Introduction NTRODUCTION System Descriptions ™ Challenger 3000 environmental control systems are available in three main system configurations: • self contained system with a scroll compressor in the room unit • self contained chilled water system • split system with an evaporator section and a remote condensing unit All three types are available in upflow or downflow configurations.
Installation NSTALLATION Room Preparation The room should be well insulated and must have a sealed vapor barrier. The vapor barrier in the ceiling can be a polyethylene film type. Use a rubber or plastic base paint on concrete walls and floors. Doors should not be undercut or have grilles in them.
Installation 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 properly. •...
Installation Piping Considerations All piping below the elevated floor must be located so that it offers the least resistance to air flow. Careful planning of the piping layout under the raised floor is required to prevent the air flow from being blocked.
Installation Figure 4 Piping connections for air cooled units DOWNFLOW (BF) MODELS Monitoring Panel Condensate Drain, 3/4” FPT Liquid Refrigerant Line Field pitch minimum of 3/8" OD CU on Models BF042A/BF040A 1/8” (3.2mm) per foot (305mm). 1/2" OD CU on Models BF067A/BF065A The drain line must comply with Hot Gas Refrigerant Line all applicable codes...
Installation Figure 5 Piping connections for split system fan coil units Piping outlet locations through the plenum are the same as the unit. See below for UPFLOW (BU) MODELS descriptions and connection sizes. Humi d ifier Water Supply Line Hot Water Return 1/4"...
Installation Figure 6 Piping connections for water/glycol and GLYCOOL units DOWNFLOW (BF, BE) MODELS Monitoring Panel Condensate Drain 3/4” FPT Condenser S upply Line Field pitch a min. of 1/8" (3.2mm) per ft. (305mm). 7/8" OD CU on Models BF046WG/BF045WG The drain line must comply 1 1/8"...
Installation Figure 7 Piping connections for chilled water self-contained units Piping outlet locations through the plenum are the same as the unit. See below for descriptions and connectoin sizes UPFLOW (BU) MODELS Humidifier Water Supply Hot Water Return Line Line 1/4" OD CU 5/8"...
Installation Electrical Connections Three-phase electrical service is required for all models in either 208, 230, 460, or 575 V, 60 Hz; or 200, 230, or 380/415 V, 50 Hz. Electrical service shall conform to national and local electrical codes. Refer to equipment nameplate regarding wire size and circuit protection requirements. Refer to elec- trical schematic when making connections.
Installation 13. Smoke detector alarm connections. Field-supplied 24V. Class 1 wiring to remote alarm circuits. Factory-wired contacts from optional smoke detector are #91 -comm., #92-NO, and #93-NC. 14. Common alarm connection. Field-supplied 24V. Class 1 wiring to common alarm terminals 75 + 76 (and optional 94 + 95, and 96 + 97), which are factory connected to common alarm relay (R3).
Installation 2.7.2 Ducted Applications For ducted applications on units, the duct work may be attached to the top perimeter of the unit. Refer to Figure 2 for information on upflow units and to Figure 3 for downflow units. The duct work on upflow units must allow access to the motors/blowers for maintenance. The duct work on upflow units must be designed within the capacity of the unit, otherwise air flow and perfor- mance will be compromised.
Air Cooled Models OOLED ODELS Condenser Location The air cooled condenser should be located for maximum security and maintenance accessibility. Avoid ground level sites with public access or areas that contribute to heavy snow or ice accumula- tions. Utilize centrifugal condensers whenever interior building locations must by used. To assure adequate air supply, it is recommended that condensers be located in a clean air area, away from loose dirt and foreign matter that may clog the coil.
Air Cooled Models Figure 9 Air cooled condensers LEE-TEMP CONDENSER Lee-Temp heater pad FAN SPEED CONDENSER connection box Hot gas line Electric service supplied by Electric others service supplied by others Liquid line Hot gas line *B - Inverted traps are to be field-supplied and installed (typ).
Air Cooled Models Refrigerant Piping All refrigeration piping should be installed with high temperature brazed joints. Prevailing good refrigeration practices should be employed for piping supports, leak testing, dehydration and charg- ing of the refrigeration circuits. Unit refrigeration components and piping are shipped from the factory with a nitrogen holding charge.
Air Cooled Models 3.4.2 Dehydration/Leak Test and Charging Procedures for R22 (standard) or R407C (Optional) Fan Speed Control Type Condenser CAUTION All local codes for handling refrigerant must be followed. NOTE As R22 and R407C are similar in properties, proper safety equipment and proper refrigeration tools are required on both types.
Air Cooled Models Figure 10 Air cooled fan speed control general arrangement Condenser Coil Schrader Valve Fusible Plug Inverted Traps* on discharge and return lines to extend above base of coil by a minimum of 7 1/2" (190mm) Evaporator Traps* every Coil 25 ft.
Air Cooled Models 3.4.3 Charging 1. Make sure unit is OFF. Open all disconnect switches and, on units supplied with circuit breakers, open all breakers. Replace all fuses for the Fan and Compressors or close breakers. 2. Remove jumper on the Fan Safety Switch and reconnect the system wire connections. Ensure that all operational components are clear of debris.
Air Cooled Models 3.5.2 Materials Supplied 1. Built-in pre-wired condenser control box 2. Air cooled condenser 3. Piping access cover to be reinstalled when piping is complete 4. Bolts (four per leg) 3/8" x 5/8" 5. Terminal block for two-wire 24V interlock connection between the unit and the condenser 6.
Air Cooled Models Dehydration/Leak Test 1. Make sure unit is OFF. Open all disconnect switches and pull all fuses except control fuses. On units supplied with circuit breakers, open all breakers except for the transformer. 2. Add a jumper to the Fan Safety Switch between Common and Normal Open and disconnect the wire connected to the Normally Closed.
Air Cooled Models Figure 11 Air cooled, Lee-Temp general arrangement Inverted Trap * on Condenser Coil discharge line to extend above base of coil by a minimum of 7 1/2" Piping Assembly * * (190mm) Rotalock Valve ** Check Valve Head Pressure Control with 1/4"...
Water Cooled Models ATER OOLED ODELS Piping Considerations Manual shut-off valves should be installed at the supply and return lines of each unit. This will pro- vide for routine maintenance or emergency isolation of the unit. When the water source for the condenser is of poor quality, it is good practice to provide cleanable fil- ters in the supply line.
Water Cooled Models Figure 12 Water cooled general arrangement Evaporator Coil Expansion Valve Sensing Bulb Sight Glass External Hot Gas Equalizers Bypass Valve Scroll Filter Compressor Drier Service Hot Gas Valves Bypass Solenoid Valve Hot Gas Bypass Tube in Tube Fluid Condenser Bypass...
Water Cooled Models Water Regulating Valve The water regulating valve automatically regulates the amount of fluid necessary to remove the heat from the refrigeration system, permitting more fluid to flow when load conditions are high and less fluid to flow when load conditions are low. The valve consists of a brass body, balance spring, valve seat, valve disc holders, capillary tube to discharge pressure, and adjusting screw.
Water Cooled Models 4.3.2 High Pressure Valve - 350 psig (2413 kPa) System for 3 Ton Units (Metrex Valve) Adjustment The valve may be adjusted using a 1/8" diameter rod. Turn the adjusting collar nut counterclockwise to raise head pressure; turn it clockwise to lower head pressure. Rotation directions are viewed from top of valve spring housing.
Glycol/GLYCOOL Cooled Models /GLYCOOL C LYCOL OOLED ODELS Drycooler Location The drycooler should be located for maximum security and maintenance accessibility. Avoid ground- level sites with public access or areas which contribute to heavy snow or ice accumulations. To assure adequate air supply, it is recommended that drycoolers be located in a clean air area, away from loose dirt and foreign matter that may clog the coil.
Glycol/GLYCOOL Cooled Models Glycol Piping CAUTION Galvanized pipe must not be used in or with systems or units that contain glycol. The phosphates in the inhibitor can react with the zinc in the galvanized pipe, precipitating an insoluble material that can eventually foul the system. CAUTION To help prevent piping failures, supply and return lines must be supported in a way that keeps their weight from bearing on the piping of the unit, drycooler or pumps.
Glycol/GLYCOOL Cooled Models 5.4.1 Expansion Tanks, Fluid Relief Valves and Other Devices An expansion tank must be provided for expansion and contraction of the fluid due to temperature change in this closed system. Vents are required at system high points to vent trapped air when fill- ing the system.
Glycol/GLYCOOL Cooled Models 5.5.2 Glycol Solutions NOTE Glycol solutions should be considered for protection of the coil. When it is not used, damage can occur from either freezing or corrosion from water. When considering the use of any glycol products in a particular application, you should review the lat- est Material Safety Data Sheets and ensure that the use you intend can be accomplished safely.
Glycol/GLYCOOL Cooled Models 5.5.3 Filling the System Installation of hose bibs at the lowest point of the system is recommended. When filling a glycol sys- tem keep air to a minimum. Air in glycol turns to foam and is difficult and time-consuming to remove. (Anti-foam additives are available and may be considered.) Open all operating systems to the loop.
Glycol/GLYCOOL Cooled Models Figure 17 Glycol general arrangement Expansion Tank Field Installed at Glycol Drycooler Highest Point in System. Pump Electric Unions* Fill * Pump Drycooler Housing Coil Expansion Fluid Evaporator Isolation Port* Return Coil Valves* to Pump Unions* Expansion Fluid Valve Supply...
Glycol/GLYCOOL Cooled Models Figure 18 GLYCOOL general arrangement Expansion Tank Field Installed at Glycol Highest Point in System Pump Unions* Pump Fill * Drycooler Drycooler Housing Electric Coil Fluid Return to Evaporator Pressure Isolation Pump Coil Port* Valves* Unions* Expansion Fluid Valve Supply...
Glycol/GLYCOOL Cooled Models Condenser The condenser is designed to operate in conjunction with a drycooler. The maximum coolant pressure is 350 psig (2413 kPa). NOTE For pressures above 150 psig (1034 kPa), the high pressure option for high pressure valve(s) is required.
Chilled Water Models HILLED ATER ODELS Piping Considerations Manual shut-off valves should be installed at the supply and return lines to each unit. This will pro- vide for routine service and emergency isolation of the unit. Consideration of the minimum water temperature to be supplied from the chiller will determine if the need exists to insulate supply and return lines.
Split System Models PLIT YSTEM ODELS Three (3) condensing unit styles are available: two (2) air cooled and one (1) water/glycol cooled con- densing unit. Location Considerations 7.1.1 Air Cooled Condensing Units To assure an adequate air supply, it is recommended that all condensing units be located in a clean air area, away from loose dirt and foreign matter that may clog the coil.
Split System Models Piping Considerations 7.3.1 Refrigerant Loop CAUTION All local codes for handling refrigerant must be followed. NOTE As R22 and R407C are similar in properties, proper safety equipment and proper refrigeration tools are required on both types. Check unit nameplate for correct refrigerant type before topping off or recharging a system.
Split System Models Once all piping is complete, check for leaks and dehydrate the field piping as follows: 1. Pressurize the field piping to 150 PSIG (1034 kPa) using dry nitrogen with a trace of refrigerant. Check system for leaks with a suitable leak detector. 2.
Split System Models 7.3.2 Quick Connect Fittings NOTE When hard piping is used, complete all piping and evacuate lines before connecting quick connects. Be especially careful when connecting the quick connect fittings. Read through the following steps before making the connections. 1.
Split System Models Outdoor Air Cooled Condensing Units Figure 22 Outdoor air cooled condensing unit—horizontal air discharge models UNIT DIMENSIONS (See Table 26) REMOVABLE (RIGHT) PANEL Fan Rotation FOR ACCESS TO REFRIGERATION COMPONENT. (left side) RIGHT DISCHARGE LEFT INTAKE SHADED AREA INDICATES A MINIMUM CLEARANCE OF 18"...
Split System Models Figure 23 Outdoor air cooled condensing unit—top air discharge models GUARD HEIGHT DISCHARGE RIGHT UNIT DIMENSIONS INTAKE (see Table 28) LEFT SHADED AREA INTAKE INDICATES A RECOMMENDED CLEARANCE OF 18" (457mm) FOR PROPER AIR FLOW 2 " (51mm) SHADED AREA INDICATES A RECOMMENDED...
Split System Models Table 28 Cabinet and floor planning dimensional data - prop fan condensing modules, top air discharge Model Numbers Dimensional Data in. (mm) Module Weight 60 Hz 50 Hz lbs (kg) net PFC067A-_H PFC066A-_H PFH067A-_H 53 (1343) 36-1/4 (918) 38-1/2 (978) 5-1/2 (140) 488 (222)
Split System Models Figure 24 Electrical field connections, prop fan condensing module TOP AIR DISCHARGE MODELS (5 Ton High Ambient & Field-supplied unit 5 Ton Quiet-Line) disconnect switch HORIZONTAL AIR DISCHARGE MODELS Field-supplied 24V NEC Class 2 wiring to evaporator module Single- or 3-phase electric...
Split System Models Centrifugal Air Cooled Condensing Units 7.5.1 Installing the Indoor Condensing Unit Refer to drawings for unit dimensions and component locations. WARNING Be sure the supporting roof structure is capable of supporting the weight of the unit(s) and the accessories during installation and service.
Split System Models 7.5.2 Ducting The total external static pressure for the inlet and outlet ducts, including grille, must not exceed 0.5 inches of H O. Hood intake dimensions should be the same as the condensing unit duct dimen- sions. If the condensing unit is located close to the outside of the building, rain hoods must be installed.
Split System Models Figure 26 2 and 3 ton centrifugal air cooled condensing unit dimensional data & piping connections Customer-supplied threaded rods for 22 3/4" (578mm) 50 1/4" (1276mm) Overall Di m ension module support Overall Di m ension 21 1/2" (546mm) from ceiling (typ.
Split System Models Figure 27 3 ton centrifugal air cooled condensing unit (con't.) Field-supplied unit disconnect switch when optional disconnect is not provided in unit Single- or three-phase electric service not by Liebert Field-supplied 24V NEC Class 2 wiring to fan/coil unit Optional factory-installed disconnect switch Factory-wired...
Split System Models Figure 29 5 ton centrifugal air cooled condensing unit dimensional data (con't.) Field Supplied Unit Disconnect Switch when Factory Unit Disconnect Switch is not Supplied. Electric service not by Liebert Optional Factory Installed Disconnect Switch AIR COOLED Line Voltage Electric Power Supply Conduit Voltage Connection terminal for field...
Split System Models Figure 30 Split systems general arrangement Hot Gas Condenser Bypass Solenoid High Pressure Coil Valve Switch Scroll Compressor Liquid Injection 1/2" (12.7mm) NPT Valve Bulb Pressure Relief Valve Suction Line Male Quick Sight Check Valve AIR COOLED Connect Glass Suction Line...
Split System Models Water and Glycol Cooled Condensing Units For installation guidelines, refer to Installing the Indoor Condensing Unit on page 52. 7.6.1 Piping Considerations It is recommended that manual service shut-off valves be installed at the supply and return line to each unit.
Split System Models Figure 32 3 ton water/glycol cooled condensing unit (con't.) Field-supplied unit disconnect Single- or three-phase electric switch when optional disconnect service not by Liebert is not provided in unit Field-supplied 24V NEC Class 1 wiring to fan/coil unit Field-supplied 24V NEC Class 1 wiring to drycooler (glycol-cooled units only)
Split System Models Figure 34 5 ton water/glycol cooled condensing unit (con't.) Field-supplied unit disconnect Electric service; switch when factory unit not by Liebert disconnect switch is not suplied WATER/GLYCOL Optional factory-installed disconnect switch Field-supplied 24V NEC Class 1 wiring to fan/coil unit Field-supplied 24V NEC Class 1 wiring to drycooler (glycol-cooled units only)
R407C Refrigerant R407C R EFRIGERANT Table 33 R407C pressure/temperature chart for operation and superheat (discharge/hot gas and suction gas) Temperature Gauge Pressure Temperature Gauge Pressure Temperature Gauge Pressure °F °C Psig °F °C Psig °F °C Psig -17.8 18.9 35.0 54.8 70.0 21.1...
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