Emerson Liebert Challenger 3000 Installation Manual

HEAT REMOVAL/ENVIRONMENTAL CONTROLChallenger™ 3000OPERATION & MAINTENANCE MANUAL3 & 5 Ton50 & 60 Hz

Introduction21.2 Start-Up ProcedureBefore beginning start-up, make certain that unit was installed according to the instructions in the Installation M

Operation with Advanced Microprocessor Controls32.0 OPERATION WITH ADVANCED MICROPROCESSOR CONTROLSThe Advanced Microprocessor (A) Control for your Li

Operation with Advanced Microprocessor Controls4Figure 2 Advanced Microprocessor (A) Control for Challenger 3000Analog in 1(2,3,4):xxAD #1(2,3,4)Use ↓

Operation with Advanced Microprocessor Controls52.2 Status DisplayThe display normally shown includes the present room temperature, humidity, active s

Operation with Advanced Microprocessor Controls62.4.4 Run Hours LogThe total operating hours of all major components in the unit can be monitored from

Operation with Advanced Microprocessor Controls72.5.2 Setup SystemThe Setup System menu includes the following selections:• SETUP OPERATION• SELECT OP

Operation with Advanced Microprocessor Controls8The following table lists the setup functions, their factory default values, and the allowable program

Operation with Advanced Microprocessor Controls9Select Control Type • Intelligent (Chilled Water only)• Proportional (all unit types)• Tunable PID (Ch

Operation with Advanced Microprocessor Controls10Enable Alarms—Each individual alarm can be selected to be ENABLED (annunciated audibly, visu-ally, an

Operation with Advanced Microprocessor Controls11Analog SetupFor installation of analog sensors, see 4.5.1 - Connecting the Analog Sensors.After selec

PRODUCT MODEL INFORMATIONTable i Model Number DesignationB F 042 A — A S E IChallenger3000E= Downflow withEcon-O-CoilNominal capacity in tho

Operation with Advanced Microprocessor Controls122.5.3 Run DiagnosticsBy selecting Run Diagnostics, maintenance personnel can check system inputs, out

Operation with Advanced Microprocessor Controls132.5.4 Change PasswordsThe display prompts you to enter a three digit password when making changes. Th

Operation with Advanced Microprocessor Controls142.8.2 Non-Volatile MemoryAll critical information is stored in nonvolatile memory. Setpoints, setup p

Operation with Advanced Microprocessor with Graphics Control153.0 OPERATION WITH ADVANCED MICROPROCESSOR WITH GRAPHICS CONTROLThe Advanced Microproces

Operation with Advanced Microprocessor with Graphics Control16Figure 4 Advanced Microprocessor with Graphics Control MenuAnalog Input 1Analog Input 2A

Operation with Advanced Microprocessor with Graphics Control173.2 Status DisplayThe normal status screen is divided into two sections, a right half an

Operation with Advanced Microprocessor with Graphics Control183.4.2 Alarm History LogA history of the 60 most recent alarms is kept in nonvolatile mem

Operation with Advanced Microprocessor with Graphics Control193.4.4 Setup Custom AlarmsSelecting SETUP CUSTOM ALARMS will step to the following menu:•

Operation with Advanced Microprocessor with Graphics Control203.5 Operating StatusThe Operating Status is intended to provide the user with displayed

Operation with Advanced Microprocessor with Graphics Control21Auto Restart DelayThis feature allows for the unit to restart automatically after a loss

iTABLE OF CONTENTSPRODUCT MODEL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSIDE FRONT COVER1.0 INTRODUCTION .

Operation with Advanced Microprocessor with Graphics Control223.7.2 Select OptionsThe following table is a list of options which should match the opti

Operation with Advanced Microprocessor with Graphics Control233.7.6 Select Humidity Sensing ModeThe user may select between RELATIVE (direct) and ABSO

Operation with Advanced Microprocessor with Graphics Control243.8 Run DiagnosticsBy selecting RUN DIAGNOSTICS, maintenance personnel can check system

Operation with Advanced Microprocessor with Graphics Control253.8.4 DIP SwitchesThe DIP switch settings can be reviewed from the display panel. Changi

Operation with Advanced Microprocessor with Graphics Control263.11 Analog/Digital InputsSelecting ANALOG/DIGITAL INPUTS steps to the following menu:•

Operation with Advanced Microprocessor with Graphics Control273.12.1 View 24 Hour Run Time HistoryThe history of each load for every hour during the p

Operation with Advanced Microprocessor with Graphics Control283.13.2 Nonvolatile MemoryAll critical information is stored in nonvolatile memory. Setpo

System Performance with Advanced Microprocessor Controls294.0 SYSTEM PERFORMANCE WITH ADVANCED MICROPROCESSOR CONTROLSThis section provides details on

System Performance with Advanced Microprocessor Controls304.1.3 Cooling Operation1-Step Cooling, Compressorized Direct Expansion (DX) SystemsCooling a

System Performance with Advanced Microprocessor Controls314.1.4 Heating OperationElectric ReheatThe two heat stages are activated when the temperature

ii3.6 View/Set Control Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203.7 System

System Performance with Advanced Microprocessor Controls324.2.4 Humidification OperationSystem ActivationThe humidifier (infrared or steam) is activat

System Performance with Advanced Microprocessor Controls33Adjust the derivative to a value calculated by the following equation:time between peaks x 5

System Performance with Advanced Microprocessor Controls344.5 Additional Features4.5.1 Connecting the Analog SensorsThe sensor inputs are factory set

System Performance with Advanced Microprocessor Controls354.5.2 Water Detection DisplayThe water detection display is designed to graphically display

System Performance with Advanced Microprocessor Controls36CalibrationCalibration should not be required for most installations. The accuracy of this d

Alarm Descriptions375.0 ALARM DESCRIPTIONSThe Advanced Microprocessor (A) and the Advanced Microprocessor with Graphics (G) Control sys-tems will audi

Alarm Descriptions385.1.3 Custom AlarmsCustom alarm messages are programmed at the LCD display. The alarms may be specified by the customer at the tim

Alarm Descriptions395.1.9 Humidifier ProblemInfrared HumidifiersThis alarm is activated by the high water float switch in the humidifier pan assembly.

Alarm Descriptions405.2 Optional/Custom Alarms 5.2.1 Loss of Water FlowAvailable only with 3-way valves and occurs when no water flow is detected in t

Component Operation and Maintenance416.0 COMPONENT OPERATION AND MAINTENANCE6.1 System Testing6.1.1 Environmental Control FunctionsThe performance of

iii4.4 Load Control Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334.4.1 Sh

Component Operation and Maintenance42Fan Safety SwitchThe Fan Safety Switch is located in the low voltage compartment and consists of a diaphragm swit

Component Operation and Maintenance43The zone leak detection kit provides leak detection for a defined zone. This kit is ideal for perimeter sensing o

Component Operation and Maintenance446.3.2 BeltThe drive belt should be checked monthly for signs of wear and proper tension. Pressing in on belts mid

Component Operation and Maintenance456.4.1 Suction PressureSuction pressure will vary with load conditions. The low pressure switch will shut the comp

Component Operation and Maintenance466.4.4 Thermostatic Expansion ValveOperationThe thermostatic expansion valve performs one function. It keeps the e

Component Operation and Maintenance476.4.6 Air Cooled CondenserRestricted airflow through the condenser coil will reduce the operating efficiency of t

Component Operation and Maintenance486.4.7 Water/Glycol Cooled CondensersCoaxial CondenserEach water or glycol cooled module has a coaxial condenser w

Component Operation and Maintenance49High Pressure Valve - 350 PSIG System (2413 kPa) for 3 Ton Units (Metrex Valve)Adjustment—The valve may be adjust

Component Operation and Maintenance506.4.8 Compressor Functional CheckThe following diagnostic procedure should be used to evaluate whether the compre

Component Operation and Maintenance51Electrical FailureAn electrical failure will be indicated by a distinct pungent odor. If a severe burnout has occ

iv6.4 Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446.4.1 Su

Component Operation and Maintenance526.5 Humidifier6.5.1 Infrared HumidifierDuring normal humidifier operation, deposits of mineral solids will collec

Component Operation and Maintenance53Autoflush Infrared Humidifier Cleaning SystemThe autoflush system will periodically flush the humidifier pan with

Component Operation and Maintenance54Figure 12 Steam generating humidifierOperation1. During start-up, when the humidity control calls for humidificat

Component Operation and Maintenance55ControlsThe humidifier RUN/DRAIN switch is located at the upper right of the humidifier assembly. This switch sho

Component Operation and Maintenance56Circuit Board AdjustmentsHumidifier operation is governed by the humidifier control board. This board is located

Troubleshooting577.0 TROUBLESHOOTINGUse this section to assist in troubleshooting your unit. Also refer to 5.0 - Alarm Descriptions. Sug-gestions are

Troubleshooting58Table 23 Compressor and refrigeration system troubleshootingSymptom Possible Cause Check or RemedyCompressor will not startPower offC

Troubleshooting59FloodingDefective or improperly set expansion valveIncrease superheat or replace valveEvaporator fan motor or beltCorrect problem or

Troubleshooting60Table 24 Dehumidification troubleshootingSymptom Possible Cause Check or RemedyNo dehumidificationControl not calling for dehumidific

Troubleshooting61Table 27 Steam generating humidifier troubleshootingSymptom Possible Cause Check or RemedyFalse canister full indicationFoamingCheck

vFIGURESFigure 1 Advanced Microprocessor Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F

Troubleshooting62Excessive arcing in the canisterDrain valve clogged or defectiveVerify that drain valve operates freely when activated. Clean valve a

Monthly Maintenance Inspection Checklist638.0 MONTHLY MAINTENANCE INSPECTION CHECKLISTNotes:Signature:________________________________________________

Semi-Annual Maintenance Inspection Checklist649.0 SEMI-ANNUAL MAINTENANCE INSPECTION CHECKLISTNotes:Signature:________________________________________

The Company Behind the ProductsWith over a million installations around the globe,Liebert is the world leader in computer protectionsystems. Since its

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Introduction11.0 INTRODUCTION1.1 System DescriptionsChallenger 3000 Liebert environmental control systems are available in several configurations. Eac