Emerson Liebert Challenger 3000 Operation & Maintenance Manual

Precision cooling for business-critical continuity
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Liebert
Challenger
®
with Liebert iCOM
Operation & Maintenance Manual - 50 & 60Hz
3000/Liebert Challenger ITR
Control
®
Precision Cooling
For Business-Critical Continuity™

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  Summary of Contents for Emerson Liebert Challenger 3000

  • Page 1 Precision Cooling For Business-Critical Continuity™ Liebert Challenger 3000/Liebert Challenger ITR ® ™ ™ with Liebert iCOM Control ® Operation & Maintenance Manual - 50 & 60Hz...
  • Page 3: Table Of Contents

    TABLE OF CONTENTS ..........1 MPORTANT AFETY NSTRUCTIONS...
  • Page 4 Standard Alarms ............32 6.1.1 Change Filter .
  • Page 5 Facility Fluid and Piping Maintenance for Water and Glycol Systems ....49 Humidifier..............50 7.7.1 Infrared Humidifier .
  • Page 6 TABLES Table 1 Keyboard icons and functions............8 Table 2 Sample Liebert iCOM network configurations .
  • Page 7: Important Safety Instructions Save These 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/Liebert Challenger ITR 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 8 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 above any equipment that could sustain water damage. Emerson recommends installing leak detection equipment for unit and supply lines.
  • Page 9: Introduction

    Introduction NTRODUCTION System Descriptions ™ ™ The Liebert Challenger 3000 and Liebert Challenger ITR Precision Cooling 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/Liebert Challenger ITR unit, or a split system, with the compressor in a separate condensing unit.
  • Page 10: 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 direc- tion.
  • Page 11 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 12: Operation With Icom Control

    Operation with iCOM Control COM C PERATION WITH I ONTROL ™ The Liebert iCOM control offers the highest capabilities in unit control, communication and moni- toring of Liebert mission-critical cooling units. Liebert iCOM may be used to combine multiple cooling units into a team that operates as a single entity, enhancing the already-high performance and efficiency of Liebert’s units.
  • Page 13: Liebert Icom Display Components And Functions

    Liebert iCOM Display Components and Functions COM D IEBERT I ISPLAY OMPONENTS AND UNCTIONS The small and the large display have a common key layout, as shown in Figure 2. Figure 2 Liebert iCOM display components Liquid Crystal Display LED Status Indicators (top LED is red or flashing red;...
  • Page 14: Table 1 Keyboard Icons And Functions

    Liebert iCOM Display Components and Functions Table 1 Keyboard icons and functions Icon Key Name Function On/Off Key Controls the operational state of the cooling unit. Alarm Key Silences an alarm. Help Key Accesses integrated help menus. ESCape Key Returns to the previous display view. Enter Key Confirms all selections and selects icons or text.
  • Page 15: Navigating Through The Liebert Icom Display

    Liebert iCOM Display Components and Functions Figure 3 Liebert iCOM default screen symbols cooling freecooling maintenance electric heat hot water dehumidification humidification Navigating Through the Liebert iCOM Display Liebert iCOM displays icons and text for monitoring and controlling your Liebert cooling unit. The number of icons and amount of text shown depends on the display size.
  • Page 16: Control Interface-Three Main Menus

    Liebert iCOM Display Components and Functions Figure 5 Liebert iCOM default home screen—Simple view Return Air Humidity Humidity Sensor Return Air Temperature Setpoint Supply Air Setpoint Reading Setpoint System or Supply UNIT 1 Air Temperature Unit # view 72.0°F 52.0°F Temperature 51.6 74.1...
  • Page 17: Accessing Menus And Settings

    Liebert iCOM Display Components and Functions 4.1.2 Accessing Menus and Settings Viewing Data No password is required to view data or settings. To view data: 1. From the home screen, press the Enter key to view the User Menu (see Figure 8). 2.
  • Page 18: Accessing Submenus

    Liebert iCOM Display Components and Functions 4.1.4 Accessing Submenus To access the User, Service or Advanced menu, press the Enter or down arrow key while viewing the Status menu of the unit you wish to access. The User menu will be displayed first. To view the Service or Advanced menus, press the right arrow key.
  • Page 19: Figure 7 Menu Tree—Large And Small Displays, Stand-Alone Or Networked

    Liebert iCOM Display Components and Functions Figure 7 Menu tree—Large and small displays, stand-alone or networked Status Menu – System View (Large Display Only) Unit 1 will be displayed in the top left corner of the screen on the large display only.
  • Page 20: Changing Operational Settings

    Liebert iCOM Display Components and Functions Changing Operational Settings Changes to the Liebert Challenger 3000/Liebert Challenger ITR’s operation settings in the Set Alarms and Setpoints menus require a password. 1. From the home screen, press the Enter key to view the User Menu (see Figure 8). 2.
  • Page 21: Changing Liebert Icom's Display Settings

    Liebert iCOM Display Components and Functions Changing Liebert iCOM’s Display Settings No password is required to change the way Liebert iCOM displays data. The Display Setup controls how the unit shows data, such as temperature, date and time. To change the display settings: 1.
  • Page 22: Graphical Data Record

    Liebert iCOM Display Components and Functions Graphical Data Record The Graphical Data Record charts the average temperature from the return air temperature sensor (see Figure 10). The temperature scales can be changed to expand or compress the data. The time scale also can be altered to any of several selectable values.
  • Page 23: Wiring For Unit-To-Unit Communications-U2U

    Liebert iCOM Display Components and Functions Wiring for Unit-to-Unit Communications—U2U The Liebert Challenger 3000/Liebert Challenger ITR with Liebert iCOM comes from the factory wired for stand-alone operation. Multiple units can be set up in a network for efficiency, ease of operation and easier control.
  • Page 24 Liebert iCOM Display Components and Functions Large Displays A network switch is required to enable Ethernet communication on one or more cooling units with large displays. Each cooling unit with a large display requires two straight-through Ethernet cables from a network switch. One cable connects to port P64 on the Liebert iCOM input/output board and the other straight-through cable connects to the female-female coupler provided with the unit.
  • Page 25: Figure 12 U2U Network Setup Diagram

    Liebert iCOM Display Components and Functions Figure 12 U2U network setup diagram Display Service /Network Liebert iCom Display Menu IP Address: 192.168.001.001 U2U Address:1 Group #: 1 --------------------------------------- Display Service /Network Display Service /Network Liebert Challenger Liebert Challenger Control Board Menu Control Board Menu IP Address: 192.168.001.003 IP Address: 192.168.001.002...
  • Page 26 Liebert iCOM Display Components and Functions Notes on Wiring for a U2U Network—Refer to Figures 13 and 15 1. See unit electrical schematic. 2. Cable ‘A’ and ‘B’ are provided with each unit. One only is used as follows: • Liebert IntelliSlot based communications - Cable ‘A’ is preconnected to P65 on I/O board and P65 on the Liebert IntelliSlot power supply •...
  • Page 27: Figure 13 Liebert Icom Wiring—Unit As Shipped

    Liebert iCOM Display Components and Functions Figure 13 Liebert iCOM wiring—Unit as shipped Cable Liebert IntelliSlot Liebert Ribbon Power Supply IntelliSlot 1 Cables See Note 3 Liebert IntelliSlot 2 P64A Connection Located Near Standard Small I/O Board Graphics Display (Rear View) Cable 'A' Red Crossover Ethernet Cable...
  • Page 28: Figure 14 Wiring A Small Display For U2U Network Operation

    Liebert iCOM Display Components and Functions Figure 14 Wiring a small display for U2U network operation Cable Cable 'C' P64A Connection Located Near I/O Board Used Standard Small Graphics Display (Rear View) U2U Networking Switch (Field-Supplied) Liebert iCOM I/O Board Straight-Through To / From Other 194273...
  • Page 29: Figure 15 Wiring A Large Display For U2U Network Operation

    Liebert iCOM Display Components and Functions Figure 15 Wiring a large display for U2U network operation Cable Red Crossover Ethernet Cable Crossover Coupler (See Note 6) Cable 'C' See Note 4 P64A Connection Located Near I/O Board Optional Large Graphics Display Used (Rear View) Customer Connection Point...
  • Page 30: Figure 16 Liebert Icom Input-Output Control Board

    Liebert iCOM Display Components and Functions Figure 16 Liebert iCOM input-output control board (RJ-45 Jack)
  • Page 31: Entering Network Setup Information

    Liebert iCOM Display Components and Functions Entering Network Setup Information Setting up a U2U network requires setting a unique IP addresses for each unit, choosing a U2U address and designating the U2U group. Refer to Figure 17 for the setup screen for the control board (installed inside the Liebert Challenger 3000/Liebert Challenger ITR) and Figure 18 for the setup screen for the Liebert iCOM on the front of the Liebert Challenger 3000/Liebert Challenger ITR.
  • Page 32: Viewing Multiple Units With A Networked Large Display

    Liebert iCOM Display Components and Functions Viewing Multiple Units with a Networked Large Display When you first wake up the control, press the ESC key to return to the System view Status menu. This view shows an average of all the units on the network and any alarms present. To view a specific unit on the network, press either the enter key or down arrow key.
  • Page 33: Operation

    Operation PERATION The Liebert iCOM display for your Liebert cooling unit features an easy-to-use, menu-driven liquid crystal display (LCD). All unit settings and parameters can be viewed and adjusted through three menus: User, Service and Advanced. All active alarms are displayed on the LCD and annunciated. The control is shipped from the factory with default selections for all necessary settings.
  • Page 34: General Compressor Requirements

    Operation WARNING Risk of electric shock. Can cause injury or death. The Liebert iCOM microprocessor does not isolate power from the unit, even in the “Unit Off” mode. Some internal components require and receive power even during the “Unit Off” mode of Liebert iCOM control.
  • Page 35: Compressor Timing

    Operation Pump Down—Air Cooled with Condenser Only Units NOTE Pump down activation is determined by the type of unit; these units do not have a pump-down function: Glycol, GLYCOOL and remote condensing units. The Pump Down operation is performed to protect the compressor oil from being diluted with liquid refrigerant, which helps ensure that the compressor is properly lubricated for the next startup.
  • Page 36: Control Types

    Operation Evaluate the start operation of the unit (with pump down). 1. Close LLSV 2. Wait for LPS to make or ignore for WSK time If LPS is made before WSK has expired, allow the compressor to continue running, if not then stop compressor and alarm low pressure alarm.
  • Page 37: Intelligent Control (Chilled Water Only)

    Operation 5.2.3 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 controlling the system.
  • Page 38: Alarm Descriptions

    Alarm Descriptions LARM ESCRIPTIONS The Liebert iCOM will audibly and visually annunciate all enabled alarms. Alarms are wired from Terminal 24 through a normally open contact to locations 50, 51, 55 and 56, respectively, for alarms 1 through 4. The alarms can be delayed from 0 to 255 seconds. The alarms can be designated as WARNING, URGENT, or DISABLED.
  • Page 39: High Head Pressure

    Alarm Descriptions 6.1.3 High Head Pressure Compressor high head is monitored with a pressure switch. One SPDT pressure switch is used for the compressor in the unit. If head pressure exceeds 360 PSIG, the switch opens the compressor contactor and sends an input signal to the control. On a self-contained system, the head pressure switch located at the compressor requires a manual reset and the alarm condition to be acknowledged on the front display panel.
  • Page 40: Loss Of Air Flow

    Alarm Descriptions 6.1.9 Loss of Air Flow A differential air pressure switch is used to indicate loss of air flow in Liebert Challenger 3000/Lie- bert Challenger ITR units. Check for blockage of unit air outlet or inlet. Check blower motor fuses and overload reset. Check for broken belts.
  • Page 41: Optional Alarms

    Alarm Descriptions Optional Alarms 6.2.1 Loss of Water Flow Available only with 3-way valves and occurs when no water flow is detected in the chilled water or condenser water supply line. An optional flow switch is required for this alarm. Check for service valves closed, pumps not working, etc.
  • Page 42: Component Operation And Maintenance

    Component Operation and Maintenance OMPONENT PERATION AND AINTENANCE System Testing 7.1.1 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 43: Figure 21 Liebert Leak Detection Units

    Component Operation and Maintenance Control 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.
  • Page 44: Figure 22 Recommended Liquid Sensor Locations

    Component Operation and Maintenance Figure 22 Recommended liquid sensor locations Liebert Unit Recommended Liebert Liqui-tect location Floor drain 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 environmental unit or at a monitoring panel.
  • Page 45: Filters

    Component Operation and Maintenance Filters Filters are usually the most neglected item in an environmental control system. To maintain efficient operation, they should be checked monthly and changed as required. Because replacement intervals vary with environmental condition and filter type, each unit is equipped with a filter clog switch. This warns of restricted airflow through the filter compartment by activating the Change Filter alarm.
  • Page 46: Air Distribution

    Component Operation and Maintenance 7.3.3 Air Distribution All unit models are designed for constant volume air delivery. Therefore any unusual restrictions within the air circuit must be avoided. For downflow models operating on a raised floor, refer to the following table for recommended free area for proper air flow. Table 5 Recommended free area ft ) for grilles or perforated panels at output velocities of...
  • Page 47: Discharge Pressure

    Component Operation and Maintenance 7.4.2 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 7, below. Table 7 Discharge pressures Discharge Pressure System Design...
  • Page 48: Hot Gas Bypass Valve-Not Available On Digital Scroll Units

    Component Operation and Maintenance 7.4.5 Hot Gas Bypass Valve—Not Available on Digital Scroll Units Operation—Self-Contained Units The hot gas bypass is inserted between the compressor discharge line and the leaving side of the expansion valve through the side outlet distributor. The system, with normal operation when the evaporator is under full load, will maintain enough pressure on the leaving side of the hot gas valve to keep the valve port closed.
  • Page 49: Water/Glycol Cooled Condensers

    Component Operation and Maintenance Checking Refrigerant Charge (Lee–Temp/Flood Back Head Pressure Control) The system refrigerant level must be checked periodically. 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.
  • Page 50: Motorized Ball Valve-Digital Scroll Compressor

    Component Operation and Maintenance 7.4.8 Motorized Ball Valve—Digital Scroll Compressor On water-cooled and glycol-cooled digital scroll units, the discharge pressure is controlled by a motor- ized ball valve. During unloaded operation, the pressure changes during each digital cycle could result in excessive repositions with a pressure operated water regulating valve. The control algorithm for the motorized ball valve uses an intelligent sampling rate and adjustable pressure thresholds to reduce valve repositions.
  • Page 51: Figure 24 Johnson Controls Valve Adjustment

    Component Operation and Maintenance To raise the head pressure setting, turn the adjusting screw counterclockwise until the desired set- ting is obtained. Figure 24 Johnson Controls valve adjustment Range Spring Valve Spring Guide Range Adjustment Screw Retainer Insert screwdrivers under the valve spring guide.
  • Page 52: 7.4.10 Drycooler Settings

    Component Operation and Maintenance 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. Shut off the water supply by using isolating valves. 2.
  • Page 53: 7.4.11 Compressor Oil

    1. Use Copeland POE Oil ULTRA 22CC, Mobil EAL Arctic 22CC or other Copeland-approved oils. 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 Appli- cation (LSCA) with the compressor that is being returned.
  • Page 54: Standard Scroll Compressor Replacement

    Component Operation and Maintenance 7.5.2 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 fail- ures, resulting in the burnout as a secondary consequence.
  • Page 55: Digital Scroll Compressor Replacement Procedure

    Component Operation and Maintenance 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. Record compressor motor connections when removing a failed compressor.
  • Page 56: Infrared Humidifier

    Component Operation and Maintenance Humidifier 7.7.1 Infrared Humidifier During normal humidifier operation, deposits of mineral solids will collect in the humidifier pan. This should be cleaned out periodically to ensure efficient operation. Each water supply has different char- acteristics, so the time interval between cleanings must be determined locally. A monthly check (and cleaning if necessary) is recommended.
  • Page 57: Figure 26 Infrared Humidifier Lamps

    Component Operation and Maintenance 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.
  • Page 58: Steam Generating Humidifier

    Component Operation and Maintenance Autoflush Controls Use the LCD display, menu, and keys on the front control panel to program the autoflush controls. 7.7.2 Steam Generating Humidifier Steam generating humidifiers are designed to operate in voltage ranges from 200 to 575 volts and generate 11 pounds (5 kg) of steam per hour.
  • Page 59 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 60: Table 11 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 61 Component Operation and Maintenance Circuit Board Adjustments WARNING Risk of electric shock. Can cause injury or death. The Liebert iCOM microprocessor does not isolate power from the unit, even in the “Unit Off” mode. The only way to ensure that there is NO voltage inside the unit is to install and open a remote disconnect switch.
  • Page 62: Table 12 Blower Troubleshooting

    Troubleshooting ROUBLESHOOTING Use this section to assist in troubleshooting your unit. Also refer to 6.0 - Alarm Descriptions. Sug- gestions are grouped by product function for convenience. WARNING Risk of electric shock. Can cause injury or death. The Liebert iCOM microprocessor does not isolate power from the unit, even in the “Unit Off” mode.
  • Page 63: Table 14 Compressor And Refrigeration System Troubleshooting

    Troubleshooting Table 14 Compressor and refrigeration system troubleshooting Symptom Possible Cause Check or Remedy Check main switch, fuses or CBs and Power Off wiring Re-set units with overload option Current overload open manually. Allow compressor to cool for Compressor will not start internal overloads to reset.
  • Page 64 Troubleshooting Table 14 Compressor and refrigeration system troubleshooting (continued) Symptom Possible Cause Check or Remedy Defective or improperly set expansion Increase superheat or replace valve valve Correct problem or replace fan motor and/ Evaporator fan motor or belt Flooding or belts. Low condensing pressure Check head pressure control device Slipping belts...
  • Page 65: Table 15 Dehumidification Troubleshooting

    Troubleshooting Table 15 Dehumidification troubleshooting Symptom Possible Cause Check or Remedy Control not calling for Check monitor status. dehumidification Compressor contactor not pulling in See 7.5.1 - Compressor Functional No dehumidification Check and Table 14. Compressor won't run; fuse blown or See 7.5.1 - Compressor Functional CB tripped Check and Table 14.
  • Page 66: Table 18 Steam Generating Humidifier Troubleshooting

    Troubleshooting Table 18 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 67: Table 19 Reheat Troubleshooting

    Troubleshooting Table 18 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 68: M Onthly M Aintenance I Nspection C Hecklist

    Monthly Maintenance Inspection Checklist ONTHLY AINTENANCE NSPECTION HECKLIST Date:_______________________________________ Prepared by:_________________________________ Model #:_____________________________________ Serial #:____________________________________ Filters Steam Generating Humidifier ___ 1. Restricted air flow ___ 1. Check canister for deposits ___ 2. Check filter switch ___ 2. Check condition of steam hoses ___ 3.
  • Page 69: S Emiannual M Aintenance I Nspection C Hecklist

    Semiannual Maintenance Inspection Checklist 10.0 S EMIANNUAL AINTENANCE NSPECTION HECKLIST Date:________________________________________ Prepared by:_________________________________ Model #:_____________________________________ Serial #:_____________________________________ Filters Steam Generating Humidifier ___ 1. Restricted air flow ___ 1. Check canister for deposits ___ 2. Check filter switch ___ 2. Check condition of steam hoses ___ 3.
  • Page 70 Semiannual Maintenance Inspection Checklist...
  • Page 72 Racks & Integrated Cabinets Connectivity Embedded Power Power Switching & Controls Services DC Power Monitoring Precision Cooling Surge Protection Business-Critical Continuity, Emerson Network Power and the Emerson Network Power logo are trademarks and service marks of Emerson Electric Co. ©2009 Emerson Electric Co.

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