Emerson Liebert Challenger 3000 Installation Manual

Liebert® Challenger™ 3000 with Liebert iCOM®Operation & Maintenance Manual - 50 & 60Hz

StartupLiebert® Challenger 3000™614. Check for unusual noises and vibration.15. Check all refrigerant and fluid lines for leaks.16. Test all functions

Component Operation and Maintenance7Liebert® Challenger 3000™3.0 COMPONENT OPERATION AND MAINTENANCE3.1 System Testing3.1.1 Environmental Control Func

Component Operation and MaintenanceLiebert® Challenger 3000™8High-Temp SensorThe optional high-temp sensor is a bimetal-operated sensing device with a

Component Operation and Maintenance9Liebert® Challenger 3000™The zone leak detection kit provides leak detection for a defined zone. This kit is ideal

Component Operation and MaintenanceLiebert® Challenger 3000™103.3 Blower PackagePeriodic checks of the blower package include: belt, motor mounts, fan

Component Operation and Maintenance11 Liebert® Challenger 3000™3.4 Refrigeration SystemEach month, the components of the refrigeration system should b

Component Operation and MaintenanceLiebert® Challenger 3000™123.4.4 Thermostatic Expansion ValveOperationThe thermostatic expansion valve performs one

Component Operation and Maintenance13 Liebert® Challenger 3000™3.4.6 Air-Cooled CondenserRestricted airflow through the condenser coil will reduce the

Component Operation and MaintenanceLiebert® Challenger 3000™143.4.7 Charging the Liebert MC™ with Refrigerant—Basic and Premium Efficiency ControlLieb

Component Operation and Maintenance15 Liebert® Challenger 3000™8. Attach pressure and temperature instruments to the liquid line of the indoor unit. M

Component Operation and MaintenanceLiebert® Challenger 3000™169. Verify the subcooling calculated from measured values at the evaporator against the s

Component Operation and Maintenance17 Liebert® Challenger 3000™Elevation CorrectionSubtract Line c. (Correction for Condenser Elevation above Evaporat

Component Operation and MaintenanceLiebert® Challenger 3000™183.4.8 Water/Glycol-Cooled CondensersCoaxial CondenserEach water- or glycol-cooled module

Component Operation and Maintenance19 Liebert® Challenger 3000™ControlThe valve actuator operates on 24VAC power and is controlled by a 2-10VDC propor

Component Operation and MaintenanceLiebert® Challenger 3000™203.4.10 Regulating Valve—Scroll CompressorThe water regulating valve automatically regula

Component Operation and Maintenance21 Liebert® Challenger 3000™Figure 5 Metrex valve adjustmentManual Flushing—The valve may be flushed by rotating th

Component Operation and MaintenanceLiebert® Challenger 3000™223.4.11 Drycooler SettingsApplications with the Optional Stat Setting require field pipin

Component Operation and Maintenance23 Liebert® Challenger 3000™3.5 Compressor ReplacementReplacement compressors are available through your local Emer

Component Operation and MaintenanceLiebert® Challenger 3000™243.5.2 Standard Scroll Compressor ReplacementInfrequently a fault in the motor insulation

Component Operation and Maintenance25 Liebert® Challenger 3000™NOTICERisk of improper wiring/phase sequencing. Could cause backward compressor rotatio

iTABLE OF CONTENTSIMPORTANT SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSIDE FRONT COVERSAVE THESE INSTRUCT

Component Operation and MaintenanceLiebert® Challenger 3000™263.7 Humidifier—InfraredDuring normal humidifier operation, deposits of mineral solids wi

Component Operation and Maintenance27 Liebert® Challenger 3000™3.7.2 Changing Humidifier Lamps1. Remove humidifier pan (see 3.7.1 - Cleaning Humidifie

Component Operation and MaintenanceLiebert® Challenger 3000™28Autoflush OperationThe operation of the autoflush is divided into four steps, beginning

Component Operation and Maintenance29 Liebert® Challenger 3000™Operation1. During startup, when the humidity control calls for humidification, the fil

Component Operation and MaintenanceLiebert® Challenger 3000™30Replacing the CanisterOver a period of operation, the humidifier electrodes become coate

Component Operation and Maintenance31 Liebert® Challenger 3000™Circuit Board AdjustmentsHumidifier operation is governed by the humidifier control boa

TroubleshootingLiebert® Challenger 3000™324.0 TROUBLESHOOTINGUse this section to assist in troubleshooting your unit. Suggestions are grouped by produ

Troubleshooting33 Liebert® Challenger 3000™Table 15 Compressor and refrigeration system troubleshootingSymptom Possible Cause Check or RemedyCompresso

TroubleshootingLiebert® Challenger 3000™34FloodingDefective or improperly set expansion valveIncrease superheat or replace valveEvaporator fan motor o

Troubleshooting35 Liebert® Challenger 3000™Table 17 Glycol pump troubleshootingSymptom Possible Cause Check or RemedySuddenly stops pumping Clogged st

iiFIGURESFigure 1 Liebert leak detection units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TroubleshootingLiebert® Challenger 3000™36Table 19 Steam generating humidifier troubleshootingSymptom Possible Cause Check or RemedyFalse canister ful

Troubleshooting37 Liebert® Challenger 3000™Excessive arcing in the canisterDrain valve clogged or defectiveVerify that drain valve operates freely whe

Maintenance WorksheetLiebert® Challenger 3000™385.0 MAINTENANCE WORKSHEETSource: DPN002952-Rev. 0Good maintenance practices are essential to minimizin

Maintenance Worksheet39 Liebert® Challenger 3000™BLOWER SECTION (EC Fan) (If Equipped)___ 1. Mounting bolts tight___ 2. Fan guard bolts tight___ 3. Im

Maintenance WorksheetLiebert® Challenger 3000™40CONTROLS___ 1. Check/verify control operation (sequence)___ 2. Check/test changeover device(s) (if equ

Maintenance Worksheet41 Liebert® Challenger 3000™CHILLED WATER / ECON-O-COIL (If Equipped)___ 1. Verify proper water maintenance is being performed___

Maintenance WorksheetLiebert® Challenger 3000™42LIEBERT MC™ (if Equipped)___ 1. Coil clean___ 2. Fans free of debris___ 3. Fans Securely Mounted___ 4.

Maintenance Worksheet43 Liebert® Challenger 3000™NOTESNameSignatureCompanyMake copies for your records. Compare readings / information to previous mai

While every precaution has been taken to ensure the accuracyand completeness of this literature, Liebert Corporation assumes noresponsibility and disc

1Liebert® Challenger 3000™IMPORTANT SAFETY INSTRUCTIONSSAVE THESE INSTRUCTIONSThis manual contains important safety instructions that should be follow

Liebert® Challenger 3000™2NOTICERisk of internal system corrosion and frozen coolant fluid. Can cause equipment damage and major fluid leaks resulting

3Liebert® Challenger 3000™NOTICERisk of damage from forklift. Can cause unit damage.Keep tines of the forklift level and at a height suitable to fit b

IntroductionLiebert® Challenger 3000™41.0 INTRODUCTION1.1 System DescriptionsLiebert Challenger 3000 Thermal Management systems are available in sever

Startup5Liebert® Challenger 3000™2.0 STARTUPBefore beginning startup, make certain that unit was installed according to the instructions in the instal