Liebert CHALLENGER 3000 Operation And Maintenance Manual Download Page 5

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4.4.2

Sequential Load Activation Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

4.5

Additional Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

4.5.1

Connecting the Analog Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

4.5.2

Water Detection Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

4.6

Communications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

5.0

LARM

ESCRIPTIONS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

5.1

Standard Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

5.1.1

Change Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

5.1.2

Compressor Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

5.1.3

Custom Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

5.1.4

High Head Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

5.1.5

High Humidity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

5.1.6

High Humidity and Low Humidity (Simultaneously) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

5.1.7

High Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

5.1.8

High Temperature and Low Temperature (Simultaneously) . . . . . . . . . . . . . . . . . . . . . . . . . 40

5.1.9

Humidifier Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

5.1.10 Loss of Air Flow  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  40
5.1.11 Loss of Power  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  40
5.1.12 Low Humidity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  40
5.1.13 Low Suction Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  40
5.1.14 Low Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  40
5.1.15 Main Fan Overload. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  40
5.1.16 Short Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  41

5.2

Optional/Custom Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

5.2.1

Loss of Water Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

5.2.2

Smoke Detected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

5.2.3

Standby GC Pump On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

5.2.4

Standby Unit On. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

5.2.5

Water Under Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

6.0

OMPONENT

PERATION

AND

AINTENANCE

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

6.1

System Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

6.1.1

Environmental Control Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

6.2

Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

6.3

Blower Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

6.3.1

Fan Impellers and Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

6.3.2

Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

6.3.3

Air Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

6.4

Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

6.4.1

Suction Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

6.4.2

Discharge Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

6.4.3

Superheat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

6.4.4

Thermostatic Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

6.4.5

Hot Gas Bypass Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

6.4.6

Air Cooled Condenser. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

6.4.7

Water/Glycol Cooled Condensers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

6.4.8

Compressor Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

6.4.9

Compressor Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Summary of Contents for CHALLENGER 3000

Page 1: ...Precision Cooling For Business Critical Continuity Liebert Challenger 3000 Operation Maintenance Manual 3 5 Ton 50 60Hz ...

Page 2: ......

Page 3: ...ints 6 2 5 2 Setup System 7 2 5 3 Run Diagnostics 12 2 5 4 Change Passwords 13 2 6 Date and Time 13 2 7 Status Display 13 2 8 Control Circuit Board 13 2 8 1 LCD Display Contrast 13 2 8 2 Non Volatile Memory 14 2 8 3 DIP Switches 14 2 8 4 Control Outputs 14 3 0 OPERATION WITH ADVANCED MICROPROCESSOR WITH GRAPHICS CONTROL 15 3 1 Basics 15 3 2 Status Display 17 3 3 Main Menu MENU ESC 17 3 4 View Set ...

Page 4: ...g 26 3 12 1 View 24 Hour Run Time History 27 3 12 2 View Total Run Hours 27 3 13 Control Circuit board 27 3 13 1 LCD Contrast 27 3 13 2 Nonvolatile Memory 28 3 13 3 DIP Switches 28 3 13 4 Control Outputs 28 4 0 SYSTEM PERFORMANCE WITH ADVANCED MICROPROCESSOR CONTROLS 29 4 1 Temperature Control 29 4 1 1 Cooling Heating Required in Percent 29 4 1 2 Response to Control Types 29 4 1 3 Cooling Operatio...

Page 5: ... 13 Low Suction Pressure 40 5 1 14 Low Temperature 40 5 1 15 Main Fan Overload 40 5 1 16 Short Cycle 41 5 2 Optional Custom Alarms 41 5 2 1 Loss of Water Flow 41 5 2 2 Smoke Detected 41 5 2 3 Standby GC Pump On 41 5 2 4 Standby Unit On 41 5 2 5 Water Under Floor 41 6 0 COMPONENT OPERATION AND MAINTENANCE 42 6 1 System Testing 42 6 1 1 Environmental Control Functions 42 6 2 Filters 44 6 3 Blower Pa...

Page 6: ...6 5 Humidifier 53 6 5 1 Infrared Humidifier 53 6 5 2 Steam Generating Humidifier 54 7 0 TROUBLESHOOTING 58 8 0 MONTHLY MAINTENANCE INSPECTION CHECKLIST 64 9 0 SEMIANNUAL MAINTENANCE INSPECTION CHECKLIST 65 ...

Page 7: ...trol output LEDs 14 Table 7 Alarm default time delays 18 Table 8 Default setpoints and ranges 20 Table 9 Setup functions default values and ranges 21 Table 10 Unit options 22 Table 11 Setting options 25 Table 12 Control output LEDs 28 Table 13 Cooling dehumidification load status response 30 Table 14 Analog input terminals 34 Table 15 Additional connections available after unit delivery 34 Table 1...

Page 8: ...vi ...

Page 9: ...ressorized water or glycol system plus a sec ond 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 ...

Page 10: ... not exceed 28 VAC Change primary tap if necessary 6 Push ON button Blower will start 7 If you do not want your unit to operate at factory default settings set temperature and humidity setpoints and sensitivity alarms and other control functions Refer to 2 0 Operation with Advanced Microprocessor Controls or 3 0 Operation with Advanced Microprocessor with Graphics Control 8 Stop unit by depressing...

Page 11: ...lay refer to Figure 2 To turn the unit ON press the ON OFF key after power is applied To turn the unit OFF press the ON OFF key before power is disconnected Active alarms are displayed on the LCD screen Alarms are also annunciated by an audible beeper To silence an alarm press the ENTER key as prompted on the display The unit stores the 10 most recent alarms for review Setpoints DIP switch setting...

Page 12: ...cle Low Suction Pressure Compressor Overload Loss of Power Custom Alarms 1 to 4 Programmed Alarm Messages Water Under Floor Smoke Detected Standby GC Pump On Loss of Water Flow Standby Unit On User Customized Alarm Messages Available for Custom Alarms Alarms Available View Setpoints Setup System Run Diagnostics Change Passwords Setpoints Setup Normal Display Some alarms require optional equipment ...

Page 13: ...e Operating Status is intended to provide the user with displayed information concerning what the control is calling for the system to do For example The display indicates the chilled water valve is 68 open On a new call for cooling it takes several seconds for the valve to travel from fully closed to 68 open So when the display reads 68 it may take a few seconds for the valve to actually open 68 ...

Page 14: ...d then dis played along with the text label assigned during setup See Analog Setup on page 11 2 5 Setpoints Setup Selecting Setpoints Setup from the Main Menu will display the following selections View setpoints Setup system Run diagnostics Change passwords 2 5 1 View Setpoints Control and alarm setpoints can be reviewed and or changed through the display The following table lists the default setp...

Page 15: ...Rate infrared humidifiers only An autoflush system automatically controls a water makeup valve to maintain the proper level in the infrared humidifier water pan during humidifier operation If humidification is needed and 15 hours have elapsed since the last time the humidifier was on the humidifier is held off until the valve completes an initial fill of the humidifier pan This pre fill is about 3...

Page 16: ...n Table 4 should match options installed on your unit and should not need to change during normal operation Switches 1 through 7 are self explanatory DIP switch 8 not shown in the table enables the password feature when set to ON and disables the password feature when set to OFF Table 2 Setup functions default values and ranges Function Default Range Cold Start Time Delay 3 0 to 3 min 0 no delay R...

Page 17: ...ABLE ALARMS ENABLE COMMON ALARM SET CUSTOM ALARMS Each individual alarm can be programmed with a time delay from 0 to 255 seconds Each individual alarm can be ENABLED or DISABLED and each individual alarm can be programmed to energize or not to energize the Common Alarm Relay Set Time Delays By programming a time delay for an alarm the system will delay the specified amount of time before recogniz...

Page 18: ...relative direct and absolute predictive humidity control If relative is selected the RH control is taken directly from the RH sensor If absolute is selected the RH control is automatically adjusted as the return air temperature deviates from the desired temperature setpoint This results in a predictive humidity control The display will indicate RH for both methods of con trol but the adjusted humi...

Page 19: ...play The Status Display can be set to display the return air temperature and humidity SENSOR READ INGS or the temperature and humidity control SETPOINTS through this selection When SET POINTS is selected the status display indicates so by displaying SETPTS If SENSOR READINGS is selected the Status Display will show the return air sensor readings Calibrate Actuator For systems that use a valve actu...

Page 20: ...y on if compressor circuit is in operation Comp overload normally on unless Compressor Overload Alarm is active High head comp normally off unless High Head Pressure alarm Compressor is active Test Outputs When this feature is selected the unit is effectively turned off When stepping from one load to the next the previous load if on is turned off automatically The loads can also be toggled ON OFF ...

Page 21: ...Main Menu is displayed you can press the MENU ESC key to return to the Status Display 2 8 Control Circuit Board The control circuit board is located inside the unit behind the LCD display and control key panel Open the front panel for access to the board The control board includes an adjustment for LCD display contrast nonvolatile memory DIP switches which should not require customer changes contr...

Page 22: ... not require any user changes The setting and function of the switches can be read from the LCD display see Show DIP Switches on page 8 or the accompanying Table 4 2 8 4 Control Outputs Active control outputs are indicated with LEDs on the lower section of the control board Each LED is lit if the control output is active on The LEDs assist in troubleshooting the system Refer to the fol lowing tabl...

Page 23: ... to Figure 4 To turn the unit ON press the ON OFF key after power is applied To turn the unit OFF press the ON OFF key before power is disconnected Active alarms are indicated on the LCD screen by a ringing bell Alarms are also annunciated by an audible beeper To silence an alarm press the ENTER key as prompted on the display The unit stores the 60 most recent alarms for review Setpoints DIP switc...

Page 24: ...own Device Low Pressure Switch Compressor Overload High Head Pressure Test Outputs Main Fan Compressor Liquid Line SV HGBP CUV CW CGV Dehumidification R5 Relay Reheat 1 Reheat 2 RH3 Dehum Damper Humidifier HMV Common Alarm Test Control Board Microcontroller Show DIP Switches Dipswitch 1 Dipswitch 2 Dipswitch 3 Dipswitch 4 Dipswitch 5 Dipswitch 6 Dipswitch 7 72 F Unit On 50 RH Dehumidifying Cooling...

Page 25: ...a shrinking water drop is shown next to the word Dehumidification 3 3 Main Menu MENU ESC Press the MENU ESC key to display the Main Menu The Menu selections include VIEW SET ALARMS OPERATING STATUS VIEW SET CONTROL SETPOINTS SYSTEM SETUP RUN DIAGNOSTICS DATE AND TIME PLOT GRAPHS ANALOG DIGITAL INPUTS VIEW RUN HOURS LOG Pressing the MENU ESC key while the Main Menu is displayed will return the scre...

Page 26: ...her DISABLED WARNING or URGENT The four cus tom alarms may also be selected to be a Status Only input If the alarm is DISABLED it is ignored If the alarm is WARNING or URGENT it will be annunciated audibly visually and communicated to a Site Products System if appropriate When the alarm is selected to be a WARNING the alarm will NOT activate the common alarm relay When the alarm is selected to be ...

Page 27: ... and DOWN arrow keys are used to position the cursor tile The UP key will move the cursor tile up and then it wraps around to the bottom of the next column to the right The DOWN arrow key moves the cursor down then to the top of the next column to the left The cursor will also wrap around from the right top tile to the left bottom tile and back There are three different types of tiles to be define...

Page 28: ... chilled water or SCR Reheats only SELECT HUMIDITY SENSING MODE SET STATUS DISPLAY CHANGE PASSWORDS 3 7 1 Setup Operation The SETUP OPERATION menu permits the review and or adjustment of the unit configuration This may include Cold Start Delay This feature also referred to as Positive Start or Winter Start Kit allows for the low pressure switch to be ignored for the programmed time during a cold s...

Page 29: ... the pan to cause about a third of the total water used to be flushed out the overflow standpipe located in the humidifier pan This flushing action helps remove solids from the pan The flush rate is adjustable from 110 to 500 If the water quality is poor it may be desirable to increase the water flushing action above the normal 150 rate Also if the supply water pressure is low the flush rate adjus...

Page 30: ...the valve travel time first enter the CALIBRATE ACTUATOR screen The display will show the present period used by the control for valve actuator full travel Press ENTER and adjust the time using the UP DOWN arrows When the correct time is displayed press ENTER to store the new time to memory 3 7 5 Select Control Algorithm Chilled Water and SCR Reheats only The type of system control method used by ...

Page 31: ...the RH will be when the dehumidification cycle ends and temperature returns to the setpoint This allows the dehu midification cycle to end at the proper time The predictive humidity control can reduce energy con sumption by minimizing compressor and reheat operation and eliminating unnecessary humidifier operation 3 7 7 Set Status Display The Status Display can be set to display the return air tem...

Page 32: ...load if on is turned off automatically The loads can also be toggled on off by select ing ENTER Once turned on the output will remain on for 5 minutes unless toggled off or the test outputs function is exited by selecting MENU ESC Compressor is limited to 15 seconds on to pre vent damage DO NOT leave the unit in the test outputs mode any longer than is necessary for trou bleshooting The outputs ar...

Page 33: ...ifferent time scales and two different resolu tions The three time scales are 90 minutes 8 hours and 24 hours The two resolutions are minimum and maximum With minimum resolution selected the full scale of the sensor is displayed In other words the largest and smallest possible sensor readings are shown Maximum resolution shows a range that covers two fifths of the full scale sensor range 3 10 1 Mo...

Page 34: ...ept The intercept is an offset from point 0 corresponding to 0 volts or 0 mA input The intercept can be positive or negative and can be a point from 0 to 999 Adding an intercept of 100 to the slope example above 1 volt would be 125 100 1x 50 2 2 volts would be 150 100 2x 50 2 3 volts would be 175 100 3x 50 2 etc Text You may enter a custom label for each analog input The text label can be 20 chara...

Page 35: ...ER within 5 minutes of applying power to the control The user will then be prompted to press ENTER to clear the selected component s run hours 3 13 Control Circuit board The control circuit board is located inside the unit behind the LCD display and control key panel Open the front panel for access to the board The control board includes an adjustment for LCD contrast nonvolatile memory DIP switch...

Page 36: ...oard and are labeled SW1 Switch 1 is at the top These switches are factory set and should not require any user changes The setting and function of the switches can be read from the LCD see 3 8 4 DIP Switches 3 13 4 Control Outputs Active control outputs are indicated with LEDs on the lower section of the control board Each LED is lit if the control output is active on Use these LEDs to assist in t...

Page 37: ... temperature setpoint plus the temperature sensitivity the SCR Reheats will be pulsed proportionally from full on to full off 0 to 100 until the return air temperature reaches the temperature setpoint plus the temperature sensitivity PID Control Chilled Water or SCR Reheats only If PID control is selected the return air temperature is controlled at or near the temperature setpoint independent of t...

Page 38: ... available GLYCOOL capacity The compressor would be activated at a cooling requirement of 100 above the available GLYCOOL capacity For example if the GLYCOOL capacity is 60 then the GLYCOOL valve would be full open at 60 cooling requirement and the compressor would be in full cooling at 160 In order to reduce compres sor cycling and prevent hunting GLYCOOL capacity first becomes available when the...

Page 39: ...ired to satisfy the requirements for heating over a control band from the Temperature Setpoint MINUS the Temperature Sensitivity MINUS 1 F 4 2 Humidity Control 4 2 1 Dehumidification Humidification Required in Percent The humidity control program for the Advanced Microprocessor is based on a calculated require ment for dehumidification humidification 4 2 2 Response to Control Types Proportional Co...

Page 40: ... this term is to adjust the control output for any deviation between the current temperature and the control setpoint The integral I term is determined by two things the difference between the temperature and control setpoint and the amount of time this difference has existed This term is expressed in cooling heat ing desired for each minute and degree above below the setpoint It is adjustable fro...

Page 41: ...stant temperature deviation exists between the temperature and setpoint increase the integral setting 4 3 3 Intelligent Control Chilled Water only The intelligent control operates from a set of general rules that define how the control output should be adjusted for different system conditions The rules are designed to duplicate the actions that an experienced human operator would take if manually ...

Page 42: ...wn power supply To reduce the effects of inter ference from any noise source the sensor input wiring should be shielded twisted pair and the shield tied to earth ground at one end Analog input terminals for field connections are factory wired to the microprocessor board if specified when ordered Eight terminals are located in the field wiring compartment of the unit Wire sensors to the terminals a...

Page 43: ...2 ft x 2 ft Installation LT750 DIP Switch Settings Install the LT750 following the instructions in the LT750 user manual The following additional switch selections should be made when connecting to an Advanced Microprocessor control DIP SW3 4 Off water alarm relay energizes for alarm DIP SW3 5 Off cable fault relay energizes for alarm Switch 1 Off LT750 sources power for 4 20 mA loop Figure 6 Conn...

Page 44: ...hould initially be set to zero The default values are zero but it may be a good idea to verify those values They can be viewed by selecting ANALOG DIGITAL INPUTS from the Main Menu then SETUP ANALOG INPUTS See 3 4 6 Setup Water Detect Floor Plan for more information Calibration Calibration should not be required for most installations The accuracy of this display is approxi mately 1 The display is...

Page 45: ...propriate device for specific installation and operation information Liebert Monitoring Devices and Software SiteScan Centralized Monitoring System Stand alone facility monitoring system SiteLink BMS Interface Module For Modbus or BACnet communication to a third party moni toring system OpenComms Network Interface Card For Ethernet connection using SNMP protocol OpenComms Nform Software package to...

Page 46: ... and can be reviewed by selecting ANALOG DIG ITAL INPUTS When a new alarm occurs it is displayed on the screen and the audible alarm is activated If commu nicating with a Liebert Site Product the alarm is also transmitted The display will also show a mes sage to PRESS ENTER KEY TO SILENCE the alarm After the alarm is silenced the display will return to the Normal Status Display For the Advanced Mi...

Page 47: ...the control does not annunciate the alarm The con trol will turn off the LLSV and delay 10 seconds The control will permit this occurrence two more times or a total of three times If on the fourth try the high head pressure switch trips within 10 sec onds the control will annunciate the alarm turn off the LLSV wait for the user to acknowledge the alarm and hold the compressor off for three minutes...

Page 48: ...of power 5 1 12 Low Humidity If the return air humidity has decreased to the Low Humidity Alarm setpoint check to make sure that the unit is setup for humidification check DIP switch Check for proper setpoints Does the room have a vapor barrier to seal it from outdoor humidity Are doors or windows open to outside air Run diagnostics to make sure the humidifier system is working properly 5 1 13 Low...

Page 49: ...er supply line An optional flow switch is required for this alarm Check for service valves closed pumps not working etc 5 2 2 Smoke Detected Smoke is detected in the return air by an optional Liebert Smoke Detector Check for source of smoke or fire and follow appropriate emergency procedures 5 2 3 Standby GC Pump On The primary pump has failed and the standby pump is activated glycol cooled and GL...

Page 50: ...capable of responding to changes in room conditions These systems utilize either a 2 or 3 way valve activated by a proportioning motor For cooling and dehumidification the microprocessor will respond by positioning the valve propor tionally to match the needs of the room Full travel of the valve takes place within the range of the sensitivity setting During dehumidification full travel of the valv...

Page 51: ...ection sensor provides leak detection at a critical point A simple two wire connec tion signals the alarms at a Liebert environmental 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 twin sensor probes The sensor is hermetically s...

Page 52: ...activating the Change Filter alarm Turn power off before replacing filters 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 hori zontal above the ele...

Page 53: ...ting plate to adjust belt tension If belt appears cracked or worn it should be replaced with a matched belt identically sized With proper care a belt should last several years 6 3 3 Air Distribution All unit models are designed for constant volume air delivery Therefore any unusual restrictions within the air circuit must be avoided Refer to the following table for recommended free area for proper...

Page 54: ...nt to cool compressor components and can result in compressor damage Minimum pres sure switch cut out setting and maximum design operating suction pressures are in Table 18 6 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 cut out setting Refer to Table 19 below 6 4 3 Su...

Page 55: ...lows the hot gas bypass valve to open Hot gas then mixes with the liquid coolant on 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 ini tial call for cooling and de ener...

Page 56: ...eriodically 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 sigh...

Page 57: ...ressure and adjusting screw Standard Valve 150 psig 1034 kPa system for 3 5 ton units Johnson Controls Valve High Pressure Valve 350 psig 2413 kPa system for 5 ton units Johnson Controls Valve Adjustment The valve may be adjusted with a standard refrigeration service valve wrench or screw driver Refer to Table 19 for recommended refrigerant pressures To lower the head pressure setting turn the squ...

Page 58: ...ation system has been off for approximately 10 to 15 minutes the water flow should stop If the water continues to flow the valve is either improperly adjusted with head pressure too low or the pressure sensing capillary is not connected properly to the condenser Glycol Solution Maintenance It is difficult to establish a specific schedule of inhibitor maintenance since the rate of inhibitor deple t...

Page 59: ...on the three phases should be investigated further 7 Before replacing or returning a compressor Be certain that the compressor is actually defective At a minimum recheck a compressor returned from the field in the shop or depot for Hipot winding resistance and ability to start before returning More than one third of compressors returned for warranty analysis are determined to have nothing wrong Th...

Page 60: ...ing standard recovery procedures and equipment Use a filter drier when charging the system with recovered refrigerant 4 Front seat service valves to isolate the compressor Reclaim charge from compressor 5 Remove service valves pressure switch capillaries and disconnect all electrical connections 6 Remove failed compressor 7 Install replacement compressor and make all connections 8 Pressurize and l...

Page 61: ...and bottom can be loosened with a stiff brush Flush with water and replace pan in humidifier Changing Humidifier Lamps 1 Open disconnect switch 2 Open front panel 3 Remove screws securing line voltage compartment cover then remove the cover 4 In line voltage compartment disconnect one end of the purple jumpers then locate the burned out bulb with a continuity meter 5 Remove humidifier pan Refer to...

Page 62: ...e has timed out the water make up valve is closed 3 The water make up valve remains OFF and the humidifier lamps are ON for a maximum of 9 1 2 minutes 4 After the 9 1 2 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 ...

Page 63: ...As the water 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 l...

Page 64: ... power wires and the two canister full wires Do not loosen the screws that secure the electrodes 7 Loosen the steam outlet hose 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 20 10 Replace the canister by reversing the ...

Page 65: ...e of three to four percent in either direction does not permit normal operation of the unit con sult your Liebert supplier The pot marked SEC controls the duration of the drain cycle The pot is clearly marked in seconds This adjustment is factory set at 60 seconds and should not be readjusted without consulting your Liebert supplier The pot marked CAP ADJ is factory set at 100 The maximum capacity...

Page 66: ...r 24 VAC between P24 2 and P24 1 If no voltage check primary voltage Control fuse blown or circuit breaker tripped Check for 24 VAC between P4 4 and E1 If no voltage check for short Replace fuse or reset circuit breaker Table 22 Chilled water troubleshooting Symptom Possible Cause Check or Remedy Chilled water or hot water steam valve not opening Motor operates but valve won t open Check linkage f...

Page 67: ...k for low gas pressure Compressor is running on Positive Start Kit air cooled systems only 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 gas bypass valve adjusted improperly Adjust properly Wate...

Page 68: ...ng through condenser or clogged condenser or dirty air cooled condenser coils Adjust fluid regulating valve to condenser Flush the condenser Discharge service valve not fully open Open valve Compressor cycles continually Faulty low pressure switch Repair or replace Dirt or restriction in tubing to pressure stat Check and clean tubing Defective liquid line solenoid valve Check valve and solenoid op...

Page 69: ...lift too high Relocate pump closer to supply Motor not up to speed low voltage Larger lead wires may be required Check for proper line voltage 10 Worn bearings Replace pump Noisy operation Worn motor bearings 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 26 Infrared h...

Page 70: ...o circuit board and that no wires are loose Contactor pulled in but no water enters canister No water available to unit Check external shut off 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...

Page 71: ...ses too slowly add another Alka Seltzer tablet On cold start up 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 28 Reheat troubleshooting Symptom Possible Cause Check or Remedy Reheat will not operate contactor not pulling in Co...

Page 72: ...ed Humidifier ___ 1 Check pan drain for clogs ___ 2 Check humidifier lamps ___ 3 Check pan for mineral deposits Compressor ___ 1 Check oil leaks ___ 2 Check for leaks Refrigeration Cycle Section ___ 1 Check refrigerant lines ___ 2 Check for moisture sight glass ___ 3 Check suction pressure ___ 4 Check head pressure ___ 5 Check discharge pressure ___ 6 Check hot gas bypass valve ___ 7 Check thermos...

Page 73: ..._ 4 Check for water glycol leaks Glycol Pump ___ 1 Glycol leaks ___ 2 Pump operation ___ 3 Inspect tighten electrical connections Steam Generating Humidifier ___ 1 Check canister for deposits ___ 2 Check condition of steam hoses ___ 3 Check water make up valve for leaks ___ 4 Inspect tighten electrical connections Infrared Humidifier ___ 1 Check pan drain for clogs ___ 2 Check humidifier lamps ___...

Page 74: ...Semiannual Maintenance Inspection Checklist 66 ...

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Page 76: ... to are trademarks or registered trademarks of their respective owners Technical Support Service Web Site www liebert com Monitoring 800 222 5877 monitoring emersonnetworkpower com Outside the US 614 841 6755 Single Phase UPS 800 222 5877 upstech emersonnetworkpower com Outside the US 614 841 6755 Three Phase UPS 800 543 2378 powertech emersonnetworkpower com Environmental Systems 800 543 2778 Out...

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