Emerson 3000 User Manual

Precision CoolingFor Business-Critical Continuity™Liebert Challenger™ 3000 with iCOMInstallation Manual - 3 & 5 Tons, 50 & 60Hz

Introduction41.1.3 Split SystemsEach air-cooled split system consists of an evaporator section and one of the following condensing units.Prop Fan Air-

Installation (Applicable to all Models)52.0 INSTALLATION (APPLICABLE TO ALL MODELS)2.1 Room PreparationThe room should be well insulated and must have

Installation (Applicable to all Models)62.4.1 Handling With Skid• Always keep the unit upright, indoors and protected from damage.• If possible, trans

Installation (Applicable to all Models)7Figure 2 Upflow (BU) cabinet dimensionsAShaded area indicates a recommendedclearance of 34" (864mm) for c

Installation (Applicable to all Models)8Figure 3 Downflow (BF) cabinet dimensionsShaded area indicatesa recommended clearance of34” (864mm) for compon

Installation (Applicable to all Models)92.5 Piping ConsiderationsAll piping below the elevated floor must be located so that it offers the least resis

Installation (Applicable to all Models)10Figure 4 Piping connections for air-cooled units - Downflow models PIPING OUTLET LOCATIONS(See Cabinet and Fl

Installation (Applicable to all Models)11Figure 5 Piping connections for air-cooled units - Upflow models Condensate Drain3/4" FPTField pitch a m

Installation (Applicable to all Models)12Figure 6 Piping connections for split system fan coil units - Downflow models PIPING OUTLET LOCATIONS(See Cab

Installation (Applicable to all Models)13Figure 7 Piping connections for split system fan coil units - Upflow models DPN000375Rev. 01Piping outlet loc

Installation (Applicable to all Models)14Figure 8 Piping connections for water/glycol and GLYCOOL units - Downflow models DPN000364Rev. 01Condensate D

Installation (Applicable to all Models)15Figure 9 Piping connections for water/glycol and GLYCOOL units - Upflow models PIPING OUTLET LOCATIONS(See Ca

Installation (Applicable to all Models)16Figure 10 Piping connections for chilled water self-contained units - Downflow models PIPING OUTLET LOCATIONS

Installation (Applicable to all Models)17Figure 11 Piping connections for chilled water self-contained units - Upflow models Condensate Drain 3/4"

Installation (Applicable to all Models)182.5.2 Humidifier Supply Water—Optional Infrared• 1/4" supply line; maximum water pressure is 150 psi (10

Installation (Applicable to all Models)19Figure 12 Electrical connections1. Electric conduit knockouts on top and bottom of electric box. Knockout siz

Installation (Applicable to all Models)2015. Heat rejection connection. Field-supplied 24V Class 1 wiring to interlock heat rejection from pigtails 70

Installation (Applicable to all Models)212.8 Balancing the Air Distribution2.8.1 Under-Floor Discharge SystemsThe systems are designed for constant ai

Installation (Applicable to all Models)222.9 Checklist for Completed Installation___ 1. Unpack and check received material.___ 2. Proper clearance for

Air-Cooled Models—Self-Contained Compressor233.0 AIR-COOLED MODELS—SELF-CONTAINED COMPRESSOR3.1 Condenser LocationThe air-cooled condenser should be l

iTABLE OF CONTENTSIMPORTANT SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.0 I

Air-Cooled Models—Self-Contained Compressor24Figure 14 Air-cooled condensersTable 4 Air-cooled condenser statisticsModel Numberof Fans Connection Size

Air-Cooled Models—Self-Contained Compressor253.3 Refrigerant PipingAll refrigeration piping should be installed with high temperature brazed joints. P

Air-Cooled Models—Self-Contained Compressor263.4 Fan Speed Control SystemsThe Variable Fan Speed Control systems (FSC & VFD) uses pressure-activat

Air-Cooled Models—Self-Contained Compressor27Variable Fan Speed Control Materials Supplied•Built-in, pre-wired condenser control box• Air-Cooled conde

Air-Cooled Models—Self-Contained Compressor28Variable Fan Speed Charging1. Check unit nameplate for refrigerant type to be used. Unit control configur

Air-Cooled Models—Self-Contained Compressor29Figure 15 General arrangement—Air-cooled models with fan speed controlDPN000349Rev. 3CondenserCoilSchrade

Air-Cooled Models—Self-Contained Compressor30Figure 16 General arrangement—Air-cooled models with digital scroll and fan speed controlInverted Trap *

Air-Cooled Models—Self-Contained Compressor313.5 Air-Cooled Condenser with Liebert Lee-Temp “Flooded Condenser” Head Pressure Control SystemThe Lieber

Air-Cooled Models—Self-Contained Compressor326. After four hours, check the pressure readings and, if they have not changed, break vacuum with dry nit

Air-Cooled Models—Self-Contained Compressor33Figure 17 General arrangement—Air-cooled models with Liebert Lee-Temp * Components are not supplied by Li

ii5.0 GLYCOL/GLYCOOL-COOLED MODELS—SELF-CONTAINED COMPRESSOR . . . . . . . . . . . . 415.1 Drycooler Location . . . . . . . . . . . . . . . . . . . .

Air-Cooled Models—Self-Contained Compressor34Figure 18 General arrangement—Air-cooled models with digital scroll and Lee-TempDigitalSolenoid ValveDPN0

Water-Cooled Models—Self-Contained Compressor354.0 WATER-COOLED MODELS—SELF-CONTAINED COMPRESSOR4.1 Piping ConsiderationsManual shutoff valves should

Water-Cooled Models—Self-Contained Compressor36Figure 19 General arrangement—Water-cooled models with scroll compressorField-SuppliedReducersRequiredo

Water-Cooled Models—Self-Contained Compressor37Figure 20 General arrangement diagram—Water-cooled models with digital scrollDPN001727Rev. 0EvaporatorC

Water-Cooled Models—Self-Contained Compressor384.3 Water Regulating ValveThe water regulating valve automatically regulates the amount of fluid necess

Water-Cooled Models—Self-Contained Compressor39Figure 22 Metrex Valve adjustmentManual FlushingThe valve may be flushed by rotating the socket head sc

Water-Cooled Models—Self-Contained Compressor404.4.2 AdjustmentBoth pressure thresholds can be shifted simultaneously over a 50psi (345kPa) range (the

Glycol/GLYCOOL-Cooled Models—Self-Contained Compressor415.0 GLYCOL/GLYCOOL-COOLED MODELS—SELF-CONTAINED COMPRESSOR5.1 Drycooler LocationThe drycooler

Glycol/GLYCOOL-Cooled Models—Self-Contained Compressor425.4 Glycol PipingThese guidelines apply to the field leak checking and fluid requirements for

Glycol/GLYCOOL-Cooled Models—Self-Contained Compressor43NOTICERisk of debris or precipitate clogging pipes. Can cause equipment damage.Galvanized pipe

iiiFIGURESFigure 1 Removing Challenger from skid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Glycol/GLYCOOL-Cooled Models—Self-Contained Compressor445.4.1 Expansion Tanks, Fluid Relief Valves and Other DevicesAn expansion tank must be provided

Glycol/GLYCOOL-Cooled Models—Self-Contained Compressor455.5.2 Glycol SolutionsWhen considering the use of any glycol products in a particular applicat

Glycol/GLYCOOL-Cooled Models—Self-Contained Compressor46NOTICERisk of corrosion from water impurities. Can cause equipment damage.The quality of water

Glycol/GLYCOOL-Cooled Models—Self-Contained Compressor47Figure 23 Drycoolers and pump packages Notes1. Single pump packages are 17-1/4" (438 mm)

Glycol/GLYCOOL-Cooled Models—Self-Contained Compressor48Figure 24 Pump packages—expansion tankTable 17 Mounting hole dimensional dataPUMP PACKAGE Ain

Glycol/GLYCOOL-Cooled Models—Self-Contained Compressor49Figure 25 General arrangement—Glycol-cooled models with scroll compressorGlycolPumpPumpHousing

Glycol/GLYCOOL-Cooled Models—Self-Contained Compressor50Figure 26 General arrangement—Glycol-cooled models with digital scrollDigitalSolenoidValveGlyc

Glycol/GLYCOOL-Cooled Models—Self-Contained Compressor51Figure 27 General arrangement—GLYCOOL models with scroll compressorField-SuppliedReducersRequi

Glycol/GLYCOOL-Cooled Models—Self-Contained Compressor52Figure 28 General arrangement—GLYCOOL models with digital scroll compressorrDigitalSolenoidVal

Glycol/GLYCOOL-Cooled Models—Self-Contained Compressor535.5.4 Motor Ball Valve—Digital Scroll CompressorsRefer to 4.4 - Motorized Ball Valve—Digital S

ivTABLESTable 1 Unit net weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chilled Water Models546.0 CHILLED WATER MODELS6.1 Piping ConsiderationsManual shut-off valves should be installed at the supply and return lines to ea

Chilled Water Models55Figure 30 Chilled water general arrangement - Downflow (BF) modelsSL-11899Pg. 6ABFlowSwitch(optional)ChilledWaterReturnChilledWa

Split System Models567.0 SPLIT SYSTEM MODELSThree condensing unit styles are available: two air-cooled and one water/glycol-cooled condensing unit.7.1

Split System Models577.2.2 Low VoltageThe control cable between the condensing unit and the evaporator unit is connected between termi-nals 1,2 and 3

Split System Models58Refrigerant charge requirements: Total refrigerant charge will be required only if units are evacuated during installation or mai

Split System Models59Figure 31 Refrigerant piping diagram7.3.2 Quick Connect FittingsBe especially careful when connecting the quick connect fittings.

Split System Models607.4 Outdoor Air-Cooled Condensing UnitsFigure 32 Outdoor air-cooled condensing unit—horizontal air discharge modelsABCShaded area

Split System Models61Table 26 Horizontal air discharge cabinet and floor planning dimensional dataModel Numbers Dimensional Data in. (mm) Module Weigh

Split System Models62Figure 33 Outdoor air-cooled condensing unit—top air discharge modelsCA2"(51mm)BD36-1/8"(918mm)25-3/32"(637mm)46-7

Split System Models63Table 28 Cabinet and floor planning dimensional data - prop fan condensing modules, top air dischargeModel Numbers Dimensional Da

1IMPORTANT SAFETY INSTRUCTIONSSAVE THESE INSTRUCTIONSThis manual contains important safety instructions that should be followed during the installatio

Split System Models64Figure 34 Electrical field connections, prop fan condensing moduleNOTE: Refer to specification sheet for full load ampand wire si

Split System Models657.5 Centrifugal Air-Cooled Condensing Units7.5.1 Installing the Indoor Condensing UnitRefer to drawings for unit dimensions and c

Split System Models66Figure 35 Detail of ceiling hanging bracket7.5.2 DuctingThe total external static pressure for the inlet and outlet ducts, includ

Split System Models67Figure 36 3-ton centrifugal air-cooled condensing unit dimensional data & piping connectionsCDBACustomer-suppliedthreaded ro

Split System Models68Figure 37 3-ton centrifugal air-cooled condensing unit (con't.)DPN000207Rev0Single- or three-phaseelectric servicenot by Lie

Split System Models69Figure 38 5-ton centrifugal air-cooled condensing unit dimensional dataSL-11087 Pg. 424"(610mm)CabinetDimension32"(812.

Split System Models70Figure 39 5-ton centrifugal air-cooled condensing unit dimensional data (con't.)DPN000226_Rev0Field-Supplied Unit Disconnect

Split System Models71Figure 40 Split systems general arrangementCondenserCoil1/2" (12.7mm) NPTPressure Relief ValvePressureBalancingValveSightGla

Split System Models727.6 Water and Glycol-Cooled Condensing UnitsFor installation guidelines, refer to Installing the Indoor Condensing Unit on page 6

Split System Models737.6.4 Glycol SystemsFor split system glycol systems, use drycooler and pump data found in 5.0 - Glycol/GLYCOOL-Cooled Models—Self

2NOTICERisk of leaking water. Can cause equipment and building damage.This unit requires a water drain connection. It may also require an external wat

Split System Models74Figure 42 3-ton water/glycol-cooled condensing unit (con't.)DPN000209_Rev0Single- orthree-phaseelectric servicenot by Lieber

Split System Models75Figure 43 5-ton water/glycol-cooled condensing unit dimensional data7/8" (22.2mm) & 1-1/8" (28.6mm)dia. knockouts e

Split System Models76Figure 44 5-ton water/glycol-cooled condensing unit (con't.)DPN000228_Rev0Field-supplied unit disconnectswitch when factory

R407C Refrigerant778.0 R407C REFRIGERANTTable 33 R407C pressure/temperature chart for operation and superheat (discharge/hot gas and suction gas)Tempe

R407C Refrigerant788.1 Calculating SubcoolingExampleMeasure the liquid pressure (e.g., 200 psig). Find the liquid saturation temperature at that press

R407C Refrigerant79NOTES

R407C Refrigerant80

Ensuring The High AvailabilityOf Mission-Critical Data And Applications.Emerson Network Power, the global leader in enabling business-criticalcontinui

Introduction31.0 INTRODUCTION1.1 System DescriptionsChallenger 3000™ environmental control systems are available in three main system configurations:•