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Emerson Liebert Challenger iCOM 3000 Operation & Maintenance Manual

50 & 60hz
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3000 with Liebert iCOM
Operation & Maintenance Manual - 50 & 60Hz


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Summary of Contents for Emerson Liebert Challenger iCOM 3000

  • Page 1 Liebert Challenger 3000 with Liebert iCOM ® ™ ® Operation & Maintenance Manual - 50 & 60Hz...
  • Page 3: Table Of Contents

  • Page 4 FIGURES Figure 1 Liebert leak detection units ............8 Figure 2 Recommended liquid sensor locations .
  • Page 5: Important Safety Instructions

    MPORTANT AFETY NSTRUCTIONS SAVE THESE INSTRUCTIONS This manual contains important safety instructions that should be followed during the installation and maintenance of the Liebert Challenger 3000 with Liebert iCOM ® . Read this manual thoroughly before attempting to install or operate this unit. Only qualified personnel should move, install or service this equipment.
  • Page 6 WARNING Risk of high-speed moving parts. Can cause injury or death. Open all local and remote electric power disconnect switches, verify with a voltmeter that power is Off and verify that the blower wheel, pulleys and drive belts have stopped rotating before working in the unit.
  • Page 7 Water leaks can cause severe property damage and loss of critical data center equipment. Do not locate unit directly above any equipment that could sustain water damage. Emerson recommends installing monitored leak detection equipment for unit and supply lines. ™...
  • Page 8: Introduction

    Introduction NTRODUCTION System Descriptions Liebert Challenger 3000 Thermal Management systems are available in several configurations. 1.1.1 Compressorized Systems 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. These systems may be air-cooled, water-cooled or glycol-cooled, depending on the heat rejection method selected.
  • Page 9: Startup

    Startup TARTUP Before beginning startup, make certain that unit was installed according to the instructions in the installation manual, SL-11962. Verify that the fan shipping bolt has been removed, the check valve has been installed (on air-cooled units), and that the scroll compressor is rotating in the proper direction.
  • Page 10 Startup 14. Check for unusual noises and vibration. 15. Check all refrigerant and fluid lines 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...
  • Page 11: Component Operation And Maintenance

    Component Operation and Maintenance OMPONENT PERATION AND AINTENANCE System Testing 3.1.1 Environmental Control Functions The performance of all control circuits can be tested by actuating each of the main functions. This is done by temporarily changing the setpoints. Cooling To test the cooling function, set the setpoint for a temperature of 10°F (5°C) below room temperature. A call for cooling should be seen and the equipment should begin to cool.
  • Page 12: Figure 1 Liebert Leak Detection Units

    The optional water detection devices available are a point leak detection sensor and a zone leak detection kit. Emerson recommends remote monitoring of these devices for timely detection of water leaks that can cause expensive building and equipment damage if not resolved immediately.
  • Page 13: Filters

    Component Operation and Maintenance The zone leak detection kit provides leak detection for a defined zone. This kit is ideal for perimeter sensing or serpentine coverage of small areas. 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.
  • Page 14: Blower Package

    Component Operation and Maintenance Blower Package Periodic checks of the blower package include: belt, motor mounts, fan bearings, and impellers. 3.3.1 Fan Impellers and Bearings Fan impellers should be periodically inspected and any debris removed. Check to see if they are tightly mounted on the fan shaft.
  • Page 15: Refrigeration System

    Component Operation and Maintenance Refrigeration System Each month, the components of the refrigeration system should be inspected for proper function and signs of wear. Since, in most cases, evidence of malfunction is present prior to component failure, periodic inspections can be a major factor in the prevention of most system failures. Refrigerant lines must be properly supported and not allowed to vibrate against ceilings, floors or the unit frame.
  • Page 16: Thermostatic Expansion Valve

    Component Operation and Maintenance 3.4.4 Thermostatic Expansion Valve Operation The thermostatic expansion valve performs one function. It keeps the evaporator supplied with enough refrigerant to satisfy load conditions. It does not effect compressor operation. Proper valve operation can be determined by measuring superheat. If too little refrigerant is being fed to the evaporator, the superheat will be high;...
  • Page 17: Air-Cooled Condenser

    Component Operation and Maintenance 3.4.6 Air-Cooled Condenser Restricted airflow through the condenser coil will reduce the operating efficiency of the unit and can result in high compressor head pressure and loss of cooling. Clean the condenser coil of all debris that will inhibit air flow. This can be done with compressed air or commercial coil cleaner.
  • Page 18: Charging The Liebert Mc ™ With Refrigerant-Basic And Premium Efficiency Control

    When adding liquid refrigerant to an operating system, it may be necessary to add the refrigerant through the compressor suction service valve. Care must be exercised to avoid damage to the compressor. Emerson recommends connecting a sight glass between the charging hose and the compressor suction service valve. This will permit adjustment of the cylinder hand valve so that liquid can leave the cylinder while allowing vapor to enter the compressor.
  • Page 19: Table 4 R-407C (R-22) And R-410A Refrigerant Required, Approximate

    Component Operation and Maintenance Table 4 R-407C (R-22) and R-410A interconnecting piping refrigerant charge (R-22) R-407C lb/100 ft. (kg/30m) R-410A, lb/100 ft. (kg/30m) Line Size O.D., in. Hot Gas Line Liquid Line Hot Gas Line Liquid Line — 3.6 (1.6) —...
  • Page 20: Table 6 Target Subcooling For Ambient Outdoor Temperature

    Component Operation and Maintenance Table 6 Target subcooling for ambient outdoor temperature Ambient Temp Subcooling Ambient Temp Subcooling °F (C°) °F (C°) °F (C°) °F (C°) 0 (-17.8) 22 (12.0) 80 (26.7) 13 (7.2) 10 (-12.2) 22 (12.0) 90 (32.2) 9 (5.0) 20 (-6.7) 22 (12.0)
  • Page 21: Table 7 Difference In Subcooling Measurements-Indoor Minus Outdoor

    Component Operation and Maintenance Elevation Correction Subtract Line c. (Correction for Condenser Elevation above Evaporator) from Line h. (Calculated Subcooling) to obtain Corrected Subcooling. Line h: 7°F Line c: -4°F Corrected Subcooling 3°F Verification Against MC Condenser Subtract Line g. (MC Condenser Subcooling Reading) from Line i. (Corrected Subcooling) to obtain Difference.
  • Page 22: Water/Glycol-Cooled Condensers

    Component Operation and Maintenance Table 8 Liquid pressure and temperature chart Pressure R407C * R410A * 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)
  • Page 23 Component Operation and Maintenance 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.
  • Page 24: 3.4.10 Regulating Valve-Scroll Compressor

    Component Operation and Maintenance 3.4.10 Regulating Valve—Scroll Compressor 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.
  • Page 25: Figure 5 Metrex Valve Adjustment

    Component Operation and Maintenance Figure 5 Metrex valve adjustment Adjusting Collar Nut Manual Flushing—The valve may be flushed by rotating the socket head screw clockwise. This screw must be in the OUT position (counterclockwise) for normal valve operation. Valve Disassembly 1.
  • Page 26: 3.4.11 Drycooler Settings

    See oil types specified in Table 11. • Do NOT mix polyol ester (POE) and mineral-based oils. • Do NOT mix oils of different viscosities. Consult Emerson or the compressor manufacturer if you have questions. Table 11 Compressor oil types Compressor Type...
  • Page 27: Compressor Replacement

    Component Operation and Maintenance Compressor Replacement Replacement compressors are available through your local Emerson office. Compressors are shipped in reusable packaging. If unit is under warranty, complete and include Liebert Service Credit Application (LSCA) with the compressor that is being returned. The original compressor should be returned in the same packaging.
  • Page 28: Standard Scroll Compressor Replacement

    Component Operation and Maintenance 3.5.2 Standard Scroll Compressor Replacement Infrequently a fault in the motor insulation may result in a motor burn, but burnouts rarely occur in a properly installed system. Of those that do, most are the effects of mechanical or lubrication failures, resulting in the burnout as a secondary consequence.
  • Page 29: Digital Scroll Compressor Replacement Procedure

    Component Operation and Maintenance NOTICE Risk of improper wiring/phase sequencing. Could cause backward compressor rotation, poor performance and compressor damage. Three-phase power must be connected to the unit line voltage terminals in the proper sequence so that the scroll compressor rotates in the proper direction. Rotation in the wrong direction will result in poor performance and compressor damage.
  • Page 30: Humidifier-Infrared

    SL-18835 for autoflush setup). To help reduce ® excessive scaling in locations with difficult water quality, the use of Vapure is recommended (contact your local Emerson representative). 3.7.1 Cleaning Humidifier Pan and Float Switch Before turning off unit: 1.
  • Page 31: Changing Humidifier Lamps

    Component Operation and Maintenance 3.7.2 Changing Humidifier Lamps NOTE Touching quartz lamps with bare hands will severely shorten bulb life. Skin oils create hot spots on lamp surface. Wear clean cotton gloves when handling lamps. 1. Remove humidifier pan (see 3.7.1 - Cleaning Humidifier Pan and Float Switch, Steps 1 through 10).
  • Page 32: Steam Generating Humidifier

    Component Operation and Maintenance Autoflush Operation The operation of the autoflush is divided into four steps, beginning with a call for humidification. 1. If the humidifier has not been activated for over 30 hours, the autoflush will flow water into the pan for about 30 seconds.
  • Page 33 Component Operation and Maintenance Operation 1. During startup, when the humidity control calls for humidification, the fill valve opens and allows water to enter the canister. When the water level reaches the electrodes, current flows and the water begins to warm. The canister fills until the amperage reaches the setpoint and the fill valve closes.
  • Page 34: Table 12 Humidifier Canister Part Numbers

    Component Operation and Maintenance Replacing the Canister Over a period of operation, the humidifier electrodes become coated with mineral solids. This coating insulates the electrodes and decreases the current flow. To maintain humidifier capacity, the water level slowly rises to expose fresh electrode. Eventually, the entire electrode becomes coated and the water level reaches the top.
  • Page 35 Component Operation and Maintenance Circuit Board Adjustments WARNING Arc flash and electric shock hazard. Open all local and remote electric power supply disconnect switches, verify with a voltmeter that power is Off and wear personal protective clothing per NFPA 70E before working within the electric control enclosure. Failure to comply can cause injury or death.
  • Page 36: Troubleshooting

    Troubleshooting ROUBLESHOOTING Use this section to assist in troubleshooting your unit. Suggestions are grouped by product function for convenience. WARNING Arc flash and electric shock hazard. Open all local and remote electric power supply disconnect switches, verify with a voltmeter that power is Off and wear personal protective clothing per NFPA 70E before working within the electric control enclosure.
  • Page 37: Table 15 Compressor And Refrigeration System Troubleshooting

    Troubleshooting Table 15 Compressor and refrigeration system troubleshooting Symptom Possible Cause Check or Remedy Power Off Check main switch, fuses or CBs and wiring Re-set units with overload option manually. Allow compressor to cool Current overload open for internal overloads to reset. Compressor will not start Loose electrical connections...
  • Page 38: Table 16 Dehumidification Troubleshooting

    Troubleshooting Table 15 Compressor and refrigeration system troubleshooting (continued) Symptom Possible Cause Check or Remedy Defective or improperly set Increase superheat or replace valve expansion valve Evaporator fan motor or belt Correct problem or replace fan motor and/or belts. Flooding Low condensing pressure Check head pressure control device Slipping belts...
  • Page 39: Table 17 Glycol Pump Troubleshooting

    Troubleshooting Table 17 Glycol pump troubleshooting Symptom Possible Cause Check or Remedy Suddenly stops pumping Clogged strainer or impeller Clean out debris. Suddenly slow pumping Clogged impeller, diffuser, or line Clean out debris and use strainer. Excessive leakage around the pump Worn seal or packing Replace seal or packing.
  • Page 40: Table 19 Steam Generating Humidifier Troubleshooting

    Troubleshooting Table 19 Steam generating humidifier troubleshooting Symptom Possible Cause Check or Remedy Check drain valve to ensure that it drains freely. Check and replace if defective. False canister full indication Foaming Check water supply. If commercially softened, reconnect to raw water supply.
  • Page 41: Table 20 Reheat Troubleshooting

    Troubleshooting Table 19 Steam generating humidifier troubleshooting (continued) Symptom Possible Cause Check or Remedy Verify that drain valve operates freely when activated. Clean Drain valve clogged or valve and replace coil or valve if defective. Flush canister defective several times and replace if arcing persists. If water is commercially softened, reconnect humidifier to Improper water supply raw water supply, drain canister, and restart If connected to...
  • Page 42: Maintenance Worksheet

    However, maintenance intervals may need to be more frequent based on site-specific conditions. Review the unit user manual for further information on unit operation. Emerson recommends the use of trained and authorized service personnel, extended service contracts and factory-certified replacement parts. Contact your local Emerson representative for more details.
  • Page 43 Maintenance Worksheet BLOWER SECTION (EC Fan) (If Equipped) ___ 1. Mounting bolts tight ___ 2. Fan guard bolts tight ___ 3. Impeller spins freely ___ 4. Check/test air sail switch (if equipped) ___ 5. Motor #1 amp draw ___ 6. Motor #2 amp draw ___ 7.
  • Page 44 Maintenance Worksheet CONTROLS ___ 1. Check/verify control operation (sequence) ___ 2. Check/test changeover device(s) (if equipped) ___ 3. Check/test water detection device(s) (if equipped) ___ 4. Check/test CAN connection between indoor and outdoor units (if equipped) REFRIGERATION PIPING ___ 1. Check refrigerant lines (clamps secure/no rubbing/no leaks) ___ 2.
  • Page 45 Maintenance Worksheet CHILLED WATER / ECON-O-COIL (If Equipped) ___ 1. Verify proper water maintenance is being performed ___ 2. Check for water/glycol leaks ___ 3. Stroke freecooling valve open and closed AIR-COOLED FIN AND TUBE CONDENSER / DRYCOOLER (if Equipped) ___ 1.
  • Page 46 Maintenance Worksheet LIEBERT MC (if Equipped) ™ ___ 1. Coil clean ___ 2. Fans free of debris ___ 3. Fans Securely Mounted ___ 4. Motor bearings in good condition ___ 5. Check all refrigerant lines for vibration isolation. support as necessary. ___ 6.
  • Page 47 Maintenance Worksheet NOTES Name Signature Company 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: or call 1-800-Liebert. ™ Liebert ®...
  • Page 48 Philippines ® Liebert is a registered trademark of Liebert Corporation. +63 2 687 6615 All names referred to are trademarks Fax: +63 2 730 9572 or registered trademarks of their respective owners. SL-11963 _REV4_10-14 Emerson Network Power Liebert

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