Emerson Liebert Challenger iCOM 3000 Operation & Maintenance Manual Download

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Introduction

Liebert

Challenger 3000

™

1.0

NTRODUCTION

1.1

System Descriptions

Liebert Challenger 3000 Thermal Management systems are available in several configurations.

1.1.1 Compressorized Systems

These systems may be air-cooled, water-cooled or glycol-cooled, depending on the heat rejection

method selected.

Cooling—

One stage standard; variable capacity with digital scroll, optional.

Heating—

Two stages of electric reheat standard; SCR controlled electric reheat, hot water reheat,

hot gas reheat on water- and glycol-cooled systems optional.

Humidification—

Infrared standard; steam generating optional.

Dehumidification

—Hot gas bypass locked out standard

1.1.2 GLYCOOL

™

(Chilled Glycol Cooling) Systems

GLYCOOL systems have all of the features of a compressorized water or glycol system, plus a second

cooling coil that is connected into the water circuit. When fluid temperature is sufficiently low (below

room temperature), cooling is provided by circulating the fluid through the second cooling coil (flow is

controlled by a motorized valve.) This is then the primary cooling source, and it greatly reduces the

compressor operation.

Cooling

—Modulated cooling valve opens proportionally to match room needs (primary), one or two

stages of mechanical refrigeration (secondary)

Heating

—Two stages of electric reheat standard; hot water reheat optional

Humidification

—Infrared standard; steam generating optional

Dehumidification

—Hot gas bypass locked out standard

1.1.3 Chilled Water Systems

These systems utilize a central chiller and control cooling by modulating a control valve in the chilled

water line.

Cooling

—Proportional in response to room needs

Heating

—Two stages of electric reheat standard; hot water reheat optional

Humidification

—Infrared standard; steam generating optional

Dehumidification

—Chilled water valve opens proportionally in response to room needs

NOTE

Compressorized systems may be a self-contained system, with the compressor in the Liebert

Challenger 3000, or a split system, with the compressor in a separate condensing unit.

FOR

HISTORICAL

USE

ONLY

Summary of Contents for Liebert Challenger iCOM 3000

Page 1: ...Liebert Challenger 3000 with Liebert iCOM Operation Maintenance Manual 50 60Hz F O R H I S T O R I C A L U S E O N L Y ...

Page 2: ...F O R H I S T O R I C A L U S E O N L Y ...

Page 3: ...s Bypass Valve Not Available on Digital Scroll Units 12 3 4 6 Air Cooled Condenser 13 3 4 7 Charging the Liebert MC with Refrigerant Basic and Premium Efficiency Control 14 3 4 8 Water Glycol Cooled Condensers 18 3 4 9 Motorized Ball Valve Digital Scroll Compressor 18 3 4 10 Regulating Valve Scroll Compressor 20 3 4 11 Drycooler Settings 22 3 4 12 Compressor Oil 22 3 5 Compressor Replacement 23 3 ...

Page 4: ...nd R 410A interconnecting piping refrigerant charge 15 Table 6 Target subcooling for ambient outdoor temperature 16 Table 7 Difference in subcooling measurements Indoor minus outdoor 17 Table 8 Liquid pressure and temperature chart 18 Table 9 Water glycol system conditions requiring optional settings for aquastats 22 Table 10 Aquastat settings two fan through four fan drycoolers 22 Table 11 Compre...

Page 5: ...witch 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 WA...

Page 6: ...ystems 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 Sediment deposits prevent the formation of a protective oxide layer on the inside of the coolant system components and piping The water coolant fluid must be treated and circulating through the system cont...

Page 7: ...contact damage NOTICE Risk of leaking water Can cause equipment and building damage This unit requires a water drain connection It may also require an external water supply to operate Improper installation application and service practice can result in water leaking from the unit Water leaks can cause severe property damage and loss of critical data center equipment Do not locate unit directly abo...

Page 8: ...d by circulating the fluid through the second cooling coil flow is controlled by a motorized valve This is then the primary cooling source and it greatly reduces the compressor operation Cooling Modulated cooling valve opens proportionally to match room needs primary one or two stages of mechanical refrigeration secondary Heating Two stages of electric reheat standard hot water reheat optional Hum...

Page 9: ...your unit to operate at factory default settings set temperature and humidity setpoints alarms and other control functions Refer to the iCOM User Manual SL 18835 8 Stop the unit by depressing the On Off button on the front display Turn Off main unit disconnect and main breaker 9 Replace all fuses or reset circuit breakers that were removed in Step 3 10 Restore power to unit turn On the main unit d...

Page 10: ...for leaks 16 Test all functions of your unit for proper operation 17 Close high voltage dead front cover and latch 18 Close front accent panel and latch Return completed startup form to Liebert Corporation Warranty Registration 1050 Dearborn Drive P O Box 29186 Columbus OH 43229 F O R H I S T O R I C A L U S E O N L Y ...

Page 11: ...ontrol Transformer and Fuses The control system is divided into four separate circuits The control voltage circuits are individually protected by fuses located on the transformer fuse board If any of the fuses are blown first eliminate shorts then use spare fuses supplied with unit Use only type and size of fuse specified for your unit The small isolation transformer on the board supplies 24 volts...

Page 12: ...rt leak detection units The point leak detection sensor provides leak detection at a critical point A simple two wire connection signals the alarms at a Liebert Thermal Management unit or at a monitoring panel Run wires to the Liebert unit and connect them to terminals 24 and 51 55 or 56 Use NEC Class 2 24V wiring The sensor contains a solid state switch that closes when water is detected by the t...

Page 13: ...ange Filter alarm Turn power Off before replacing filters Liebert Challenger 3000 filters are 28 1 2 by 29 1 2 either 2 or 4 thick plus an optional 2 thick pre filter The filter is replaced from the front of the unit On upflow units the filter is vertical in front of the lower compartment Pull the filter out toward you to remove it On downflow units the filter is horizontal above the electrical pa...

Page 14: ...ICE Risk of improper adjustment Can cause equipment damage After adjusting or changing the belt check to ensure that the motor base nuts are tightened The bottom adjustment nut should be finger tight The top locking nut should be tightened with a wrench The motor sheave must be parallel to and aligned with the blower wheel pulley to maximize belt life 3 3 3 Air Distribution All unit models are des...

Page 15: ...tional low pressure management routines may apply during compressor start and normal operation See the Liebert iCOM user manual SL 18835 for more information The document is available on Liebert s Web site www liebert com 3 4 2 Discharge Pressure Discharge Pressure can be increased or decreased by load conditions or condenser efficiency The high pressure switch will shut the compressor down at its...

Page 16: ...the discharge side of the expansion valve raising the temperature and pressure in the evaporator The net result is a reduction in the cooling capacity of the unit to match the load To aid in lubricating the compressor the hot gas bypass solenoid is delayed for 30 seconds on the initial call for cooling and de energized for 30 seconds during every 60 minutes of continuous operation Adjustment Upon ...

Page 17: ...cally To do so 1 Adjust temperature setpoint in the unit so that the compressor will run continuously 2 The refrigerant level is visible through two sight glasses on the receiver and will vary with ambient temperature a 40 F 4 4 C and lower Midway on the bottom sight glass b 40 to 60 F 4 4 to 15 6 C Bottom sight glass should be clear with liquid c 60 F 15 6 C and above Midway on the top sight glas...

Page 18: ...ch of the required system charge as possible before starting the unit Do not exceed the calculated charge by more than 0 5 lb 23kg NOTICE Risk of improper refrigerant charging Can cause equipment damage Refrigerant R 407C and R 410A are blended refrigerants and must be introduced and charged from the cylinder only as a liquid When adding liquid refrigerant to an operating system it may be necessar...

Page 19: ...ubcooling Table 5 R 407C R 22 and R 410A refrigerant required approximate Condenser models Single Circuit lb kg Dual Circuit lb circuit kg circuit Approximate R 407C R 22 Refrigerant Needed MCS 028 2 2 1 0 N A MCM 040 3 0 1 4 N A MCM 080 7 5 3 4 3 0 1 4 MCL 055 5 0 2 3 N A MCL 110 10 5 4 8 5 1 2 3 MCM160 NA 7 5 3 4 MCL 165 18 3 8 3 N A MCL 220 27 0 12 3 12 2 5 6 Approximate R 410A Refrigerant Need...

Page 20: ...407C a Ambient Temperature 94 8 F b Condenser Elevation 40 ft c Condenser Elevation Temperature Correction 4 F d Liquid Line Pressure 300 e Liquid Pressure converted to Saturated Liquid Temperature 120 3 F f Measured Liquid Line Temperature 113 2 F g MC Condenser Subcooling Reading 5 F Menu ID F50 for Circuit 1 or Menu ID F51 for Circuit 2 Subtract Line f Measured Line Temperature from Line e Liqu...

Page 21: ... F NO charge adjustment is needed If Line j Difference value is less than 3 F add additional charge If Line j Difference value is greater than 3 F the system is overcharged and charge must be removed 10 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 Table 7 Difference in subcooling me...

Page 22: ...e and actuator Table 8 Liquid pressure and temperature chart Pressure R407C R410A R22 Psig Bar F C F C F C 170 11 7 81 5 27 5 59 8 15 4 90 6 32 6 180 12 4 85 1 29 5 63 1 17 3 94 3 34 6 190 13 1 88 6 31 5 66 3 19 1 97 9 36 6 200 13 8 92 0 33 3 69 5 20 8 101 4 38 6 210 14 5 95 2 35 1 72 5 22 5 104 7 40 4 220 15 2 98 3 36 8 75 4 24 1 108 0 42 2 230 15 9 101 4 38 5 78 2 25 7 111 1 44 0 240 16 6 104 3 ...

Page 23: ...50 PSI 345 kPa to raise or lower the control band similar to the pressure adjustment on a water regulating valve Units are factory set at a 30 PSI 207 kPa setpoint offset 30 PSI 207 kPa above minimum This results in a 220 PSIA 1517 kPa lower threshold and a 255 PSIA 1758 kPa upper threshold pressure Startup The setpoint offset is adjusted to the minimum value during startup then transitions to the...

Page 24: ...ure 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 setting is obtained Figure 4 Johnson Controls valve adjustment Manual Flushing The valve may be flushed by inserting a screwdriver or similar tool under the two sides of the main spring and l...

Page 25: ...lve 3 Remove four screws extending through the main spring housing 4 Remove the center assembly screws for access to all internal parts 5 Clean the seat if possible If the seat is pitted or damaged replace the valve rubber disc and valve seat 6 After valve is reassembled check for leaks 7 Readjust head pressure control Testing Function of Valve When the refrigeration system has been Off for approx...

Page 26: ...g optional settings for aquastats Cooling Type Glycool Glycol Flow Control MBV WRV MBV WRV Drycoolers in Loop 1 Multiple 1 Multiple 1 Multiple 1 Multiple Stat Setting 1 Optional Optional Optional Optional Optional Factory Factory Factory Insulate Field Piping Yes Yes Yes Yes Yes No No No 1 See Table 10 2 MBV motor ball valve WRV water regulating valve Table 10 Aquastat settings two fan through fou...

Page 27: ... internal motor short or ground fault has developed If the protector has opened the compressor must be allowed to cool sufficiently to allow it to reset 3 Proper indoor and outdoor blower fan operation should be verified Condenser glycol flow should be verified 4 With service gauges connected to suction and discharge pressure fittings turn On the compressor If suction pressure falls below normal l...

Page 28: ...ct the problem that caused the burnout and clean the system It is important to note that successive burnouts of the same system are usually caused by improper cleaning Electrical Failure An electrical failure will be indicated by a distinct pungent odor If a severe burnout has occurred the oil will be black and acidic In the event that there is an electrical failure and a complete burnout of the r...

Page 29: ...ing a digital scroll compressor digital solenoid valve and coil must be replaced Compressor and valve kit are shipped separately Valve kit must be field brazed to top of compressor in proper orientation and supported with original factory bracket 3 6 Facility Fluid and Piping Maintenance for Water and Glycol Systems Facility water and glycol quality remain a requirement throughout the life of the ...

Page 30: ...nit 1 With unit operating remove call for humidification at the Liebert iCOM 2 Let the blower operate 5 minutes to allow the humidifier and water to cool 3 If unit has a condensate pump turn unit OFF at the Liebert iCOM 4 Pull out the humidifier standpipe in pan 5 Inspect the O ring replace if necessary 6 Let the pan drain and condensate pump operate if applicable 7 Disconnect power from the unit ...

Page 31: ...ared humidifier lamps Autoflush Infrared Humidifier Cleaning System NOTICE Risk of low water flow pressure Can cause improper humidifier operation To operate properly the Autoflush Humidifier requires a water source that can deliver at least 1 gpm 0 063 l s with a minimum pressure of 20 psig 138 kPa The autoflush system will periodically flush the humidifier pan with water to prevent the buildup o...

Page 32: ...minute delay the autoflush adds water to the pan to replenish the water used in humidification and flush the pan of mineral solids This amount of water is adjustable from 110 to 500 in increments of 10 At the end of this cycle the make up valve is closed Steps 3 and 4 repeat as long as humidification is required Autoflush Controls Use the LCD display menu and keys on the front control panel to pro...

Page 33: ...ater quickly boils off and less of the electrode is exposed the current flow decreases When the current crosses the low threshold point factory set at 90 before the end of the time cycle the drain valve opens draining the mineral laden water out and replacing it with fresh water This lowers the mineral concentration and returns the canister to steady state operation and prolongs canister life The ...

Page 34: ...ose clamp and slide the steam hose away from the canister top fitting 8 The canister is now ready to be removed Pull the canister straight up and out of the cabinet toward you 9 Replace the canister with the part indicated in Table 12 10 Replace the canister by reversing the above procedure Make special note of the following WARNING Risk of electric shock Can cause injury or death Open all local a...

Page 35: ...ed without consulting your Liebert supplier The pot marked CAP ADJ is factory set at 100 The maximum capacity is determined by a fixed resistor R4 which is factory selected based on unit voltage Drain Tempering Feature All units are equipped with a drain tempering feature which mixes cold fill water with hot drain water to protect drain piping This feature can lower drain water temperature to as l...

Page 36: ...elieve pressure before working with piping Table 13 Blower troubleshooting Symptom Possible Cause Check or Remedy Blower will not start No main power Check L1 L2 and L3 for rated voltage Blown fuse or tripped circuit breaker CB Check fuses or CBs to main fan Overloads tripped Push reset button on main fan overload Check amp draw No output voltage from transformer Check for 24 VAC between P24 2 and...

Page 37: ...s contactor drops out Inadequate suction pressure Low Pressure alarm iCOM has built in positive start kit see Low Pressure Time Delay in SL 18835 Liquid line solenoid valve not opening Check magnetic field to see if energized High discharge pressure Dirty condenser or drycooler fins Clean coil Condenser equipment not operating Check operation High refrigerant charge Check refrigerant charge Hot ga...

Page 38: ... Compressor cycles continually Dirt or restriction in tubing to pressure stat Check and clean tubing Defective liquid line solenoid valve Check valve and solenoid operator replace if necessary Plugged filter drier Replace filter Compressor motor protectors tripping or cycling High discharge pressure Check for loss of condenser water or blocked condenser fan or coil Defective overload relay Replace...

Page 39: ...s Replace pump Low discharge head Throttle discharge improve suction conditions Debris lodged in impeller Remove cover and clean out Cavitating pumps Adjust system pressures Table 18 Infrared humidifier troubleshooting Symptom Possible Cause Check or Remedy No humidification Humidifier pan not filling Check water supply Check fill valve operation Check drain stand pipe adjustment Check for clogged...

Page 40: ...t board and that no wires are loose Contactor pulled in but no water enters canister No water available to unit Check external shutoff valves Clogged fill line strainer Clean or replace fill line strainer Wiring breaks or loose connections Check for faulty wiring and loose connections Faulty circuit board Replace circuit board Water enters canister but canister full circuit activates at a low wate...

Page 41: ...slowly add another Alka Seltzer tablet On cold startup canister fills high water alarm activates and humidifier fails to reach full amperage Fill solenoid not closing tightly If humidifier returns to canister full condition verity that the fill solenoid closes tightly Table 20 Reheat troubleshooting Symptom Possible Cause Check or Remedy Reheat will not operate contactor not pulling in Control not...

Page 42: ..._ 4 Coil clean ___ 5 Clean condensate pan ___ 6 Clean trap in condensate drain ___ 7 Check test filter clog switch operation if equipped BLOWER SECTION Centrifugal If Equipped ___ 1 Blower wheels free of debris ___ 2 Check belt tension and condition replace if needed ___ 3 Check lube bearings DS bearings are sealed and do not require lubrication even though grease fittings are present ___ 4 Check ...

Page 43: ...RED HUMIDIFIER If Equipped ___ 1 Check drain lines and trap for clogs leaks ___ 2 Check clean pan for mineral deposits ___ 3 Clean reflector ___ 4 Check water make up valve for leaks ___ 5 Check humidifier lamps replace if burnt out ___ 6 Check retorque wire connections inside humidifier box ___ 7 Check humidifier high water alarm operation CONDENSATE PUMP If Equipped ___ 1 Check for debris in sum...

Page 44: ... inside compressor box ___ 6 Compressor operation vibration noise ___ 7 Check crankcase heater fuses operation if equipped ___ 8 Check condenser fan cycling Liebert IntelleCool ___ 9 Check for refrigerant leaks WATER COOLED CONDENSERS If Equipped ___ 1 Verify proper water glycol maintenance treatment is performed at scheduled intervals ___ 2 Check water regulating valve operation ___ 3 Verify wate...

Page 45: ... 7 Check fuses ___ 8 Verify fan speed control operation if equipped ___ 9 Check surge protection device status indicator lights if equipped ___ 12 Glycol level ___ 13 Glycol solution ________ ___ 14 Water glycol solution flowing continuously clean and free of debris ___ 15 Water treatment plan established and followed for open cooling tower application ___ 16 Check refrigerant glycol lines for sig...

Page 46: ...___ 12 Motor amp draw GLYCOL PUMP If Equipped ___ 1 Check pump rotation ___ 2 Check for glycol leaks ___ 3 Pump pressures ___ 4 Amp Draw ___ 5 Verify Pump Changeover If Multiple Pumps LIEBERT ECONOPHASE PUMPED REFRIGERANT ECONOMIZER If Equipped ___ 1 Check for refrigerant leaks ___ 2 Check retorque wire connections ___ 3 Check contactors for pitting replace if pitted ___ 4 Verify pump speed contro...

Page 47: ...pany Make copies for your records Compare readings information to previous maintenance worksheet To locate your local Emerson representative for Liebert engineered parts go to the Liebert Web site www liebert com or call 1 800 Liebert F O R H I S T O R I C A L U S E O N L Y ...

Page 48: ...ebert 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 2778 Outside the United States 614 888 0246 Locations United States 1050 Dearborn Drive P O Box 2918...

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