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Component Operation and Maintenance

Liebert

Challenger 3000

™

Control

The valve actuator operates on 24VAC power and is controlled by a 2-10VDC proportional control

signal. The valve full open to full close time is 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 pressure threshold with a 35 PSI (241 kPa) deadband to

reduce valve movement. If the liquid pressure is between the upper and lower threshold the valve

remains at the current position. If the liquid pressure exceeds the upper threshold the valve opens,

and if the pressure falls below the lower threshold the valve closes.

There are multiple adjustment bands to

ease discharge pressure back into control range.

Adjustment

Both pressure thresholds can be shifted simultaneously over a 50 PSI (345 kPa) range (the 35 PSI

[241 kPa] differential remains constant). The ball valve setpoint offset parameter in the Service menu

can be adjusted from 0 to 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 set value

once the compressor reaches normal operating pressures. Additionally changes in fluid temperature

could cause pressure changes that do not result in valve movement within the dead band on

drycoolers. Fan cycling stats should be set to prevent continuous fluid temperature swings greater

than 10

F (5.6

C) (see

3.4.11 - Drycooler Settings

Location

The motorized ball valves are located in the condenser fluid return line. The three-way valve is piped

in a mixing arrangement with the common port at the valve outlet.

Manual Control

The valve can be manually set by disconnecting AC power, depressing the manual override button on

the valve actuator, and adjusting the valve position with the handle. You also have the option to

control the motorized ball valves through the Service menu using manual mode to override the

normal control.

FOR

HISTORICAL

USE

ONLY

Содержание Liebert Challenger iCOM 3000

Страница 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 ...

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

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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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