 wiring is required Pump and Drycooler All wiring to the pump and drycooler from the control box should be done in accordance with the elec trical schematic on the inside lid of the drycooler control box and with local and national codes 41 Glycol GLYCOOL Cooled Models Self Contained Compressor 5 4 Glycol Piping These guidelines apply to the field leak checking and fluid requirements for field piping systems General Guidelines Equipment damage and personal injury can result from improper piping installation leak check ing fluid chemistry and fluid maintenance Follow local piping codes safety codes Qualified personnel must install and inspect system piping Contact a local water consultant regarding water quality corrosion protection and freeze protec tion requirements Install manual shutoff valves at the supply and return line to each indoor unit and drycooler to permit routine service and emergency isolation of the unit A A CAUTION Risk of frozen fluids Can cause equipment damage and building damage Freezing system fluids can rupture piping Complete system drain down cannot be ensured When the field piping or unit may be exposed to freezing temper
54. atures charge the system with the proper percentage of glycol and water for the coldest design ambient Automotive antifreeze is unacceptable and must NOT be used in any glycol fluid system CAUTION Risk of corrosion Can cause equipment damage Read and follow individual unit installation instructions for precautions regarding fluid system design material selection and use of field provided devices Liebert systems contain iron and copper alloys that require appropriate corrosion protection Contact a local water consultant regarding water quality corrosion and freeze protection requirements Water chemistry varies greatly by location as do the required additives called inhibitors that reduce the corrosive effect of the fluids on the piping systems and components The chemistry of the water used must be considered because water from some sources may contain corrosive elements that reduce the effectiveness of the inhibited formulation Preferably surface waters that are classified as soft and are low in chloride and sulfate ion content should be employed Proper inhibitor maintenance must be performed in order to prevent corrosion of the system Consult glycol manufacturer for testing and maintenance of inhibitors Commercial ethylene glycol Union Carbide Ucartherm Dow Chemical Dowtherm SR 1 and Texaco E G Heat Transfer Fluid 100 when pure is generally less corrosive to the common metals of construction than water itself It wil
55. bert Challenger 3000 unit It must NOT be located below the Liebert Challenger 3000 Recommended clearance between ceiling grids and building structural members is unit height plus three inches Install the four field supplied rods by suspending them from suitable building structural members Locate the rods so that they will align with the four mounting holes in the flanges that are part of the unit base Using a suitable lifting device raise the unit up and pass the threaded rods through the four mount ing holes in the flanges that are part of the unit base Attach the threaded rods to the unit flanges using the supplied nuts and grommets See Figure 35 Detail of ceiling hanging bracket Threaded Rod and Hardware Kit Installation The rubber grommets provide vibration isolation 1 Use the plain nuts to hold unit in place Adjust these nuts so that the weight of the unit is supported evenly by the four rods does not rest on the ceiling grid and is level NOTE The untts must be level in order to operate properly 2 Use the Nylock nuts to jam the plain nuts Table 30 Indoor centrifugal condensing unit Model Net Weight 60 Hz 50 Hz Ib kg MC_40A MC_39A 240 109 MC_65A MC_64A 449 204 65 Split System Models Figure 35 Detail of ceiling hanging bracket 7 5 2 3 8 threaded rod field supplied 3 8 hex nut 3 8 washer Sleeve Isolator 00000000000000 3
56. centage of glycol to water must be determined by using the lowest design outdoor temperature in which the system is operating Table 16 indicates the solution freeze point at several concentra tion levels of ethylene glycol Propylene glycol concentrations should be 1 higher than the ethylene glycol table values to find the freeze point For example 41 propylene glycol freezes at 10 F 45 Glycol GLYCOOL Cooled Models Self Contained Compressor Table 16 Ethylene glycol concentrations Glycol by Volume 0 10 20 30 40 50 Freezing Point F C 32 0 25 3 9 16 8 9 5 15 0 10 23 3 32 35 5 Apparent Specific Gravity 50 F 10 C 1 1 014 1 028 1 042 1 057 1 071 A minimal amount of glycol should be considered for inhibitive coil protection NOTICE Risk of corrosion from water impurities Can cause equipment damage The quality of water used for dilution must be considered because water may contain corrosive elements which reduce the effectiveness of the inhibited formulation Water that is classified as soft low in chloride and sulfate ion content less than 100 parts per million each should be used 5 5 3 Filling the System Installation of hose bibs at the lowest point of the system is recommended When filling a glycol sys tem keep air to a minimum Air in glycol turns to foam and is difficult and time consuming to remove Anti foam additives are available and may
57. cuit operation ze a K and maintenance gt from Field Supplied D 4 FACTORY PIPING Unit Reducers Required Y on 3 Ton Units DPN000361 ET O O FIELD PIPING Rev 02 49 Glycol GLYCOOL Cooled Models Self Contained Compressor Figure 26 General arrangement Glycol cooled models with digital scroll Expansion Tank Field Installed at Highest Point in System mo Fill Drycooler Electric Fluid Evaporator Expansion a 5 Port P to Pump Valves es as e Expansion Ge Z Fluid Suppl gt Aa uid Supply Valve Dy amp lt from Pump Z 7 Z Aa L IHosell 7 Bibs Flow Regulating Sight Air Vents 7 at Top of e Valve Glass External Risers II T Pressure 4 Equalizer Port l Digital Compressor S l Na SA a Service 3A4 igital 7 Aal Solenoid Il a Valve I lt S Tube in Tube Condenser Tube ae in Tube Supply Condenser to Unit Fluid I Return d from xr Unit er Isolation I Valves J en alle 1 Yee AR Motorized IN EZ Ball Valve all 9 Motorized a Fluid Ball Valve Hose Bibs 7 Supply x optional Z to Unit cs De x Fluid 7 A Return Field Supplied 27 FACTORY PIPING Reducers Hose 4 7FIELDPIPING Unit Requiredon3 Bibs z 115 Ton Units pad Components are not supplied by Liebert but DPN001722 are recom
58. damage Refrigerant R407C is a blend of three components and must be introduced and charged from the cylinder only as a liquid When adding liquid refrigerant to an operating system it may be necessary to add the refrigerant through the compressor suction service valve Care must be exercised to avoid damage to the compressor Emerson recommends connecting a sight glass between the charging hose and the compressor suction service valve This will permit adjustment of the cylinder hand valve so that liquid can leave the cylinder while allowing vapor to enter the compressor Turn on unit disconnect switch Operate the unit for 30 minutes using the charging function for the system in the diagnostic section of the Liebert COM control see Liebert COM user manual SL 18835 The charging function operates the compressor at full capacity and energizes the blower motor and the liquid line solenoid valve The reheat and humidifier are disabled A minimum 20psig 138kPa must be established and maintained for the compressor to operate The charging function can be reset as many times as required to complete unit charging Table 10 Fan speed suction pressure transducer settings R 407C Gauge Sea Level Absolute Function psiG kPa psiA kPa Pump Down Cutout 20 138 35 241 Pump Down Reset 65 448 80 552 Minimum to Start Cooling 35 241 50 344 Low Pressure Cutout DX only 52 358 67 461 6 Charge the
59. dels BF042A BF040A 7 8 OD CU on Models BF067A BF065A Hot Water Return 5 8 OD CU optional nn Hot Water Supply 5 8 OD CU optional See Cabinet and Floor Planning Dimensional Data for Piping Opening Sizes DPNO000353 Rev 01 10 Installation Applicable to all Models Figure 5 Piping connections for air cooled units Upflow models nr Piping outlet locations through the plenum are the same as the unit See below for descriptions and connection sizes ug ae 3 Hot Water Return Humidifier Water Supply Line 7 5 8 OD CU 1 4 OD CU optional Liquid Refrigerant Line Hot Gas Refrigerant Lne 74 lr 3 8 OD CU on Models BU042A BU040 5 8 OD CU on Models BUO42A BUOAOA I 1 2 OD CU on Models BU067A BU065A 7 8 OD CU on Models BU067A BU065A ea cae Hot Water Supply Condensate Pump Line Il 5 8 OD CU optional 1 2 OD CU Used only if optional condensate pump is ordered Liebert iCOM Control RR PIPING OUTLET LOCATIONS See Cabinet and Floor Planning Dimensional Data for Piping QQ nj Condensate Drain 4 Opening Sizes 3 4 FPT Field pitch a min of 1 8 3 2mm per ft 305mm Units without a condensate pump have a factory supplied trap in the unit so a DPN000352 field trap should notbe added Units with a condensate pump will Rev 01 require a field s
60. directly connected to each of the unit solenoid valves 2 Attach a jumper hose from the service valve fitting on the outlet of the receiver and the Schrader fitting on the discharge header of the condenser Front seat the service valve approximately two 2 turns 3 For scroll and digital scroll compressors connect refrigerant gauges to the suction rotalock valves and discharge line Schrader valves see Note above 4 Open the service valves and place a 150 PSIG 1034 kPa of dry nitrogen with a tracer of refrigerant Check system for leaks with a suitable leak detector 5 After completion of leak testing release the test pressure per local code and pull an initial deep vacuum on the system with a suitable pump 31 Air Cooled Models Self Contained Compressor 6 After four hours check the pressure readings and if they have not changed break vacuum with dry nitrogen Pull a second and third vacuum to 250 microns or less Recheck the pressure after two hours 7 Remove the jumper hose installed previously from between the service valve fitting and the condenser After completing this step proceed to Lee Temp Charging Lee Temp Charging 1 Check unit nameplate for refrigerant type to be used Unit control configurations differ depending on refrigerant type 2 Refrigerant charging requires unit operation Refer to 2 9 Checklist for Completed Installation 3 Calculate the amount of charge for the system Refer to the un
61. e Dia Testing Valve Func en a RE IE ml nos CHILLED WATER MODELS ii a nee Piping Considerations 2 0 05 oe hatte la da ia she ia SPLIT SYSTEM MODELS our abi rn rue Location Gonsiderations 1 2 20 is a a AS in tb 7 1 1 Air Cooled Condensing Units 7 1 2 Water Glycol Cooled Condensing Units ro Electrical Connections o nase ini En als OE ae td ale 12 L Lime Volare ra aa Bee ie une Dei 122 LOW Volta BEY a a eh Fae Ra nei Piping Considerations 0 0 eee ete ees TIL Refrigerant Do A nn Bern Re A E Bee cls ta 3 25 Quick Connect Fittings a fa a ee Outdoor Air Cooled Condensing Units 0 noana cc eee teens Centrifugal Air Cooled Condensing Units ooooooococoooooor eens 7 5 1 Installing the Indoor Condensing Unit 1 92 UCU GN Eee u ee ans te Blea et Sukie ak ae ieee ales ia aueh Water and Glycol Cooled Condensing Units 0 0 cc eens 7 6 1 Piping Considerations A IE bo Se BD ae Se eek 7 6 2 Condenser Water Requirements 1 6 3 Regulating Valve a ren 00 2 22 Bias ee BB er anid ee Rae HD ee ln EGA Glycol Syste MS ar ert Bid dt La ADE Hh GA a ME Ain di dew Bk Raed har rb aloe hashed R407C REFRIGERANT 4 2 22 2 er et tes Se ire eae res ia ete Calculating Subcooling 0 ee eee eee eee eee e nent een nes Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15
62. e under current applicable laws and regulations NOTICE Risk of using improper cooling agent Can cause reduced cooling performance and damage to equipment and piping Proper formulations of inhibited formula ethylene glycol and propylene glycol must be used in the Challenger 3000 system Automotive antifreeze is unacceptable and must NOT be used Typical inhibited formula ethylene glycol and propylene glycol manufacturers and suppliers are Union Carbide Ucartherm or Dow Chemical Dowtherm SR 1 Dowfrost These glycols are supplied with corrosion inhibitors and do not contain a silicone anti leak formula Commercial ethylene glycol when pure is generally less corrosive to the common metals of construction than water itself Aque ous solutions of these glycols however assume the corrosivity of the water from which they are pre pared and may become increasingly corrosive with use if not properly inhibited There are two basic types of additives corrosion inhibitors and environmental stabilizers The corro sion inhibitors function by forming a surface barrier that protects the metals from attack Environ mental stabilizers while not corrosion inhibitors in the strictest sense of the word decrease corrosion by stabilizing or favorably altering the overall environment An alkaline buffer such as borax is a sim ple example of an environmental stabilizer since its prime purpose is to maintain an alkaline condi tion pH above 7 The per
63. e use of any glycol products in a particular application you should review the lat est Material Safety Data Sheets and ensure that the use you intend can be accomplished safely For Material Safety Data Sheets and other product safety information contact the supplier nearest you Before handling any other products mentioned in the text you should obtain available product safety information and take necessary steps to ensure safety of use NOTICE Risk of improper handling of glycol Can cause environmental damage and violate national regional and local laws When mishandled glycol products pose a threat to the environment Before using any glycol products review the latest Material Safety Data Sheets and ensure that you can use the product safely Glycol manufacturers request that the customer read understand and comply with the information on the product packaging and in the current Material Safety Data Sheets Make this information available to anyone responsible for operation maintenance and repair of the drycooler and related equipment No chemical should be used as or in a food drug medical device or cosmetic or in a product or pro cess in which it may contact a food drug medical device or cosmetic until the user has determined the suitability and legality of the use Since government regulations and use conditions are subject to change it is the user s responsibility to determine that this information is appropriate and suitabl
64. ed models with scroll compressor Evaporator Coil Bypass Solenoid Valve Scroll Hot Gas Bypass Tube in Tube as Condenser upply Fluid To Return Unit From Unit y L m Shutoff a tS Oe iy valves 3 3 Way Water L Regulating Valve I tional a optional 7 4 7 117 we 4 ay Pa P Supply K ade Se ar Hose Bibs 4 Field Supplied To A omponents are not supplied ya Reducers Unit Fluid _ A by Liebert but are recommended A Required Return for proper circuit operation ZA on 3 Ton Units From and maintenance Unit 7 er NS FACTORY PIPING DPN000359 or 7 FIELD PIPING REV 02 36 Water Cooled Models Self Contained Compressor Figure 20 General arrangement diagram Water cooled models with digital scroll Fluid Elia SUPPIY Return le Unit From iI Unit 18 2 SR Il 4 rt a Shutoff Evaporator Coil External Equalizer Digital Filter Solenoid Dryer Valve Digital Compressor To Liebert A Valves j iCOM Control l Br Motorized gt Th of pall valve To Liebert as COM Control at A EA Pa E e a Motorized iha upp Hose Bibs 7 Fiela Supplied UA xXx no te Reducers Y p LA Required Fluid 7 Components are not supplied 7 on 3 Ton Units Return by Liebert but are recommended ee From Unit for proper circuit operation Ke FAC
65. ek 21 Air cooled condenser statistics 6 eee eee een teens 24 Recommended line sizes OD copper inches 22222 ccc cee eee nes 25 Equivalent lengths feet for various pipe fittings 0 26 Indoor unit refrigerant charge lb kg nennu aeee 26 Line charges refrigerant per 100 ft 30 m of Type L copper tube oooo o 26 Condenser refrigerant per serial tag 6 eee een eens 26 Fan speed suction pressure transducer settingS 1 0 0 sunsn unner 28 Lee Temp suction pressure transducer settidgS ooooooorooooororrrrara 32 Refrigerant control settings psi kPa 6 eee eens 39 Room dew point temperatures 43 Indoor unit glycol volume approximate gallons liters max ooooooooooooooomoo 44 Volume in standard Type L copper pipe 44 Ethylene glycol concentrati0OS ooooo eee een e eee eee ene 46 Mounting hole dimensional data 48 Drycooler data s ci oe bes Mines we Gn bee Be gf Ras idl een Be a a 48 Glyeol pump datar A eee Sa eC teh ts nc A og Gd 48 Refrigerant control settings psi kPa 0 cece een ne ees 53 Unit r frigerant Charge ii ri ner a wir sacs ee sie eat Done Ra 58 Line charges refrigerant per 100 ft 30 m of Type L copper tube ooooo o 58 Recommended refrigerant lines R407C sizes OD copper 0 0 ec ees 58 Tamecouphings1Zes lt 5 au un er ee di ban Pn aaa ORE Rta Ea Ae bees 59 Equivalent leng
66. emovable 1 2 12 7mm dia holes for 24 module rigging typ 2 each end 610mm Cabinet Hanger Dimension Bracket 33 5 8 854 1mm Threaded Rod Centers Shaded area indicates a 29 13 16 recommended clearance of 757 2mm 30 762mm for component threaded Rod access and removal NOTE Unit is evenly spaced in reference to threaded rod centers Centers 7 8 22 2mm 8 1 1 8 28 6mm x 7 8 22 2mm amp 1 1 8 28 6mm dia knockouts electrical entrance for line voltage connection dia knockouts electrical entrance for 8 7 16 line voltage connection Single Point 214 4mm Power Kit 95 2mm N 7 er N e 5 Suction Line male quick connect location Liquid Line male quick connect location 1 25 4mm NPT Female Water Glycol Inlet Connection 1 25 4mm NPT Female Water Glycol Outlet Connection 7 8 22 2mm dia electrical entrance for low voltage connection 718 22 2mm dia knockout electrical entrance for alternate SL 11087 control panel low voltage routing Pg 6 75 Split System Models Figure 44 5 ton water glycol cooled condensing unit con t Field supplied unit disconnect switch when factory unit disconnect switch is not suplied Electric service not by Liebert WATER GLYCOL Optional factory installed disconnect switch Field supplied 24V ___ NEC Class 1 wiring to fan coil unit Field supplied 24V
67. er sequence so that the scroll compressor rotates in the proper direction Rotation in the wrong direction will result in poor performance and compressor damage Use a phase sequence and motor rotation sensor to ensure that the three phase power is correctly connected and the compressor is rotating properly 18 Installation Applicable to all Models Figure 12 Electrical connections Terminal Block for customer connections 15 13 72 71 ge 70 Electrical Handy Box factory installed with cover inside unit on top for upflow and on base for downflow 14 14 9 9 10 11 13 12 16 17 18 Eoy I 4 T EEN E ok Y EY COO eegee Boog AA geoad eeo DPN000354 75 76 94 95 98 97 37C88d378888 37 38 24 50151 55 56 Time 91 92 93 1 2 3 4 82183184185188l89 aa aalalacaaVaaaa aa Bebola ebeo Rev 01 10 11 12 13 14 Electric conduit knockouts on top and bottom of electric box Knockout size 1 3 4 44 5mm Three phase connection Electric service connection terminals when factory disconnect is NOT supplied Three phase connection Electric service connection terminals
68. er specifications for grilles and perfo rated panels should indicate the total free area required for air delivery rather than the number of panels and grilles See Table 3 for recommended free area required for each model This table indicates the recommended free area based on having the supply air grilles and perforated panels sized to handle approximately 75 of the total cubic feet per minute CFM of the units at a veloc ity of 550 to 600 ft min 2 8 3 1 m s The remaining 25 of the air flow in the raised floor passes through cable cutouts cracks between the panels and other leakage areas Table 3 Recommended free area ft m2 for grilles or perforated panels at output velocities of 550 and 600 fpm 2 8 and 3 1 m s 50 Hz Units 60 Hz Units 550 2 8 600 3 1 550 2 8 600 3 1 Model FPM m s FPM m s Model FPM m s FPM m s 3 ton 2 5 0 01 2 3 0 01 3 ton 2 5 0 01 2 3 0 01 5 ton 3 5 0 02 3 3 0 02 5 ton 3 8 0 02 3 5 0 02 Ducted Applications For ducted supply applications on upflow units the duct work should be attached to the blower dis charge flanges of the unit For ducted return air applications the duct work should be attached to the filter box flanges on upflow rear return units and on the unit top flange for downflow units Refer to Figure 2 for information on upflow units and to Figure 3 for downflow units The duct work on upflow units must allow access to the motors blo
69. erminal Line Voltage Electric Power for field supplied Supply Conduit Voltage earth grounding wire Removable Access Panels Heat rejection connection Field supplied 24V NEC Class 2 wiring See Note 2 Wire connections from evaporator module Field Supplied 24V NEC Class 2 wiring between condensing unit Low voltage 1 24V GND and fan coil unit electric power 2 24V supply supply conduit s 3 High pressure alarm optional entrance 4 Hot gas bypass connection only on NOTES units with hot gas bypass Refer to specification sheet for full load amp and wire size amp ratings Control voltage wiring must be a minimum of 16 GA 1 6mm for up to 75 23m or not to exceed 1 volt drop in control line DPNO00226_Rev0 70 Split System Models Figure 40 Split systems general arrangement Hot Gas Bypass Solenoid Condenser Valve Coil Scroll Compressor Liquid Injection 1 2 12 7mm NPT Valve Bulb Pressure Relief Valve Suction Line Male Quick Sight O AIR COOLED vale gu i Suction Line Coupling Female Quick Service Connect Head Pressure Lee Temp Access ina Control with Receiver Coupling Ports Integral Check Pressure Valve i i External Liquid Hot Gas Balancing DR in Equalizer Bypass Control Valve ube jeni Liquid is Valve Receiver Heater Condenser Pressure Limiting DEE Male Quick Switch Connect Liquid Line gt l A 2 Y Liquid Line Couplin
70. ers at the location of the condenser This power supply does not have to be the same voltage as the indoor unit This separate power source may be 208 230 460 or 575 V 60 Hz or 200 230 or 380 415 V 50 Hz The disconnect switch may be factory supplied and mounted in the electrical panel or field supplied and mounted per local and national codes Low Voltage A control interlock between the condenser and the indoor unit is required and is connected between 70 and 71 in the handy box of the indoor unit and the electric panel of the air cooled condenser NEC Class 1 wiring is required Liebert Lee Temp Flood Back Head Pressure Control Condensers Liebert Lee Temp condensers require a separate power supply for the heated receivers This power supply is connected to the electrical connection box on the end of the receiver 23 Air Cooled Models Self Contained Compressor Figure 14 Air cooled condensers FAN SPEED AND VFD CONDENSER Liebert Lee Temp heater pad connection box N LIEBERT LEE TEMP CONDENSER Electric service supplied by a others 4 service 5 supplied by Liquid line others Hot gas line B Inverted traps are to be field supplied and installed typ When installing traps provide clearance for swing end of access door Traps are to extend above base of Secure each leg to condenser frame at all coil by a minimum of 7 1 2 190 mm points shown using hardware provided SINSUE FAN AIR G
71. for proper circuit Pa 6 operation and maintenance 9 55 Split System Models 7 0 SPLIT SYSTEM MODELS 7 1 7 1 1 7 2 7 2 1 Three condensing unit styles are available two air cooled and one water glycol cooled condensing unit Location Considerations Air Cooled Condensing Units To assure an adequate air supply 1t is recommended that all condensing units be located in a clean alr area away from loose dirt and foreign matter that may clog the coil The outdoor condensing unit must not be located in the vicinity of steam hot air or fume exhausts or closer than 18 from a wall obstruction or adjacent unit The outdoor condensing unit should be located for maximum security and maintenance accessibility Avoid ground level sites with public access or areas that will contribute to heavy snow accumulations Do not allow the discharge air to blow into another condensing unit The outdoor condensing unit must be located at the same level or above the indoor Liebert Challenger 3000 unit It must NOT be located below the indoor unit A solid base capable of supporting the weight of the condenser and at least 2 51 mm higher than the surrounding grade and at least 2 51 mm larger than the condensing unit base dimensions should be installed at the pre determined location In snow areas a base of sufficient height to clear snow accumulation must be installed The centrifugal fan air cooled condensing unit may be
72. g Solenoid Valve High Pressure Female Quick Switch Connect eh y q Sy O Expansion Coupling Scroll N Da KS Valve Compressor ZY L Liquid Injection el Pie Valve Bulb Evaporator A Solenoid J Water Glycol Coil l A gt Valve pA x Return ST D Eins Water Glycol Suction Line A A Supply Line L WATER COOLED Male Quick KA anon Connect uid Return O GLYCOL COOLED Coupling lt AA from Unit Service Suction Line Ar Access Female Quick N gt Shutoff ary os Ports Connect S f Valves rm de Coupling ae oe Fluid Supply s External y Hot Gas S to Unit gif sy Equalizer Sensing Liquid x Bypass Control 2 A oF Injection dui Valve E A 2 Way Water Tube in Valve iquid Line W OR ee Tube N Male Quick ADS Regulating Valve Condenser y Ed Liquid Line a Female Quick Hose Bibs Connect Coupling Expansion Valve Evaporator Coil TT FACTORY PIPING OPTIONAL PIPING Components are not supplied by Liebert but are recommended for proper circuit operation maintenance Fluid Return from Unit SL 11900 Pg 5 Fluid Supply 3 Way Water to Unit Regulating Valve optional 71 Split System Models 7 6 7 6 1 7 6 2 7 6 3 Water and Glycol Cooled Condensing Units For installation guidelines refer to Installing the Indoor Condensing Unit on page 65 Piping Considerations It is recommended that manual service shut off valves be installed at the supply and return line to each unit This will provide for rou
73. g emerson com 800 222 5877 Outside North America 00800 1155 4499 Single Phase UPS amp Server Cabinets liebert upstech emerson com 800 222 5877 Outside North America 00800 1155 4499 Three Phase UPS amp Power Systems 800 543 2378 Outside North America 614 841 6598 Environmental Systems 800 543 2778 Outside the United States 614 888 0246 Locations United States 1050 Dearborn Drive P O Box 29186 Columbus OH 43229 Europe Via Leonardo Da Vinci 8 Zona Industriale Tognana 35028 Piove Di Sacco PD Italy 39 0499719111 to changes in criticality density and capacity Enterprises benefit from greater IT system availability operational flexibility and reduced capital equipment and operating costs While every precaution has been taken to ensure the accuracy Fax 39 049 5841 257 and completeness of this literature Liebert Corporation assumes no Asia responsibility and disclaims all liability for damages resulting from use of Jd this information or for any errors or omissions 29 F The Orient Square Building O 2008 Liebert Corporation F Ortigas Jr Road Ortigas Center All rights reserved throughout the world Specifications subject to change Pasig City 1605 without notice Philippines Liebert is a registered trademark of Liebert Corporation All names referred to are trademarks 63 2 687 6615 or registered trademarks of their respective owners Fax 63 2 730 9572 SL 11962_REVO_09 09 Emerson Network Po
74. gs for equipment installed Control wiring connections completed to evaporator and condensing unit Verify water detection is properly installed around all units if installed All wiring connections are tight Control panel DIP switches set based on customer requirements Foreign materials have been removed from in and around all equipment installed literature shipping materials construction materials tools etc Fans and blowers rotate freely Inspect all piping connections for leaks during initial operations Correct as needed Verify that a blank startup sheet has been sent with the unit s and is ready to be completed by the installer 22 Air Cooled Models Self Contained Compressor 3 0 AIR COOLED MODELS SELF CONTAINED COMPRESSOR 3 1 3 2 3 2 1 3 2 2 3 2 3 Condenser Location The air cooled condenser should be located for maximum security and maintenance accessibility Avoid ground level sites with public access or areas that contribute to heavy snow or ice accumula tions Utilize centrifugal condensers whenever interior building locations must by used To assure adequate air supply it is recommended that condensers be located in a clean air area away from loose dirt and foreign matter that may clog the coil In addition condensers should not be located in the vicinity of steam hot air or fume exhausts Also condensers should be located no closer than three feet 1 meter from a wall obst
75. he compressor Control Method The control utilizes an upper and lower pressure threshold with a 35psi 241kPa deadband to reduce valve movement If the liquid pressure is between the upper and lower threshold the valve remains at the current position If the liquid pressure exceeds the upper threshold the valve opens and ifthe pressure falls below the lower threshold the valve closes There are multiple adjustment bands to ease discharge pressure back into control range 39 Water Cooled Models Self Contained Compressor 4 4 2 4 4 3 4 4 4 4 4 5 Adjustment Both pressure thresholds can be shifted simultaneously over a 50psi 345kPa range the 35psi 241kPa differential remains constant The ball valve setpoint offset parameter in the Liebert COM Service menu can be adjusted from 0 to 50 PSI 845 kPa to raise or lower the control band similar to the pressure adjustment on a water regulating valve Changing the setpoint offset will adjust the pressure thresholds for both circuits Units are factory set at a 30psi 207 kPa setpoint offset 30psi 207 kPa above minimum This results in a 220psiA 1517kPa lower threshold and a 255psiA 1758kPa upper threshold pressure Startup The setpoint offset is adjusted to the minimum value during startup then changes to the set value once the compressor reaches normal operating pressures Changes in fluid temperature could cause pressure changes that do not result in valve m
76. imension 41 1mm 15 3 4 Customer supplied 400mm 8 15 16 1219 2mm threaded rods for 227mm module support 3 3 8 from ceiling typ 4 85 7mm 14 1 2 368 3mm 21 1 4 610mm 539 8mm Cabinet Dimension Shaded area indicates a recommended clearance of 33 5 8 51 13 16 Hanger 30 762mm for component 854 1mm 1316mm Bracket access and removal Threaded Rod Threaded Rod Centers Centers NOTE Unit is spaced evenly in 1 2 12 7mm dia holes for reference to threaded threaded rods typ 2 each end rod centers 7 8 22 2mm amp 1 1 8 28 6mm dia knockouts electrical entrance for high voltage connection Single Point Power Kit 7 8 22 2mm amp 1 1 8 28 6mm dia knockouts electrical entrance for high voltage connection Single Point Power Kit connection to Evaporator Air Inlet Air Outlet Liquid Line male quick connect location Suction Line male quick connect location 7 8 22 2mm dia 7 8 22 2mm dia knockout electrical entrance electrical entrance for alternate for low voltage connection control panel low voltage routing SL 11087 Pg 4 69 Split System Models Figure 39 5 ton centrifugal air cooled condensing unit dimensional data con t Field Supplied Unit Disconnect Switch when Factory Unit Disconnect Switch is not Supplied nn Electric service not by Liebert el u Optional Factory Installed Disconnect Switch AIR COOLED Connection t
77. iring 3 phase to evaporator electric module service not by Liebert Factory wired to components on electric panel Heat rejection connection Field supplied 24V NEC class 2 wiring Wire connections from evaporator module 1 24V GND 2 24V Supply 3 High Pressure Alarm 4 Hot Gas Bypass Connection only on units with hot gas bypass If no hot gas bypass connection is provided in the evaporator module Connect wire 4 with wire 2 to the 24V supply 64 Split System Models 7 5 7 5 1 Centrifugal Air Cooled Condensing Units Installing the Indoor Condensing Unit Refer to drawings for unit dimensions and component locations A WARNING Risk of heavy unit falling from supports Can cause equipment and building damage injury and death Be sure the supporting roof structure is capable of supporting the weight of the unit s and the accessories during installation and service See Table 30 Indoor centrifugal condensing unit Be sure to securely anchor the top ends of the suspension rods Make sure all nuts are tight The indoor condensing unit is usually mounted above the ceiling and must be securely mounted to the roof structure The ceiling and ceiling supports of existing buildings may require reinforcements Be sure to follow all applicable codes Use field supplied threaded suspension rods and 3 8 16 factory hardware kit The indoor condensing unit must be located at the same level or above the Lie
78. it condenser and refrigerant line charge data in Tables 6 7 8 and 9 4 Weigh in as much of the system charge as possible before starting the unit CAUTION Risk of improper refrigerant charging Can cause equipment damage Refrigerant R407C is a blend of three components and must be introduced and charged from the cylinder only as a liquid When adding liquid refrigerant to an operating system it may be necessary to add the refrigerant through the compressor suction service valve Care must be exercised to avoid damage to the compressor Emerson recommends connecting a sight glass between the charging hose and the compressor suction service valve This will permit adjustment of the cylinder hand valve so that liquid can leave the cylinder while allowing vapor to enter the compressor 5 Turn on unit disconnect switch Operate the unit for 30 minutes using the charging function for the system in the diagnostic section of the Liebert COM control The charging function operates the compressor at full capacity and energizes the blower motor and liquid line solenoid valve The reheat and humidifier are disabled A minimum 20psig 138kPa must established and maintained for the compressor to operate The charging function can be reset as many times as required to complete unit charging Table 11 Lee Temp suction pressure transducer settings R 407C Gauge Reading Sea Level Absolute Function psiG kPa psiA kPa Pump Do
79. itch when optional disconnect electric service is not provided in unit not by Liebert N r Field supplied 24V NEC Class 1 wiring to fan coil unit Field supplied 24V NEC Class 1 wiring to drycooler glycol cooled units only Lm M Earth ground connection Connection terminal for field supplied earth grounding wire Factory wired components on electric panel Line voltage electric power supply entrance Optional factory installed disconnect switch Low voltage electric power supply entrance Remote drycooler connection Terminals 70 amp 71 supplied Heat rejection connection for connection to remote drycooler a Field supplied 24V NEC Class 2 wiring ued Ie euppied Zav Deg Class Wire connections from evaporator mod wiring glycol cooled units only 1 24V GND NOTES 2 24V supply 1 Refer to specification sheet for full load amp 3 High pressure alarm optional and wire size amp ratings 4 Hot gas bypass connection 2 Control voltage wiring must be a minimum only on units with hot gas bypass of 16 GA 1 6mm for up to 75 23m or not to exceed 1 volt drop in control line DPN000209_RevO 74 Split System Models Figure 43 5 ton water glycol cooled condensing unit dimensional data 32 32 812 8mm 812 8mm Customer supplied Cabinet Cabinet threaded rods Dimension Di for module support imension ae from ceiling typ 4 R
80. l however assume the corrosivity of the water from which it is prepared and may become increasingly corrosive with use if not properly inhibited CAUTION Risk of oxide layer formation Can cause equipment damage Idle fluid allows the collection of sediment that prevents the formation of a protective oxide layer on the inside of tubes Keep unit switched ON and system pump operating 42 Glycol GLYCOOL Cooled Models Self Contained Compressor NOTICE Risk of debris or precipitate clogging pipes Can cause equipment damage Galvanized pipe must not be used in or with systems or units that contain glycol The phosphates in the inhibitor can react with the zinc in the galvanized pipe precipitating an insoluble material that can eventually foul the system Fluid cooled condensers have small internal flow passages To avoid clogging and other resulting system operation problems install a 16 20 mesh filter in the fluid supply line to the indoor unit The filter should be located where it can be easily serviced or replaced Do not install unit on open loop systems Debris carried by the fluid will clog the brazed plate condenser NOTICE Risk of improper installation Can cause equipment or structural damage Supply and return lines must be supported in a way that keeps their weight from bearing on the piping of the unit drycooler or pumps Failure to support piping can strain the equipment s structural integrity A relief valve
81. l refrigeration piping should be installed with high temperature brazed joints Prevailing good refrigeration practices should be employed for piping supports leak testing evacuation dehydration and charging of the refrigeration circuits The refrigeration piping should be isolated from the build ing by the use of vibration isolating supports It is important to handle the pre charged lines for 3 ton units with care so they will not get kinked or damaged Use tube benders and make all bends before making connections to either end Coil any excess tubing in a horizontal plane with the slope of the tubing toward the condensing unit To prevent tube damage when sealing openings in walls and to reduce vibration transmission use a soft flexible material to pack around the tubes When installing remote condensing units mounted above the evaporator the suction gas line should be trapped at the evaporator This trap will retain refrigerant oil in the off cycle When the unit starts oil in the trap is carried up the vertical riser and returns to the compressor 57 Split System Models Refrigerant charge requirements Total refrigerant charge will be required only if units are evacuated during installation or maintenance Total refrigerant charge evaporator lines condensing unit NOTE All condensing units and 3 ton evaporator units are fully charged with refrigerant All 5 ton evaporator units include a nitrogen holding charge only
82. lass Traps Every x 25 Ft 7 6m Pr 4 of rise on Hot an ZL Gas Line only Liquid Return Z Evaporator Coil from Condenser Expansion SN hot Gas vale a Bypass ys Valve vr 7 Solenoid Valves Sensing Bulb Shutoff Sight Glass Valve G Filter Dryer Liquid Return A 7 External L g Equalizers Sr Hot Gas Scroll A Bypass Compressor P Components are not supplied by Liebert I but are recommended for proper y S Check Valve circuit operation and maintenance Hot Gas Discharge Components supplied by Liebert ft and must be field installed FACTORY PIPING OPTIONAL PIPING DPN000674 Z ZI FIELD PIPING PENOZ 33 Air Cooled Models Self Contained Compressor Figure 18 General arrangement Air cooled models with digital scroll and Lee Temp Condenser Coil Inverted Trap on discharge line to extend above base of coil by a minimum Piping Assembly of 7 1 2 190mm Z X gt Check valve Y eee Rotalock Valve tae Mead Pressure 1 4 6 4mm Control with 4 Integral Check Pressure Relief Valve Liebert 2 Valve Lee Temp Fr Receiver z Traps Every 25 Ft 7 6m of rise on Hot Gas Line only Liquid Return from Condenser 7 AA ui eC N x Sensing Bulb N Liquid Return xternal Equalizer i 4 Last gt Digital Solenoid Valve Digital Compressor
83. mended for proper circuit operation Rev 0 and maintenance 50 Glycol GLYCOOL Cooled Models Self Contained Compressor Figure 27 General arrangement GLYCOOL models with scroll compressor Expansion Tank Field Installed at Highest Point in System Drycooler Electric Box gt Drycooler Unions Fill Coil GEH Return a lati _ Pump Zz lt SO anon Z Valves Evaporator Coil Pressur x nionst lt A Y S fuia 7 7 Supply sA Z from Pump EN Air Vents Flow Regulating Valve at Top of Pressure Glass Risers External Equalizers Scroll Compressor Bypass 3 Way Water II Fluid Regulating Valve 9 Supply to Actuator Fluid Unit Condenser Return from M Econ O CycleN Unit pa Comparator A A Isolation ao Valves pol p ARE TER ES Components are not supplied by Liebert but are recommended A Field Supplied for proper circuit operation x Reducers and maintenance P A Required on 3 Ton Units IE Hose LE _ lA FACTORY PIPING Bibs GERD DPN000379 tof _ TT gt FIELD PIPING Rev 03 51 Glycol GLYCOOL Cooled Models Self Contained Compressor Figure 28 General arrangement GLYCOOL models with digital scroll compressor Expansion Tank Field Installed at Highest Point in System Drycooler Hectric Drycooler Coil e KEA e Fluid 37 CEE Evaporator Return to Dr Coil
84. n be used for energy savings with any Liebert Challenger 3000 unit Variable Fan Speed Control Piping A discharge line and a liquid line must be field installed between the indoor unit and the outdoor con denser See Figures 15 and 16 for details 26 Air Cooled Models Self Contained Compressor Variable Fan Speed Control Materials Supplied Built in pre wired condenser control box Air Cooled condenser Piping access cover to be reinstalled when piping is complete Bolts four per leg 3 8 x 5 8 Terminal block for two wire 24V interlock connection between unit and condenser Condenser legs four with 1 fan 2 fan and 3 fan models six with 4 fan models Variable Fan Speed Control Leak Check and Evacuation Procedure Proper leak check and evacuation can be accomplished only with all system solenoid valves open and check valves accounted for NOTE Systems with a scroll or digital scroll compressor include a factory installed check valve and an additional downstream Schrader valve with core in the compressor discharge line Proper evacuation of the condenser side of the compressor can be accomplished only using the downstream Schrader valve See piping schematic Figures 15 and 16 If unit power is available open the unit liquid line solenoid valves using the evacuation function in the diagnostic section of the Liebert COM control refer to the Liebert COM user manual SL 18835 If unit power is not available
85. ngs NOTE When hard piping is used complete all piping and evacuate lines before connecting quick connects Be especially careful when connecting the quick connect fittings Read through the following steps before making the connections 1 QUE gt o gt Remove protector caps and plugs Carefully wipe coupling seats and threaded surfaces with a clean cloth Lubricate the male diaphragm and synthetic rubber seal with refrigerant oil Thread the coupling halves together by hand to ensure that the threads mate properly Tighten the coupling body hex nut and union nut with the proper sized wrench until the coupling bodies bottom out or until a definite resistance is felt Using a marker or pen make a line lengthwise from the coupling union nut to the bulkhead Tighten the nuts an additional quarter turn the misalignment of the lines shows how much the coupling has been tightened This final quarter turn is necessary to ensure that the joint will not leak Refer to Table 24 for torque requirements Add charge for the additional piping refer to Table 22 59 Split System Models 7 4 Outdoor Air Cooled Condensing Units Figure 32 Outdoor air cooled condensing unit horizontal air discharge models UNIT DIMENSIONS See Table 26 a Fan Rotation Removable Right Panel CCW left side for access to refrigeration A components Right Air Discharge 7 Shaded area indicates a minimum clearance of 1
86. on on the supply and return lines To provide for the emergency of water leaks and the consequences of sub floor flooding floor drains should be provided with wet traps or a water detection system such as a Liebert Liqui tect that is installed near the base of the unit or below the elevated floor Figure 29 Chilled water general arrangement Upflow BU Chilled Water Supply Chilled j Water Chilled Coil Water Return 3 WAY VALVE Switch Air optional Flow iges yd Hose Ra Bibs Chilled Water Supply ae Chilled 44 ee Chilled Blake Water Valve Coil 2 WAY VALVE Shutoff Valves TT FACTORY PIPING Hose gt gt FIELD PIPING SL 11899 Bibs x Pg 5 RS Components are not supplied by Liebert but g are recommended for proper circuit operation and maintenance 54 Chilled Water Models Figure 30 Chilled water general arrangement Downflow BF models Chilled Valve Water Return cl a Chilled ou Water mae Coil Shutoff Valves ee 3 WAY VALVE o T er Wg Switch Y gt BI optional oe ee Air Chilled Flow Hose Water Valve Chilled Actuator Water qa Supply Chilled Shutoff Aa x S oil Valves Mi gt ga 2 Way Chilled a ii 2 Water Valve 2 WAY VALVE I er oll E Il Po Lee FACTORY PIPING Er FeDPPNG 1 2 Hose Bibs Components are not supplied by Liebert SL 11899 but are recommended
87. ovement within the deadband Fan cycling stats should be set to prevent continuous fluid temperature swings greater than 10 F 5 6 C Location The motorized ball valve is located in the condenser fluid return line Three way valves are piped in a mixing arrangement with the common port at the valve outlet Manual Control The valve can be manually set by disconnecting AC power depressing the manual override button on the valve actuator and adjusting the valve position with the handle The motorized ball also can be controlled through the Liebert 1 COM s Service menu using manual mode to override the normal con trol 40 Glycol GLYCOOL Cooled Models Self Contained Compressor 5 0 GLYCOL GLYCOOL COOLED MODELS SELF CONTAINED COMPRESSOR 5 1 5 2 5 3 5 3 1 5 3 2 5 3 3 Drycooler Location The drycooler should be located for maximum security and maintenance accessibility Avoid ground level sites with public access or areas which contribute to heavy snow or ice accumulations To assure adequate air supply it is recommended that drycoolers be located in a clean air area away from loose dirt and foreign matter that may clog the coil In addition drycoolers should not be located in the vicinity of steam hot air or fume exhausts Also drycoolers should not be located closer than 3 feet 1 meter from a wall obstruction or adjacent unit Drycooler Installation For roof installation mount drycoolers on s
88. recharging a system R407C refrigerant must be introduced and charged from the cylinder only as a liquid NOTICE Risk of improper piping installation Can cause contamination of hygroscopic oil with water When installing field piping care must be taken to protect all refrigerant lines from the atmosphere especially when using refrigerants such as R407C which requires use of polyol ester oils Do not allow the piping to stand open to air for more than 15 minutes Units designed for R407C have a compressor that contains polyol ester oil which is very hygroscopic that is it quickly absorbs water from the air The longer the compressor piping is left open to air the harder it will be to fully evacuate If left open too long the polyol ester oil may need to be replaced before achieving the required vacuum level NOTE Complete all piping and evacuate lines before connecting quick connects when using an optional sweat adapter kit and field installed hard piping Follow all proper brazing practices including a dry nitrogen purge to maintain system cleanliness All split systems require two refrigerant lines an insulated copper suction line and a copper liquid line between the evaporator and the condensing unit Two possible methods exist for installing the copper suction and liquid lines 1 Using an optional Sweat Adapter Kit and hard piping between the two units 2 Using optional pre charged line sets for 3 ton models only Al
89. relief valve For systems requiring EU CE compliance 50Hz the pressure relief valve must be CE certified to the EU Pressure Equipment Directive by an EU Notified Body NOTE A pressure relief valve is provided with Liebert Lee Temp condensers A fusible plug is provided on Liebert Fan Speed Control condensers The Liebert indoor cooling unit has a factory installed high pressure safety switch in the high side refrigerant circuit WARNING Risk of high speed moving parts Can cause injury or death Disconnect all local and remote electric power supplies before working in the unit Do not operate upflow units without installing a plenum ductwork or guard over the blower opening s on the top surface of the unit cabinet Ductwork must be connected to the blower s or a plenum must be installed on the blower deck for protection from rotating blower wheel s on upflow units A CAUTION Risk of contact with hot surfaces Can cause injury The compressor refrigerant discharge lines humidifiers and reheats are extremely hot during unit operation Allow sufficient time for them to cool before working within the unit cabinet Use extreme caution and wear protective gloves and arm protection when working on or near hot compressors discharge lines humidifiers and reheats NOTICE Risk of leaking water Can cause equipment and building damage This unit requires a water drain connection It may also require an external wa
90. rn 1 4 OD CU 5 8 OD CU optional Chilled Water Supply Line y lr ER E Chilled Water Return Line 1 1 8 OD CU 1 1 8 OD CU Condensate Pump Line J I oS See Hot Water Supply 1 2 OD CU used only if optional I 5 8 OD CU optional condensate pump is ordered COM Control Panel QQ QQ KK N PIPING OUTLET LOCATIONS See Cabinet and Floor Planning Dimensional Data for Piping Opening Sizes QW Condensate Drain 3 4 FPT u Field pitch a min of 1 8 3 2mm per ft 305mm Units without a condensate pump have a factory supplied trap in the unit so a field trap should not be added Units with a condensate pump will require a field supplied trap downstream from the pump The drain line must comply with all applicable codes If condensate DPN000370 pump is ordered piping is out top of unit Rev 01 17 Installation Applicable to all Models 2 5 2 Humidifier Supply Water Optional Infrared 2 6 2 7 1 4 supply line maximum water pressure is 150 psi 1034kPa Size humidifier supply line for 1 gpm 3 8 1 m with a minimum water pressure of 20 psi 138kPa Do not supply de ionized water to the humidifier Facility Fluid and Piping Maintenance Facility water and glycol quality remain a requirement throughout the life of the piping system Fluid and piping system maintenance schedules must be established and performed A local fluid m
91. rorno a aa a aa E mera 21 2 9 Checklist for Completed Installation 4 249 0d0004 4003 ar 2 2 0 aa aaa 22 3 0 AIR COOLED MODELS SELF CONTAINED COMPRESSOR 0000000eceeeueaes 23 3 1 Condenser Location 34 bad la a se ee ee ee a Ses ake E 23 3 2 Electrica Connections a E ea Gate Sate ee Moma DAA aa ee ew Ad a 23 8 251 Bine VO Ge ais coh ale A ee EIR en RGR en oe ara 23 3 22 IowVoltage nun 2 3 he pannid a a da tee tanh BA de aber a A bys 23 3 2 3 Liebert Lee Temp Flood Back Head Pressure Control Condensers 000055 23 3 3 Refrigerant Piping 1 432 022 dn be da aed foe nie Bat nah 25 3 4 Fan Speed Control Systems 26 3 5 Air Cooled Condenser with Liebert Lee Temp Flooded Condenser Head Pressure Control System dara ad ra al Oa ahaa Sel oan ED Bee ne 31 4 0 WATER COOLED MODELS SELF CONTAINED COMPRESSOR 20000000eeeee 35 4 1 Piping Consid Gra tions u 2a ii dele the an da 35 4 2 Condenser na a ae a aa E aus Se Pd eae eae i i 35 4 3 Water Regulating Valve 38 4 3 1 Standard Valve 150psig 1034kPa System for 3 amp 5 Ton Units Johnson Controls Valve High Pressure Valve 350psig 2413kPa System for 5 Ton Units Johnson Controls Malva Dennerle a 38 4 3 2 High Pressure Valve 350 psig 2413 kPa System for 3 Ton Units Metrex Valve 38 4 4 Motorized Ball Valve Digital Scroll Compressors oooooooooooooooomomomoo 39 AAV Controla ds wade aida een os as do De DS ais io 39 LAD AQUEL A A A
92. ruction or adjacent unit NOTE If the condenser is located below the level of the room unit the factory should be consulted Install condensers in a level position to assure proper refrigerant flow and oil return For roof instal lation mount condensers on steel supports in accordance with local codes To minimize sound and vibration transmission mount steel supports across load bearing walls For ground installation a concrete pad will provide adequate support Condenser legs have mounting holes for securing the con denser to the steel supports or concrete pad Electrical Connections Refer to equipment nameplate regarding wire size and circuit protection requirements Refer to elec trical schematic when making connections Make all wiring and electrical connection in accordance with local and national codes A WARNING Risk of electric shock Can cause injury or death Potentially lethal voltages exist within this equipment during operation Observe all cautions and warnings on unit and in this manual The Liebert COM microprocessor does not isolate power from the unit even in the Unit Off mode The only way to ensure that there is NO voltage inside the unit is to install and open a remote disconnect switch Refer to unit electrical schematic Use voltmeter to make sure power is turned off before making any electrical connections Line Voltage Line voltage electrical service is required for all air cooled condens
93. t counterclockwise to raise head pressure turn it clockwise to lower head pressure Rotation directions are viewed from top of valve spring housing 38 Water Cooled Models Self Contained Compressor Figure 22 Metrex Valve adjustment Adjusting collar nut 4 4 4 4 1 Table 12 Refrigerant control settings psi kPa Low Pressure Low Pressure High Pressure Cut Out Cut In Cut Out 20 137 9 65 448 2 400 2758 Manual Flushing The valve may be flushed by rotating the socket head screw clockwise This screw must be in the OUT position counterclockwise for normal valve operation Motorized Ball Valve Digital Scroll Compressors On digital scroll units discharge pressure is controlled by a motorized ball valve During unloaded operation the pressure changes during each digital cycle could cause excessive repositions with a pressure operated water regulating valve The control algorithm for the motorized ball valve uses an intelligent sampling rate and adjustable pressure thresholds to reduce valve repositions The valve assembly consists of the brass valve linkage and actuator Control The valve actuator operates on 24VAC power and is controlled by a 2 10VDC proportional control sig nal The valve will move from fully open to fully closed in 60 seconds At 2VDC the valve is closed at 10VDC the valve is fully open There is a 20 second delay to position the motorized ball valve before starting t
94. teel supports in accordance with local codes To minimize sound and vibration transmission mount steel supports across load bearing walls For ground instal lation a concrete pad will provide adequate support Drycooler legs have mounting holes for securing the drycooler to steel supports or concrete pad Electrical Connections Refer to equipment nameplate regarding wire size and circuit protection requirements Refer to elec trical schematic when making connections Make all wiring and electrical connections in accordance with local and national codes A WARNING Risk of electric shock Can cause injury or death Potentially lethal voltages exist within this equipment during operation Observe all cautions and warnings on unit and in this manual The Liebert iCOM microprocessor does not isolate power from the unit even in the Unit Off mode The only way to ensure that there is NO voltage inside the unit is to install and open a remote disconnect switch Refer to unit electrical schematic Use voltmeter to make sure power is turned off before making any electrical connections Line Voltage Line voltage electrical service is required for all drycoolers at the location of the drycooler This power supply does not have to be the same voltage as the indoor unit This separate power source may be 208 230 460 or 575 V 60 Hz or 200 230 or 380 415 V 50 Hz The disconnect switch is factory sup plied and mounted in the electric p
95. ter supply to operate Improper installation application and service practice can result in water leakage from the unit Water leakage can result in severe property damage and loss of critical data center equipment Do not locate unit directly above any equipment that could sustain water damage Emerson recommends installing leak detection equipment for unit and supply lines Introduction 1 0 INTRODUCTION 1 1 System Descriptions Challenger 3000 environmental control systems are available in three main system configurations self contained system with a scroll compressor in the room unit self contained chilled water system e split system with an evaporator section and a remote condensing unit All three types are available in upflow or downflow configurations The standard upflow configuration is front return All models require three phase power Units are available in 208 230 460 or 575V 60Hz and 200 230 or 380 415V 50Hz The following features are included as standard in all room units regardless of the type of system Lie bert iCOM control A frame coil V frame on upflows infrared humidifier finned tubular stainless steel electric reheat 2 filter individual high voltage fused protection and fan assembly Self Contained Systems Air Cooled Models Complete refrigeration system including hot gas bypass and crankcase heater with standard scroll compressor standard condenser and fan speed control for
96. ths feet for various pipe fittings 0 ccc cece nes 59 Horizontal air discharge cabinet and floor planning dimensional data 61 Horizontal air discharge piping and electrical connection data suasa cece eee 61 Cabinet and floor planning dimensional data prop fan condensing modules top air discharge a ee TV Set Br et ooh hie OSA Beast a6 A Ce pu Pes 63 Piping and electrical connections top air discharge 0 0 cece cece eee teens 63 Indoor centrifugal condensing unit 6 cence eee nena 65 Airflow GEM EMRA 4 peed 32 dan ige hdd bod de ee ogee ied Abe dd 66 Water and glycol cooled condensing unit data ccc seen 72 R407C pressure temperature chart for operation and superheat discharge hot gas and SUCTION OAS een a eae Pas eee Ee RoR ORI ee eee eae 77 R407C pressure temperature chart for subcooling only liquid measurements 78 iv IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This manual contains important safety instructions that should be followed during the installation and maintenance of the Liebert Challenger 3000 Read this manual thoroughly before attempting to install or operate this unit Only qualified personnel should move install or service this equipment Adhere to all warnings cautions and installation operating and safety instructions on the unit and in this manual Follow all operating and user instructions A A
97. tine service or emergency isolation of the unit When the water source for the condenser is of poor quality it is good practice to provide cleanable fil ters in the supply line These filters will trap the particles in the water supply and extend the service life of the water cooled condenser 3 Ton Connection Sizes Condenser Water Inlet 7 8 OD Cu Condenser Water Outlet 7 8 OD Cu Suction Line 1 1 8 12 male 11 quick connect Liquid Line 5 8 18 male 6 quick connect 5 Ton Connection Sizes Condenser Water Inlet 1 1 8 OD Cu Condenser Water Outlet 1 1 8 OD Cu Suction Line 1 7 16 16 male 12 quick connect Liquid Line 1 1 16 12 male 10 quick connect Table 32 Water and glycol cooled condensing unit data Net Weight Glycol Volume Model Ib kg gal 1 MC_44W MC_43W 200 91 1 7 6 4 MC_69W MC_68W 282 128 2 0 7 6 Condenser Water Requirements The standard maximum water pressure is 150 psig 1034 kPa For applications above this pressure consult the factory about high pressure systems The system will operate in conjunction with a cooling tower city water or drycooler Regulating Valve For details refer to sections 4 3 1 Standard Valve 150 psig 1034kPa System for 3 5 Ton Units Johnson Controls Valve High Pressure Valve 350 psig 2413kPa System for 5 Ton Units Johnson Controls Valve and 4 3 2 High Pressure Valve 350 psig 2413 kPa System for 3 Ton Units Metrex Val
98. unit until the liquid line sight glass becomes clear Then add one additional pound 2 2kg of refrigerant NOTE A digital scroll compressor will have a clear sight glass only when operating at 100 capacity 7 When operating below 100 the sight glass may show bubbles with each 15 second unloading cycle As head pressure builds the variable fan speed controlled condenser fan begins rotating The fan will run at full speed when sufficient head pressure is developed fan starts to rotate at 190 psig 1310 kPA and is full speed at 250 psig 1724 kPA 28 Air Cooled Models Self Contained Compressor Figure 15 General arrangement Air cooled models with fan speed control Schrader Valve Inverted Trap on discharge line to extend above base Condenser n gt LS A of coil by a minimum R 7 Plu Zz g of 7 1 2 190mm Y A 5 yee aa a Y Ge 36 O ie Z 7 li Evapor Traps every Coil 25 ft 7 6m of rise 47 f _ J Hot Gas 7 Bypass I Valve Liquid Return f Solenoid Sensing Shutoff Valve Ce zZ a External Equalizers Hot Gas Scroll Bypass Compressor FACTORY PIPING I ZZL _ L FIELD PIPING H Br Components are not supplied by Liebert but gt a Gas are recommended for proper circuit operation 7 Discharge and maintenance DPNO00349 Rev 3 29 Air Cooled Models Self Contained Compressor Figure 16
99. upplied trap downstream from the pumpThe drain line must comply with all applicable codes If condensate pump is ordered piping is out top of unit 11 Installation Applicable to all Models Figure 6 Piping connections for split system fan coil units Downflow models Condensate Drain 3 4 FPT Field pitch a minimum of 1 8 3 2mm per ft 305mm The drainline must comply with all applicable codes HumidifierWater Supply Line 1 4 OD CU LiebertiCOM Control PIPING OUTLET LOCATIONS See Cabinet and Floor Planning Dimensional Data for Piping Opening Sizes L __ _ Liquid Refrigerant Line 6 Quick Connect on Models BFO36E BF035E 1 2 OD CU on Models BFO60E BF059E Le o L Suction Refrigerant Line 11 Quick Connect on Models BFO36E BFO35E 1 1 8 OD CU on Models BFO60E BF059E EESE F 5 8 OD CU optional L Hot Water Return HotWater Supply 5 8 OD CU optional DPNO000376 Rev 01 12 Installation Applicable to all Models Figure 7 Piping connections for split system fan coil units Upflow models 2 22 22 Piping outlet locations through the PI MT plenum are the same as the unit I See below for descriptions and T connection sizes Humidifier Water Supply Line Tr Hot Water Return 1 4 OD CU 5 8 OD CU optional Suction Refrigerant Line
100. ure 24 on page 48 1 3 4 4 1 4 25 4mm 25 4mm Eu ER q 25 4mm 37 11 16 957mm l 1 2 12 7mm diameter anchor bolts typ TYPICAL FOOTPRINT UNIT ANCHOR PLAN 47 Glycol GLYCOOL Cooled Models Self Contained Compressor Figure 24 Pump packages expansion tank 30 1 2 774 7mm 29 6 13 16 17 114 1 2 FPT 228 6mm 1 2 FPT 1 73mm T 438 ne Fitting Fitting ee a zZ Br mm 1 25 4mm 1 101 6mm Y 1 2 12 7mm 8 holes s esaum EXPANSION TANK 1 1 2 1 1 2 38 1mm 8 8 gal 33 31 38 1mm 6 1 8 76 2mm SL 10070 Pg 6B Table 17 Mounting hole dimensional data A B Cc PUMP PACKAGE in mm in mm in mm SINGLE 0 75 7 5Hp 15 1 4 387 4 2 1 2 63 5 22 1 2 571 5 DUAL 0 75 5 Hp 30 1 4 768 4 2 1 2 63 5 22 1 2 571 5 Table 18 Drycooler data Drycooler Model No of Weight Conn Sizes A Dimension B Dimension C Dimension Coil Internal No Fans Ib kg Suct amp Disc in in mm in mm in mm Volume gal 1 069 1 410 186 1 1 4 51 1 2 1308 44 1118 42 1067 2 4 9 2 092 1 430 195 1 1 2 51 1 2 1308 44 1118 42 1067 3 7 13 9 109 1 450 204 2 51 1 2 1308 44 1118 42 1067 4 9 18 6 112 1 470 213 2 51 1 2 1308 44 1118 42 1067 5 8 22 0 139 2 565 256 2 9
101. ve 72 Split System Models 7 6 4 Glycol Systems For split system glycol systems use drycooler and pump data found in 5 0 Glycol GLYCOOL Cooled Models Self Contained Compressor See Table 18 Drycooler data Electrical control interconnect to drycooler is wired from water glycol condensing unit Figure 41 3 ton water glycol cooled condensing unit 8 7 8 225mm 14 356mm Overall Cabinet Dimension 12 305mm Threaded Rod Centers 50 1 4 1276mm Overall Dimension 48 1 4 1225mm Threaded Rod Centers 46 1 2 1181mm Cabinet Dimension 20 3 4 S 527mm 22 1 2 572mm Cabinet Dimension a 3 7 8 98mm 8 7 16 214mm Customer Supplied Threaded Rods for Module Support from Ceiling typ 4 Holes for Module Rigging typ 2 each end Minimum Clearance DIMENSIONAL DATA 33 838mm This side for component access Integral Hanging Bracket and removal 3 4 19mm NPT Female Water Glycol Inlet Connection 3 4 19mm NPT Female ee Dia Water Glycol Outlet Connection Electrical Entrance for High Voltage Connection Suction Line Male Quick Connect Liquid Line Male Quick Connect PIPING CONNECTIONS 7 8 22mm Dia Electrical Entrance for Low Voltage Connection SENSE 73 Split System Models Figure 42 3 ton water glycol cooled condensing unit con t Single or Field supplied unit disconnect three phase sw
102. wer The global leader in enabling Business Critical Continuity EmersonNetworkPower com EI AC Power EI Embedded Computing I Outside Plant HI Racks amp Integrated Cabinets HI Connectivity EI Embedded Power EI Power Switching amp Controls DE Services EI DC Power E Monitoring E Precision Cooling I Surge Protection Business Critical Continuity Emerson Network Power and the Emerson Network Power logo are trademarks and service marks of Emerson Electric Co 2008 Emerson Electric Co
103. wers for maintenance The duct work on upflow units must be designed within the capacity of the unit otherwise air flow and perfor mance will be compromised Plenum Installation A solid plenum or plenum with discharge grille s may be installed The plenum and instructions for its installation ship separately from the unit 21 Installation Applicable to all Models 2 9 Checklist for Completed Installation 1 P MD 15 16 17 18 19 20 21 22 23 Unpack and check received material Proper clearance for service access has been maintained around the equipment Equipment is level and mounting fasteners are tight Piping completed to refrigerant or coolant loop if required Piping has been leak checked evacuated and charged if required Check piping within the unit amp outside of the unit Remove potential of rub through or chaffing Condensate pump installed if required Drain line connected Water supply line connected to humidifier if required Field provided pan with drain installed under all ceiling mounted fluid condensing units if installed Filter box installed if applicable Ducting completed if applicable Filter s installed Line voltage to power wiring matches equipment serial tag Power wiring connections completed between disconnect switch evaporator and condensing unit including earth ground Power line circuit breakers or fuses have proper ratin
104. wn Cutout 20 138 35 241 Pump Down Reset 65 448 80 552 Minimum to Start Cooling 50 345 65 448 Low Pressure Cutout DX only 52 358 67 461 6 Charge the unit until the liquid line sight glass becomes clear Then add one additional pound 2 2 kg of refrigerant NOTE Q A digital scroll compressor will have a clear sight glass only when operating at 100 capacity When operating below 100 the sight glass may show bubbles with each 15 second unloading cycle Lee Temp Receiver Refrigerant Level On each receiver at the condenser are two refrigerant level sight glasses Refrigerant level will vary with outside temperature Check refrigerant level after the unit has been on for at least 15 minutes Sight Glass Levels 40 F 4 5 C and lower bottom sight glass is 3 4 full 40 to 60 F 4 5 to 15 5 C bottom sight glass is full 60 F 15 5 C and higher top sight glass is 3 4 full 32 Air Cooled Models Self Contained Compressor Figure 17 General arrangement Air cooled models with Liebert Lee Temp Condenser Coil Inverted Trap on 3 discharge line to extend above base of coil by a minimum of 7 1 2 190mm 7 X y Check y Ze Valve Rotalock Valve ee Hye Head Pressure r A Control with Piping Assembly 1 4 6 4mm 7 Integral Check Pressure Relief Valve x Liebert Zz Valve Lee Temp s IN Receiver lt l L Sight G

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