Emerson Liebert Challenger 3000 Installation Manual Download

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Air-Cooled Models—Self-Contained Compressor

3.4

Fan Speed Control Systems

The Variable Fan Speed Control systems (FSC & 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 can 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

for details.

Table 6

Equivalent lengths (feet) for various pipe fittings

Copper Pipe

O.D. in.

90 Degree

Elbow Copper

90 Degree

Elbow Cast

45 Degree

Elbow

Tee

Gate

Valve

Globe

Valve

Angle

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.

Table 7

Indoor unit refrigerant charge lb (kg)

Model

R407C

Approximate Charge

lb (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

O.D.

R407C

Liquid Line

lb (kg)

Hot Gas Line

lb (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)

7/8"

24.4 (11.1)

4.4 (2.0)

Table 9

Condenser refrigerant (per serial tag)

Model

R407C

Approximate Charge

lb (kg)

Fan Speed

Liebert

Lee-Temp*

083

8 (3)

25 (12)

104

9 (4)

37 (17)

165

15 (6.8)

50 (22.7)

* Charge includes the receiver charge.

Summary of Contents for Liebert Challenger 3000

Page 1: ...Precision Cooling For Business Critical Continuity Liebert Challenger 3000 with iCOM Installation Manual 3 5 Tons 50 60Hz ...

Page 2: ......

Page 3: ...allation 22 3 0 AIR COOLED MODELS SELF CONTAINED COMPRESSOR 23 3 1 Condenser Location 23 3 2 Electrical Connections 23 3 2 1 Line Voltage 23 3 2 2 Low Voltage 23 3 2 3 Liebert Lee Temp Flood Back Head Pressure Control Condensers 23 3 3 Refrigerant Piping 25 3 4 Fan Speed Control Systems 26 3 5 Air Cooled Condenser with Liebert Lee Temp Flooded Condenser Head Pressure Control System 31 4 0 WATER CO...

Page 4: ... Johnson Controls Valve 53 5 7 2 High Pressure Valve 350 psig 2413 kPa System for 3 Ton Units Metrex Valve 53 5 7 3 Testing Valve Function 53 6 0 CHILLED WATER MODELS 54 6 1 Piping Considerations 54 7 0 SPLIT SYSTEM MODELS 56 7 1 Location Considerations 56 7 1 1 Air Cooled Condensing Units 56 7 1 2 Water Glycol Cooled Condensing Units 56 7 2 Electrical Connections 56 7 2 1 Line Voltage 56 7 2 2 Lo...

Page 5: ... models with digital scroll 37 Figure 21 Johnson Controls valve adjustment 38 Figure 22 Metrex Valve adjustment 39 Figure 23 Drycoolers and pump packages 47 Figure 24 Pump packages expansion tank 48 Figure 25 General arrangement Glycol cooled models with scroll compressor 49 Figure 26 General arrangement Glycol cooled models with digital scroll 50 Figure 27 General arrangement GLYCOOL models with ...

Page 6: ...ncentrations 46 Table 17 Mounting hole dimensional data 48 Table 18 Drycooler data 48 Table 19 Glycol pump data 48 Table 20 Refrigerant control settings psi kPa 53 Table 21 Unit refrigerant charge 58 Table 22 Line charges refrigerant per 100 ft 30 m of Type L copper tube 58 Table 23 Recommended refrigerant lines R407C sizes OD copper 58 Table 24 Line coupling sizes 59 Table 25 Equivalent lengths f...

Page 7: ...al 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 sys...

Page 8: ...ipment Do not locate unit directly above any equipment that could sustain water damage Emerson recommends installing leak detection equipment for unit and supply lines 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 u...

Page 9: ... 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 valv...

Page 10: ... 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...

Page 11: ...onal 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 Avoid placing units in an alcove or at the extreme end of a room that has a high aspect ratio long nar...

Page 12: ... 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 p...

Page 13: ...vailable with 2 3 or 4 grilles Solid sides with a 7 8 22mm duct flange on top Standard Piping Location Standard Electrical Outlet Location Through Unit Standard Electrical Outlet Location Through Plenum 29 3 4 756mm 1 5 8 41mm 9 5 8 244mm 30 1 2 775mm 30 1 2 775mm 1 7 8 48mm 12 1 2 318mm 5 1 2 140mm 8 1 2 216mm Filter Access Through Top 7 1 2 191mm 29 737mm 2 1 2 67mm 1 3 4 44mm REAR VIEW rear ret...

Page 14: ...6 1930mm 30 1 2 775mm 30 1 2 775mm 30 1 2 775mm 30 1 2 775mm 30 1 2 775mm 30 1 2 775mm 30 1 2 775mm Projection of Display Bezel 5 8 16mm Optional 1 5 8 41mm Flange for Duct or Plenum Connection 1 25 4mm 1 25 4mm 1 25 4mm 1 25 4mm FLOOR CUTOUT DIMENSIONS 8 203mm 9 229mm OPTIONAL FLOOR STAND DIMENSIONAL DATA 4 102mm 1 25 4mm 28 1 2 724mm 12 305mm Floor Level Standard Piping Location Standard Electri...

Page 15: ...ppropriate 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 i...

Page 16: ...ensate Drain 3 4 FPT 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 1 4 OD CU Hot Gas Refrigerant Line 5 8 OD CU on Models BF042A BF040A 7 8 OD CU on Models BF067A BF065A Hot Water Return 5 8 OD CU optional Liquid Refrigerant Line 3 8 OD CU on Models BF042A BF040A 1 2 OD CU on Models BF067A BF065A Hot Water Supply...

Page 17: ...piping is out top of unit DPN000352 Rev 01 Piping outlet locations through the plenum are the same as the unit See below for descriptions and connection sizes Humidifier Water Supply Line 1 4 OD CU Hot Gas Refrigerant Line 5 8 OD CU on Models BU042A BU040 A 7 8 OD CU on Models BU067A BU065 A Condensate Pump Line 1 2 OD CU Used only if optional condensate pump is ordered Hot Water Return 5 8 OD CU ...

Page 18: ...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 Suction Refrigerant Line 11 Quick Connect on Models BF036E BF035E 1 1 8 OD CU on Models BF060E BF059E Hot Water Return 5 8 OD CU optional Liquid Refrigerant Line 6 Quick Connect on Models BF036E BF035E 1 2 OD CU on Models BF060E BF059E Hot Water Su...

Page 19: ...ered Hot Water Return 5 8 OD CU optional Liquid Refrigerant Line 6 Quick Connect on Models BU036E BU035E 1 2 OD CU on Models BU060E BU059E Hot Water Supply 5 8 OD CU optional iCOM Control Panel Condensate Drain 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...

Page 20: ...h all applicable codes Humidifier Water Supply Line 1 4 OD CU Condenser Return Line 7 8 OD CU on Models BF046WG BF045WG 1 1 8 OD CU on Models BF071WG BF070WG Hot Water Return 5 8 OD CU optional Condenser Supply Line 7 8 OD CU on Models BF046WG BF045WG 1 1 8 OD CU on Models BF071WG BF070WG Hot Water Supply 5 8 OD CU optional PIPING OUTLET LOCATIONS See Cabinet and Floor Planning Dimensional Data fo...

Page 21: ... Condensate Pump Line 1 2 OD CU Used only if optional condensate pump is ordered Hot Water Return 5 8 OD CU optional Condenser Supply Line 7 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 iCOM Control Condensate Drain 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 ...

Page 22: ...sional Data for Piping Opening Sizes Condensate Drain 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 Chilled Water Return Line 1 1 8 OD CU Hot Water Return 5 8 OD CU optional Chilled Water Supply Line 1 1 8 OD CU Hot Water Supply 5 8 OD CU optional DPN000371 Rev 01 Liebert iCOM Control ...

Page 23: ...ust comply with all applicable codes If condensate pump is ordered piping is out top of unit Piping outlet locations through the plenum are the same as the unit See below for descriptions and connection sizes Humidifier Water Supply Line 1 4 OD CU Chilled Water Supply Line 1 1 8 OD CU Condensate Pump Line 1 2 OD CU used only if optional condensate pump is ordered Hot Water Return 5 8 OD CU optiona...

Page 24: ...ion 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 NOTICE Risk of improper scroll compressor installation Could cause poor performance and compressor damag...

Page 25: ...ng 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 50 24 51 24 55 or 24 56 11 SiteScan connection Terminals 77 and 78 are for connection of...

Page 26: ...Refer to specification sheet for full load amp and wire size amp ratings Figure 13 Electrical field connections for Liebert iCOM 19 Network Cable C Connection Eight wire Ethernet cable from U2U networking switch 20 Network Cable D connection Eight wire Ethernet cable from U2U networking switch Cable D connection supplied on units with large Liebert iCOM display only 21 Opening for Field Wiring Sug...

Page 27: ...r supplier before specifying the total number of perforated panels and grilles required to handle the air flow The proper 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 hav...

Page 28: ...completed if applicable ___ 12 Filter s installed ___ 13 Line voltage to power wiring matches equipment serial tag ___ 14 Power wiring connections completed between disconnect switch evaporator and condensing unit including earth ground ___ 15 Power line circuit breakers or fuses have proper ratings for equipment installed ___ 16 Control wiring connections completed to evaporator and condensing un...

Page 29: ...l connection in accordance with local and national codes 3 2 1 Line Voltage Line voltage electrical service is required for all air cooled condensers 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 mo...

Page 30: ...alled typ When installing traps provide clearance for swing end of access door Traps are to extend above base of coil by a minimum of 7 1 2 190 mm Liquid line Hot gas line Electric service supplied by others Electric service supplied by others Hot gas line B LIEBERT LEE TEMP CONDENSER FAN SPEED AND VFD CONDENSER 44 1118mm 18 457 2mm 43 9 16 1106mm 51 7 16 1306 5mm 37 7 8 962mm Common to all models...

Page 31: ...rge 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 Traps should be installed in the hot gas line on vertical risers at the base and every 25 feet 7 6 meters in elevation These traps will collect condensed refrigerant and refrig...

Page 32: ...90 Degree Elbow Copper 90 Degree Elbow Cast 45 Degree Elbow Tee Gate Valve Globe Valve Angle 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 ...

Page 33: ...he unit solenoid valves 2 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 3 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 4 After completion of leak testing release the test ...

Page 34: ...f refrigerant 7 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 CAUTION Risk of improper refrigerant charging Can cause equipment damage Refrigerant R407C is a blend of three components and must be introdu...

Page 35: ...t 7 6m of rise Solenoid Valves Sight Glass Filter Dryer Liquid Return Shutoff Valve Sensing Bulb External Equalizers Scroll Compressor Service Valves Hot Gas Bypass Hot Gas Discharge Check Valve FIELD PIPING FACTORY PIPING Components are not supplied by Liebert but are recommended for proper circuit operation and maintenance Expansion Valve Inverted Trap on discharge line to extend above base of c...

Page 36: ...ser Coil Schrader Valve Fusible Plug Traps every 25 ft 7 6m of rise Evaporator Coil Expansion Valve Solenoid Valve Sight Glass Filter Dryer Liquid Return Shutoff Valve Sensing Bulb External Equalizer Service Valves Hot Gas Discharge Check Valve FACTORY PIPING FIELD PIPING Components are not supplied by Liebert but are recommended for proper circuit operation and maintenance Digital Compressor Digi...

Page 37: ...accomplished only with all system solenoid valves open and check valves accounted for 1 If unit power is available open the unit liquid line solenoid valves using the evacuation function in the diagnostic section of the Liebert iCOM control If unit power is not available a field supplied 24VAC 75VA power source must be directly connected to each of the unit solenoid valves 2 Attach a jumper hose f...

Page 38: ... sight glass becomes clear Then add one additional pound 2 2 kg of refrigerant 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...

Page 39: ... 4mm Pressure Relief Valve Sight Glass Liebert Lee Temp Receiver Head Pressure Control with Integral Check Valve Check Valve Evaporator Coil Sensing Bulb Expansion Valve Hot Gas Bypass Valve Hot Gas Bypass Solenoid Valves Sight Glass Filter Dryer Shutoff Valve Liquid Return External Equalizers Service Valves Scroll Compressor Liquid Return from Condenser Traps Every 25 Ft 7 6m of rise on Hot Gas L...

Page 40: ...G FACTORY PIPING Piping Assembly Condenser Coil Rotalock Valve 1 4 6 4mm Pressure Relief Valve Sight Glass Liebert Lee Temp Receiver Head Pressure Control with Integral Check Valve Check Valve Liquid Return from Condenser Inverted Trap on discharge line to extend above base of coil by a minimum of 7 1 2 190mm Traps Every 25 Ft 7 6m of rise on Hot Gas Line only Evaporator Coil Sensing Bulb Expansio...

Page 41: ... 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...

Page 42: ...rvice Valves Hot Gas Bypass Solenoid Valve Hot Gas Bypass Valve Sight Glass Filter Dryer Hot Gas Bypass Tube in Tube Condenser Tube in Tube Condenser Bypass Valve 2 Way Water Regulating Valve 3 Way Water Regulating Valve optional Fluid Return From Unit Fluid Supply To Unit Fluid Return From Unit Fluid Supply To Unit Shutoff Valves Hose Bibs FACTORY PIPING FIELD PIPING Components are not supplied b...

Page 43: ...r Tube in Tube Condenser Fluid Return From Unit Fluid Supply To Unit Fluid Return From Unit Fluid Supply To Unit Shutoff Valves Hose Bibs FACTORY PIPING FIELD PIPING Digital Compressor Digital Solenoid Valve To Liebert iCOM Control To Liebert iCOM Control 3 Way Motorized Ball Valve optional 2 Way Motorized Ball Valve Components are not supplied by Liebert but are recommended for proper circuit ope...

Page 44: ...nt 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 4 3 2 H...

Page 45: ...or 4 4 1 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 the compressor Control Method The control utilizes an upper and lower pre...

Page 46: ... 3 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 movement within the deadband Fan cycling stats should be set to prevent continuous fluid temperature swings greater than 10 F 5 6 C 4 4 4 Location The...

Page 47: ...ll wiring and electrical connections in accordance with local and national codes 5 3 1 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 pl...

Page 48: ...terial 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 sys...

Page 49: ...ed 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 ...

Page 50: ...nation 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 with oil or a protective film dirt and scale are also common Any residual contaminants co...

Page 51: ...oling 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 gly...

Page 52: ...d time consuming to remove Anti foam additives are available and may 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 Tabl...

Page 53: ...ackage only 30 1 4 768mm A B 19 483mm 43 3 16 1097mm 43 9 16 1105mm 37 7 8 1095mm GLYCOL PUMP PACKAGE See Note 1 A B C 3 4 19mm 37 11 16 957mm 1 2 12 7mm diameter anchor bolts typ B C PUMP PACKAGE MOUNTING ANGLES TYPICAL FOOTPRINT UNIT ANCHOR PLAN See Table 18 for keys to dimensions A B and C See Table 17 for keys to dimensions A B and C 1 2 diameter holes for mounting 4 typ Note Angles located in...

Page 54: ...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 91 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 Connection in Pump Discharge Connection in Hp Hz 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 ...

Page 55: ...t Top of Risers Hose Bibs Flow Regulating Valve Pressure Port Sight Glass Filter Dryer Evaporator Coil Sensing Bulb External Equalizers Hot Gas Bypass Valve Scroll Compressor Service Valves Hot Gas Bypass Solenoid Valve Hot Gas Bypass Tube in Tube Condenser Tube in Tube Condenser Bypass Valve 2 Way Water Regulating Valve Fluid Return from Unit Fluid Supply to Unit Fluid Return from Unit Fluid Supp...

Page 56: ...egulating Valve Pressure Port Sight Glass Filter Dryer Evaporator Coil Sensing Bulb External Equalizer Digital Compressor Service Valves Tube in Tube Condenser Tube in Tube Condenser 2 Way Motorized Ball Valve Fluid Return from Unit Fluid Supply to Unit Isolation Valves Hose Bibs Hose Bibs Hose Bibs Fluid Supply to Unit Fluid Return From Unit 3 Way Motorized Ball Valve optional FACTORY PIPING Comp...

Page 57: ...p of Risers Flow Regulating Valve Sight Glass Sensing Bulb External Equalizers Hot Gas Bypass Valve Scroll Compressor Service Valves Filter Dryer Hot Gas Bypass Econ O Coil 3 Way Water Regulating Valve 3 Way Chilled Glycol Valve Valve Actuator Econ O Cycle Comparator Econ O Coil Circuit Tube in Tube Condenser Fluid Supply to Unit Fluid Return from Unit Isolation Valves Hose Bibs FACTORY PIPING FIE...

Page 58: ...g Valve Pressure Port S ight Glass S ensing Bulb External Equalizer Service Valves Filter Dryer Econ O Coil 3 Way Chilled Glycol Valve 3 Way Motorized Ball Valve Valve Actuator E con O Cycle Comparator Econ O Coil Circuit Tube in Tube Condenser Fluid Supply to Unit Fluid Return from Unit Isolation Valves Hose Bibs F ACTORYPIPING FIELD PIPING Componentsare not supplied by Liebert but are recommende...

Page 59: ... 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 For details refer to 4 3 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 5 7 2 High Pressure Valve 350 psig 2413 kPa System for 3 To...

Page 60: ... 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 A B AB FACTORY PIPING SL 11899 Pg 5 Air Flow Air Flow Chilled Water Coil Chilled Water Coil Bleed Valve Bleed Valve Valve Actuator Valve Actuator Valve 2 Way Ch...

Page 61: ...Chilled Water Coil Chilled Water Coil 2 Way Chilled Water Valve Chilled Water Supply Shutoff Valves Hose Bibs 3 WAY VALVE 2 WAY VALVE 3 Way Chilled Water Valve Air Flow Air Flow Valve Actuator Valve Actuator AB Bleed Valve Bleed Valve Hose Bibs Shutoff Valves Components are not supplied by Liebert but are recommended for proper circuit operation and maintenance FACTORY PIPING FIELD PIPING ...

Page 62: ...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 7 1 2 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 person...

Page 63: ...oo long the polyol ester oil may need to be replaced before achieving the required vacuum level 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 uni...

Page 64: ...de a nitrogen holding charge only See Table 21 for field charge required If field supplied refrigerant piping is installed refrigerant must be added to the system Table 21 Unit refrigerant charge Model R407C Charge Model R407C Charge lb kg lb 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...

Page 65: ...nal quarter turn is necessary to ensure that the joint will not leak Refer to Table 24 for torque requirements 8 Add charge for the additional piping refer to Table 22 Table 24 Line coupling sizes Model Tons Line Size OD Cu in Coupling Size Torque lb ft 3 3 8 6 10 12 5 1 2 5 8 10 35 45 3 7 8 11 35 45 5 1 1 8 12 50 65 Table 25 Equivalent lengths feet for various pipe fittings Copper Pipe OD in 90 D...

Page 66: ...tage and low voltage connections and refrigeration components Shaded area indicates a minimum clearance of 24 610mm for component access and removal Removable Right Panel for access to refrigeration components Right Air Discharge Left Air Intake Fan Rotation CCW left side SL 11081 Pg 4 C C Liquid Line Quick Connect Male Coupling Suction Line Quick Connect Male Coupling Except as noted Electrical E...

Page 67: ... 1 4 918 18 457 351 159 PFH042A _H PFCZ42A _L PFCZ41A _L PFC067A _L PFC066A _L PFH067A _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 C D E F G PFC042A _L PFC041A _L 2 51 5 3 4 146 8 1 2 216 4 3 4 121 6 3 4 171 8 1 2 216 PFH042A _L PFC042A _H PFC041A _H 2 51 6 152 8 1 2 216 4 3 4 121 7 3 4 197...

Page 68: ...arance of 18 457mm for proper air flow Removable Front Panel for access to high voltage and low voltage connections and refrigeration components Shaded area indicates a minimum clearance of 24 610mm for component access and removal Right Air Discharge Top Air Discharge Left Air Intake Guard Height SL 11081 Pg 5 F G B C A D E Suction Line Quick Connect Male Coupling Liquid Line Quick Connect Male C...

Page 69: ... net 60 Hz 50 Hz A B C D PFC067A _H PFC066A _H 53 1343 36 1 4 918 38 1 2 978 5 1 2 140 488 222 PFH067A _H PFCZ67A _L PFCZ66A _L Table 29 Piping and electrical connections top air discharge Model Numbers Dimensional Data in mm Piping Connections in mm 60 Hz 50 Hz A B C D E F PFC067A _H PFC066A _H 2 51 6 152 8 1 2 216 4 3 4 121 7 3 4 197 8 1 2 216 PFH067A _H PFCZ67A _L PFCZ66A _L ...

Page 70: ...d in the evaporator module Connect wire 4 with wire 2 to the 24V supply 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 SL 11081 Pg 8A TOP AIR DISCHARGE MODELS 5 Ton High Ambient 5 Ton Quiet Line HORIZO...

Page 71: ...se 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...

Page 72: ...ing 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...

Page 73: ...0 1 4 1276mm Overall Dimension 46 1 2 1181mm Cabinet Dimension 48 1 4 1225mm Threaded Rod Centers 21 1 2 546mm Cabinet Dimension 22 1 2 572mm Cabinet Dimension 19 1 2 495mm Threaded Rod Centers Duct Flange 2 1 4 57mm 1 25 4mm 20 7 16 519mm Coil Inlet Duct Conn Minimum Clearance 33 838mm This End for ComponentAccess and Removal 20 3 4 527mm 1 2 13mm 7 8 22 2mm Dia Electrical Entrance for Low Voltag...

Page 74: ...d supplied unit disconnect switch when optional disconnect is not provided in unit 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 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...

Page 75: ...ustomer supplied threaded rods for module support from ceiling typ 4 1 2 12 7mm dia holes for threaded rods typ 2 each end Air Outlet Air Inlet 7 8 22 2mm 1 1 8 28 6mm dia knockouts electrical entrance for high voltage connection Single Point Power Kit 7 8 22 2mm 1 1 8 28 6mm dia knockouts electrical entrance for high voltage connection Suction Line male quick connect location Liquid Line male qui...

Page 76: ...unding wire Removable Access Panels Field Supplied 24V NEC Class 2 wiring between condensing unit and fan coil unit Low voltage electric power supply conduit entrance Heat rejection connection Field supplied 24V NEC Class 2 wiring See Note 2 Wire connections from evaporator module 1 24V GND 2 24V supply 3 High pressure alarm optional 4 Hot gas bypass connection only on units with hot gas bypass NO...

Page 77: ...orts Service Access Ports Sensing Bulb Sensing Bulb Expansion Valve Expansion Valve External Equalizer External Equalizer Evaporator Coil Evaporator Coil High Pressure Switch Tube in Tube Condenser Tube in Tube Condenser Water Glycol Return Line AIR COOLED WATER COOLED GLYCOL COOLED Liquid Injection Valve Bulb Liquid Injection Valve Bulb Hot Gas Bypass Solenoid Valve Hot Gas Bypass Solenoid Valve ...

Page 78: ...34 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 7 6 3 Regulating Valve For details refer to sections 4 3 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 and ...

Page 79: ...l Customer Supplied Threaded Rods for Module Support from Ceiling typ 4 Outlet Inlet DIMENSIONAL DATA 3 4 19mm NPT Female Water Glycol Outlet Connection Integral Hanging Bracket 22 1 2 572mm SL 11085 Pg 6 PIPING CONNECTIONS 12 305mm Threaded Rod Centers 14 356mm Overall Cabinet Dimension Holes for Module Rigging typ 2 each end 3 4 19mm NPT Female Water Glycol Inlet Connection 7 8 22mm Dia Electric...

Page 80: ...tory wired components on electric panel Optional factory installed disconnect switch Low voltage electric power supply entrance Remote drycooler connection Terminals 70 71 supplied for connection to remote drycooler Use field supplied 24V NEC Class 1 wiring glycol cooled units only Heat rejection connection Field supplied 24V NEC Class 2 wiring Wire connections from evaporator mod 1 24V GND 2 24V ...

Page 81: ...T Female Water Glycol Inlet Connection 7 8 22 2mm dia knockout electrical entrance for alternate control panel low voltage routing 7 8 22 2mm dia electrical entrance for low voltage connection Suction Line male quick connect location Liquid Line male quick connect location 7 8 22 2mm 1 1 8 28 6mm dia knockouts electrical entrance for line voltage connection 32 812 8mm Cabinet Dimension 32 812 8mm ...

Page 82: ...on 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 Remote drycooler connection field supplied 24V NEC Class 1 wiring glycol cooled units only Connection terminal for field supplied earth grounding wire Low voltage electric power supply conduit...

Page 83: ...187 1287 15 0 9 4 31 8 219 50 0 10 0 77 1 531 100 0 37 8 193 1329 16 0 8 9 32 8 226 51 0 10 6 78 7 543 102 0 38 9 199 1372 17 0 8 3 33 8 233 52 0 11 1 80 4 554 104 0 40 0 205 1416 18 0 7 8 34 8 240 53 0 11 7 82 1 566 106 0 41 1 212 1461 19 0 7 2 35 8 247 54 0 12 2 83 9 578 108 0 42 2 219 1507 20 0 6 7 36 9 254 55 0 12 8 85 6 590 110 0 43 3 225 1553 21 0 6 1 38 0 262 56 0 13 3 87 4 603 112 0 44 4 2...

Page 84: ... 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 61 0 16 1 118 815 98 0 36 7 216 1488 39 0 3 9 77 533 62 0 16 7 120 830 100 0 37 8 222 1532 40 0 4 4 79 544 63 0 17 2 123 845 102 0 38 9 229 1578 41 0 5 0 81 556 64 0 17 8 125 860 104 0 40 0 236 1624 42 0 5 6 82 567 65 0 18 3 127 875 106 0 41 1 242 1671 43 0 6 1 84 579 66 0 18 9 129 891 108 0 42 2 249 1720 44 0 6 7 86 59...

Page 85: ...R407C Refrigerant 79 NOTES ...

Page 86: ...R407C Refrigerant 80 ...

Page 87: ......

Page 88: ...rademarks of their respective owners Technical Support Service Web Site www liebert com Monitoring liebert monitoring emerson com 800 222 5877 Outside North America 00800 1155 4499 Single Phase UPS Server Cabinets liebert upstech emerson com 800 222 5877 Outside North America 00800 1155 4499 Three Phase UPS Power Systems 800 543 2378 Outside North America 614 841 6598 Environmental Systems 800 543...

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Emerson Liebert Challenger 3000, Installation Manual

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