Precision Cooling For Business-Critical Continuity™ Liebert® Challenger™ 3000 with Liebert iCOM® Installation Manual - 3 & 5 Tons, 50 & 60Hz
TABLE OF CONTENTS IMPORTANT SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 SAVE THESE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 1.0 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 1.1 System Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.3 Water Regulating Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 4.3.1 4.3.2 4.4 Standard Valve - 150psig (1034kPa) System for 3 & 5-Ton Units (Johnson Controls Valve) High Pressure Valve - 350psig (2413kPa) System for 5-Ton Units (Johnson Controls Valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4 Outdoor Air-Cooled Condensing Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 7.5 Centrifugal Air-Cooled Condensing Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 7.5.1 7.5.2 7.6 Installing the Indoor Condensing Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Ducting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 36 Figure 37 Figure 38 Figure 39 Figure 40 Figure 41 Figure 42 Figure 43 Figure 44 3-ton centrifugal air-cooled condensing unit dimensional data & piping connections . . . . . . . . . 3-ton centrifugal air-cooled condensing unit (con’t.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-ton centrifugal air-cooled condensing unit dimensional data . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-ton centrifugal air-cooled condensing unit dimensional data (con’t.) . . . .
Important Safety Instructions IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS This manual contains important safety instructions that should be followed during the installation and maintenance of the Liebert Challenger 3000. Read this manual thoroughly before attempting to install or operate this unit. Only qualified personnel should move, install or service this equipment. Adhere to all warnings, cautions and installation, operating and safety instructions on the unit and in this manual.
Important Safety Instructions ! WARNING Risk of improper handling of top heavy unit. Can cause unit to fall over, resulting in equipment damage, serious injury or death. Read all instructions before attempting to move, lift, remove packaging from or preparing unit for installation. ! WARNING Risk of high-speed moving parts. Can cause injury or death. Disconnect all local and remote electric power supplies before working in the unit.
Important Safety Instructions NOTICE Risk of damage from forklift. Can cause unit damage. Keep tines of the forklift level and at a height suitable to fit below the skid and/or unit to prevent exterior and/or underside damage. NOTICE Risk of improper storage. Can cause unit damage. Keep the Liebert Challenger 3000 upright, indoors and protected from dampness, freezing temperatures and contact damage.
Introduction 1.0 INTRODUCTION 1.1 System Descriptions Liebert Challenger 3000 Precision Cooling 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. The standard upflow configuration is front return. All models require three-phase power.
Introduction 1.1.3 Split Systems Each air-cooled split system consists of an evaporator section and one of the following condensing units. Prop Fan Air-Cooled Prop Fan units include scroll compressor, condenser coil, prop fan, high pressure switch, hot gas bypass and Liebert Lee-Temp™ head pressure control. Unit is designed for outdoor location.
Installation (Applicable to all Models) 2.0 INSTALLATION (APPLICABLE TO ALL MODELS) 2.1 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. Outside (or fresh) air should be kept to an absolute minimum.
Installation (Applicable to all Models) 2.4.1 Handling With Skid • Always keep the unit upright, indoors and protected from damage. • If possible, transport the unit using a fork lift; otherwise, use a crane with belts or cables, avoiding pressing on the top edges of the packaging. • If using a fork lift, make sure the forks, if adjustable, are spread to the widest allowable distance to still fit under the skid. NOTICE Risk of overhead interference. Can cause unit and/or structure damage.
Installation (Applicable to all Models) Figure 2 Upflow (BU) cabinet dimensions 32-1/2" (826mm) 30-1/2" (775mm) A A STD 3 & 5T 11-3/4 (299mm) Hi Static 3T 8-5/8 (219mm) Hi Static 5T 11-3/4 (299mm) UNIT TOP VIEW 9-5/8" (244mm) 8-1/2" (216mm) 10-1/4" (260mm) 13" (330mm) Standard Piping Location 12-1/2" (318mm) Projection of Display Bezel 5/8" (16mm) 5-1/2" (140mm) 32-1/2" 32-1/2" (826mm) (826mm) Overall Overall Dimension Dimension 7-1/2" (191mm) Filter Access Through Top 18" (457mm) 1-5/8" (
Installation (Applicable to all Models) Figure 3 Downflow (BF) cabinet dimensions 32-1/2" (826mm) Overall Dimension 32-1/2" (826mm) Overall Dimension 30-1/2" (775mm) Projection of Display Bezel 5/8" (16mm) 30-1/2" (775mm) Optional 1-5/8" (41mm) Flange for Duct or Plenum Connection 76" (1930mm) 1" (25mm) FRONT & SIDES 3/4" (19mm) REAR 1" (25.4mm) 30-1/2" (775mm) 9" (229mm) 30-1/2" (775mm) 4" (102mm) Shaded area indicates a recommended clearance of 34” (864mm) for component access.
Installation (Applicable to all Models) 2.5 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. When installing piping on the subfloor, it is recommended that the pipes be mounted in a horizontal plane rather than stacked one above the other. Whenever possible, the pipes should be run parallel to the air flow.
Installation (Applicable to all Models) Table 2 Piping connection size (continued) Chilled Water Unit Connection Sizes—in. Model No. BF/BU Supply Line (50 Hz) CWS 068C (072C) 1-1/8 102C (101C) 1-1/8 Figure 4 Return Line CWR 1-1/8 1-1/8 Piping connections for air-cooled units - Downflow models Liebert iCOM Control Panel Condensate Drain 3/4" FPT Field-pitch a minimum of 1/8" (3.2mm) per foot (305mm). The drain line must comply with all applicable codes.
Installation (Applicable to all Models) Figure 5 Piping connections for air-cooled units - Upflow models Piping outlet locations through the plenum are the same as the unit. See below for descriptions and connection sizes.
Installation (Applicable to all Models) Figure 6 Piping connections for split system fan coil units - Downflow models Liebert iCOM Control PIPING OUTLET LOCATIONS (See Cabinet and Floor Planning Dimensional Data for Piping Opening Sizes.) Liquid Refrigerant Line #6 Quick Connect on Models BF036E/BF035E 1/2" OD CU on Models BF060E/BF059E Condensate Drain 3/4" FPT Field pitch a minimum of 1/8" (3.2mm) per ft. (305mm). The drainline must comply with all applicable codes.
Installation (Applicable to all Models) Figure 7 Piping connections for split system fan coil units - Upflow models Piping outlet locations through the plenum are the same as the unit. See below for descriptions and connection sizes. Humidifier Water Supply Line 1/4" OD CU Hot Water Return 5/8" OD CU (optional) Suction Refrigerant Line #11 Quick Connect on Models BU036E/BU035E 1 1/8" OD CU on Models BU060E/BU059E Condensate Pump Line 1/2" OD CU; used only if optional condensate pump is ordered.
Installation (Applicable to all Models) Figure 8 Piping connections for water/glycol and GLYCOOL units - Downflow models iCOM Control Panel Condenser Supply Line 7/8" OD CU on Models BF046WG/BF045WG 1-1/8" OD CU on Models BF071WG/BF070WG Condensate Drain 3/4" FPT Field pitch a minimum of 1/8" (3.2mm) per ft. (305mm).
Installation (Applicable to all Models) Figure 9 Piping connections for water/glycol and GLYCOOL units - Upflow models Piping outlet locations through the plenum the same as the unit. See below for descriptions and connection sizes.
Installation (Applicable to all Models) Figure 10 Piping connections for chilled water self-contained units - Downflow models Liebert iCOM Control PIPING OUTLET LOCATIONS (See Cabinet and Floor Planning Dimensional Data for Piping Opening Sizes.) Condensate Drain 3/4" FPT Field pitch a minimum of 1/8" (3.2mm) per ft. (305mm). The drain line must comply with all applicable codes.
Installation (Applicable to all Models) Figure 11 Piping connections for chilled water self-contained units - Upflow models Piping outlet locations through the plenum are the same as the unit. See below for descriptions and connection sizes. Humidifier Water Supply Line 1/4" OD CU Hot Water Return 5/8" OD CU (optional) Chilled Water Supply Line 1-1/8" OD CU Chilled Water Return Line 1-1/8" OD CU Condensate Pump Line 1/2" OD CU; used only if optional condensate pump is ordered.
Installation (Applicable to all Models) 2.5.2 Humidifier Supply Water—Optional Infrared • 1/4" supply line; maximum water pressure is 150 psi (1034kPa) • Size humidifier supply line for 1 gpm (3.8 l/m), with a minimum water pressure of 20 psi (138kPa) • Do not supply de-ionized water to the humidifier 2.6 Facility Fluid and Piping Maintenance Facility water and glycol quality remain a requirement throughout the life of the piping system.
Installation (Applicable to all Models) Figure 12 Electrical connections 1 Electrical Handy Box * 2 (Factory-Installed With Cover) 14 73 3 72 71 4 70 8 5 Terminal Block (for Customer Connectons 13 13 75 76 94 95 96 97 9 7 9 10 37C38C37B 38B 37 38 24 50 51 55 56 6 12 91 92 93 12 1 11 34 15 16 17 82 83 84 85 88 89 DPN000354 Rev. 2 2.7.1 Electrical Field Connections for Liebert Challenger 3000 Models Source: DPN00354, Rev. 2 1.
Installation (Applicable to all Models) 14. Heat rejection connection. Field-supplied 24V Class 1 wiring to interlock heat rejection from pigtails 70 + 71, which are factory-connected to compressor side switch (self-contained units only) or to GLYCOOL relay (K11, GLYCOOL units only). On Dual Cool units only, pigtails 72 + 73 connect auxiliary cooling source to GLYCOOL relay K11. 15. Reheat and Humidifier Lockout.
Installation (Applicable to all Models) 2.8 Balancing the Air Distribution 2.8.1 Under-Floor Discharge Systems The systems are designed for constant air delivery, therefore any unusual restrictions within the air circuit must be avoided. For under-floor air distribution, observe the following guidelines: • Select the air supply grilles and perforated panels for the raised floor to ensure minimum loss of pressure in the circuit.
Installation (Applicable to all Models) 2.9 Checklist for Completed Installation ___ 1. Unpack and check received material. ___ 2. Proper clearance for service access has been maintained around the equipment. ___ 3. Equipment is level and mounting fasteners are tight. ___ 4. Piping completed to refrigerant or coolant loop (if required). Piping has been leak checked, evacuated and charged (if required). ___ 5. Check piping within the unit & outside of the unit. Remove potential of rub-through or chaffing.
Air-Cooled Models—Self-Contained Compressor 3.0 AIR-COOLED MODELS—SELF-CONTAINED COMPRESSOR 3.1 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 accumulations. Utilize centrifugal condensers whenever interior building locations must by used.
Air-Cooled Models—Self-Contained Compressor Figure 14 Air-cooled condensers FAN SPEED AND VFD CONDENSER LIEBERT LEE-TEMP CONDENSER Liebert Lee-Temp™ heater pad connection box *B Hot gas line Electric service supplied by others *B Liquid line Hot gas line Electric service supplied by others *B - Inverted traps are to be field-supplied and installed (typ). When installing traps, provide clearance for swing end of access door.
Air-Cooled Models—Self-Contained Compressor 3.3 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 charging of the refrigeration circuits. Unit refrigeration components and piping are shipped from the factory with a nitrogen holding charge. ! WARNING Risk of explosive discharge from high-pressure refrigerant. Can cause injury or death.
Air-Cooled Models—Self-Contained Compressor Table 5 Recommended line sizes — OD copper, inches * 3.5-ton 042A (040A) Hot Gas Line Liquid Line 5/8 1/2 3/4 1/2 3/4 5/8 Equivalent Length 50 ft. (15 m) 100 ft. (30 m) 150 ft. (45 m) 5-ton 067A (065A) Hot Gas Line Liquid Line 7/8 1/2 7/8 5/8 7/8 5/8 *Recommended vertical line sizes must be used for proper oil return at all cooling and dehumidification steps. Table 6 Equivalent lengths (feet) for various pipe fittings Copper Pipe O.D. in.
Air-Cooled Models—Self-Contained Compressor 3.4 Fan Speed Control Systems The Variable Fan Speed Control systems (FSC & VFD) uses pressure-activated electronic fan speed control systems and remotely located thermostat(s) to ensure operation at ambient temperatures as low as 0°F (-18°C). For this ambient temperature range, the VFD Control Condenser must be used with digital scroll indoor units and can be used for energy savings with any Liebert Challenger 3000™ unit.
Air-Cooled Models—Self-Contained Compressor Variable Fan Speed Charging 1. Check unit nameplate for refrigerant type to be used. Unit control configurations differ depending on refrigerant type. 2. Refrigerant charging requires unit operation. Refer to 2.9 - Checklist for Completed Installation. 3. Calculate the amount of charge for the system. Refer to the unit, condenser and refrigerant line charge data in Tables 6, 7, 8 and 9. 4.
Air-Cooled Models—Self-Contained Compressor Figure 15 General arrangement—Air-cooled models with fan speed control Condenser Coil Schrader Valve * Inverted trap on discharge and liquid lines to extend above base of coil by a minimum of 7-1/2" (190mm) Schrader Valve Optional Field-Installed Fusible Plug * For rises over 25ft. (7.6m), trap every 20ft.
Air-Cooled Models—Self-Contained Compressor Figure 16 General arrangement—Air-cooled models with digital scroll and fan speed control Condenser Coil Schrader Valve * Inverted trap on discharge and liquid lines to extend above base of coil by a minimum of 7-1/2" (190mm) Schrader Valve Optional Field-Installed Fusible Plug * For rises over 25ft. (7.6m), trap every 20ft.
Air-Cooled Models—Self-Contained Compressor 3.5 Air-Cooled Condenser with Liebert Lee-Temp™ “Flooded Condenser” Head Pressure Control System The Liebert Lee-Temp system consists of a modulating type head pressure control valve and insulated receivers with heater pads to ensure operation at ambient temperatures as low as -30°F (-34.4°C). The Liebert Lee-Temp system can be used with any compressor choice.
Air-Cooled Models—Self-Contained Compressor 6. After four hours, check the pressure readings and, if they have not changed, break vacuum with dry nitrogen. Pull a second and third vacuum to 250 microns or less. Recheck the pressure after two hours. 7. Remove the jumper hose installed previously from between the service valve fitting and the condenser. After completing this step, proceed to Liebert Lee-Temp™ Charging. Liebert Lee-Temp™ Charging 1. Check unit nameplate for refrigerant type to be used.
Air-Cooled Models—Self-Contained Compressor Liebert Lee-Temp Receiver Refrigerant Level On each receiver at the condenser are two refrigerant-level sight glasses. Refrigerant level will vary with outside temperature. Check refrigerant level after the unit has been on for at least 15 minutes. Sight Glass Levels 40°F (4.5°C) and lower—bottom sight glass is 3/4 full 40 to 60°F (4.5 to 15.5°C)—bottom sight glass is full 60°F (15.5°C) and higher—top sight glass is 3/4 full.
Air-Cooled Models—Self-Contained Compressor Figure 18 General arrangement—Air-cooled models with digital scroll and Liebert Lee-Temp™ Condenser Coil Inverted trap * on discharge and liquid lines to extend above base of coil by a minimum of 7-1/2" (190mm) Piping Assembly ** Check Valve Head Pressure Control with Integral Check Valve * For rises over 25ft. (7.6m), trap every 20ft. (6m) or at evenly spaced points (hot gas line only) Liquid Return from Condenser Rotalock Valve ** 1/4" ( 6.
Water-Cooled Models—Self-Contained Compressor 4.0 WATER-COOLED MODELS—SELF-CONTAINED COMPRESSOR 4.1 Piping Considerations Manual shutoff valves should be installed at the supply and return lines of each unit. This will provide 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 filters in the supply line.
Water-Cooled Models—Self-Contained Compressor Figure 19 General arrangement—Water-cooled models with scroll compressor Evaporator Coil Expansion Valve Sensing Bulb Sight Glass Hot Gas Bypass Valve Filter Dryer Hot Gas Service Valves Bypass Solenoid Valve External Equalizers Scroll Compressor Hot Gas Bypass Tube in Tube Condenser Fluid Supply Fluid To Return Unit From Unit Shutoff* Valves Hose Bibs* Bypass Valve Tube in Tube Condenser 2-Way Water Regulating Valve 3-Way Water Regulating Valve (opt
Water-Cooled Models—Self-Contained Compressor Figure 20 General arrangement diagram—Water-cooled models with digital scroll Evaporator Coil Expansion Valve Sensing Bulb Sight Glass External Equalizer Digital Solenoid Valve Service Valves Filter Dryer Digital Compressor Tubein-Tube Condenser Tubein-Tube Condenser Fluid Supply Fluid To Return Unit From Unit Shutoff* Valves To Liebert iCOM Control 2-Way Motorized Ball Valve Hose Bibs* Field-Supplied Reducers Required on 3-Ton Units Fluid Return
Water-Cooled Models—Self-Contained Compressor 4.3 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. 4.3.
Water-Cooled Models—Self-Contained Compressor 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.
Water-Cooled Models—Self-Contained Compressor Control Method The control utilizes an upper and lower pressure threshold with a 35psi (241kPa) 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.
Glycol/GLYCOOL-Cooled Models—Self-Contained Compressor 5.0 GLYCOL/GLYCOOL-COOLED MODELS—SELF-CONTAINED COMPRESSOR 5.1 Drycooler Location The drycooler should be located for maximum security and maintenance accessibility. Avoid groundlevel 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—Self-Contained Compressor 5.4 Glycol Piping These guidelines apply to the field leak checking and fluid requirements for field piping systems. General Guidelines • Equipment damage and personal injury can result from improper piping installation, leak checking, fluid chemistry and fluid maintenance. • Follow local piping codes, safety codes. • Qualified personnel must install and inspect system piping.
Glycol/GLYCOOL-Cooled Models—Self-Contained Compressor from which it is prepared and may become increasingly corrosive with use if not properly inhibited. NOTICE Risk of no-flow condition. Can cause equipment and building damage from corrosion and resulting leaks. Do not leave the unit in a no-flow condition. Idle fluid allows the collection of sediment that prevents the formation of a protective oxide layer on the inside of tubes. Keep unit switched On and system pump operating.
Glycol/GLYCOOL-Cooled Models—Self-Contained Compressor 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 filling the system. A relief valve is a also a necessary piping component. Depending on the complexity of the system, various other devices may be specified.
Glycol/GLYCOOL-Cooled Models—Self-Contained Compressor 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 latest Material Safety Data Sheets and ensure that the use you intend can be accomplished safely.
Glycol/GLYCOOL-Cooled Models—Self-Contained Compressor NOTICE Risk of corrosion from water impurities. Can cause equipment damage. The quality of water used for dilution must be considered because water may contain corrosive elements which reduce the effectiveness of the inhibited formulation. Water that is classified as soft (low in chloride and sulfate ion content less than 100 parts per million each) should be used. 5.5.
Glycol/GLYCOOL-Cooled Models—Self-Contained Compressor Figure 23 Drycoolers and pump packages 43-9/16" (1105mm) DRYCOOLER A GLYCOL PUMP PACKAGE See Note 1 30-1/4" (768mm) 37-7/8" (1095mm) 19" (483mm) B 43-3/16" (1097mm) Provided on dual pump package only See Table 18 for keys to dimensions “A”, “B” and “C”. PUMP PACKAGE MOUNTING ANGLES 1/2" diameter holes for mounting (4 typ) Note: Angles located inside, bottom of pump package. View used for mounting reference. 3/4" (19mm) C Notes 1.
Glycol/GLYCOOL-Cooled Models—Self-Contained Compressor Figure 24 Pump packages—expansion tank O 9" (228.6mm) 1/2" FPT Fitting 2-3/4" (69.9mm) 2-1/2" (63.5mm) 1-1/2" (38.1mm) Table 17 7" (177.8mm) 4" (101.6mm) 1" (25.4mm) 1" (25.4mm) 6-13/16" (173mm) 1/2" FPT Fitting 30-1/2 (774.7mm) 17-1/4" (438.2mm) 1-1/2" (38.1mm) 6-1/8" (155.6mm) O 1/2" (12.7mm) 8 holes EXPANSION TANK 8.8 gal. (33.3L) 3" (76.2mm) SL-10065 Pg. 7B SL-10070 Pg.
Glycol/GLYCOOL-Cooled Models—Self-Contained Compressor Figure 25 General arrangement—Glycol-cooled models with scroll compressor Expansion Tank Field-Installed at Highest Point in System Drycooler Fill* Hose Bibs* Pump Housing Drycooler Coil Fluid Return to Pump Unions* Air Vents* at Top of Risers Unions* Electric Box Expansion Port* Glycol Pump Isolation Valves* Expansion Valve Fluid Supply from Pump Flow Regulating Valve* Pressure Port* Evaporator Coil Sensing Bulb Sight Glass Hot Gas Byp
Glycol/GLYCOOL-Cooled Models—Self-Contained Compressor Figure 26 General arrangement—Glycol-cooled models with digital scroll Expansion Tank Field-Installed at Highest Point in System.
Glycol/GLYCOOL-Cooled Models—Self-Contained Compressor Figure 27 General arrangement—GLYCOOL models with scroll compressor Expansion Tank Field-Installed at Highest Point in System Drycooler Electric Box Fill* Glycol Fluid Return to Pump Unions* Air Vents* at Top of Risers Hose Bib* Unions* Drycooler Coil Pressure Port* Pump Housing Evaporator Coil Isolation Valves* Expansion Valve Fluid Supply from Pump Flow Regulating Valve* Pressure Port* Filter Dryer Pump Sight Glass Sensing Bulb Hot G
Glycol/GLYCOOL-Cooled Models—Self-Contained Compressor Figure 28 General arrangement—GLYCOOL models with digital scroll compressor Expansion Tank Field-Installed at Highest Point in System Drycooler Electric Drycooler Fill* Box Coil Unions* Hose Bib* Pump Unions* Fluid Return to Pump Pressure Port* Air Vents* at Top of Risers Glycol Pump Housing Evaporator Coil Isolation Valves* Expansion Valve Fluid Supply from Pump Flow Regulating Valve* Sensing Bulb External Equalizer Pressure Port* Sig
Glycol/GLYCOOL-Cooled Models—Self-Contained Compressor 5.5.4 Motor Ball Valve—Digital Scroll Compressors Refer to 4.4 - Motorized Ball Valve—Digital Scroll Compressors for details on the motorized ball valve. 5.6 Condenser The condenser is designed to operate in conjunction with a drycooler. The maximum coolant pressure is 350 psig (2413 kPa). 5.
Chilled Water Models 6.0 CHILLED WATER MODELS 6.1 Piping Considerations Manual shutoff valves should be installed at the supply and return lines to each unit. This will provide 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. Insulation will prevent condensation on the supply and return lines.
Chilled Water Models Figure 30 Chilled water general arrangement - Downflow (BF) models Air Flow Bleed Valve Chilled Water Return Valve Actuator AB A Chilled Water Supply Shutoff Valves * Chilled Water Coil 3-Way B Chilled Water Valve 3-WAY VALVE Flow Switch (optional) Air Flow Chilled Water Return Hose Bibs * Chilled Water Supply Bleed Valve Valve Actuator Chilled Water Coil Shutoff Valves * 2-Way Chilled Water Valve 2-WAY VALVE FACTORY PIPING FIELD PIPING Hose Bibs * Liebert® Challenger 3
Split System Models 7.0 SPLIT SYSTEM MODELS Three condensing unit styles are available: two air-cooled and one water/glycol-cooled condensing unit. 7.1 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 7.2.1 Line Voltage Line voltage electrical service is required for all condensing units at the location of the condensing unit. This power supply does not have to be the same voltage as the indoor unit. This separate power source may be 208, 230, 460 or 575V, 60 Hz; or 200, 230, or 380/415V, 50 Hz. A disconnect switch is required and must be mounted per local and national codes to isolate the unit for maintenance. 7.2.
Split System Models All split systems require two refrigerant lines (an insulated copper suction line and a copper liquid line) between the evaporator and the condensing unit. Two possible methods exist for installing the copper suction and liquid lines. 1. Using an optional Sweat Adapter Kit and hard piping between the two units. 2. Using optional pre-charged line sets (for 3-ton models only). All refrigeration piping should be installed with high temperature brazed joints.
Split System Models Table 22 Line charges - refrigerant per 100 ft. (30 m) of Type “L” copper tube R407C O.D. Liquid Line lb (kg) Suction Line lb (kg) 1/2" 7.3 (3.3) - 5/8" 11.7 (5.3) 0.4 (0.2) 7/8" 24.4 (11.1) 1.0 (0.4) 1-1/8" 41.6 (18.9) 1.7 (0.7) 1-3/8" 63.3 (28.7) 2.7 (1.1) Table 23 Recommended refrigerant lines (R407C) sizes OD copper 3.
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. 2. 3. 4. 5. Remove protector caps and plugs. Carefully wipe coupling seats and threaded surfaces with a clean cloth. Lubricate the male diaphragm and synthetic rubber seal with refrigerant oil.
Split System Models 7.
Split System Models Table 26 Horizontal air discharge cabinet and floor planning dimensional data Model Numbers 60 Hz 50 Hz PFC042A-_L PFC041A-_L PFH042A-_L — PFC042A-_H PFC041A-_H PFH042A-_H — PFCZ42A-_L PFCZ41A-_L PFC067A-_L PFC066A-_L PFH067A-_L — Table 27 Dimensional Data in.
Split System Models Figure 33 Outdoor air-cooled condensing unit—top air discharge models Guard Height Top Air Discharge D Right Air Discharge UNIT DIMENSIONS (see Table 28) B Shaded area indicates a minimum clearance of 18" (457mm) for proper air flow Left Air Intake 2" (51mm) A C Shaded area indicates a minimum clearance of 18" (457mm) for proper air flow Shaded area indicates a minimum clearance of 24" (610mm) for component access and removal Removable (Front) Panel for access to high-voltage
Split System Models Table 28 Cabinet and floor planning dimensional data - prop fan condensing modules, top air discharge Model Numbers 60 Hz 50 Hz PFC067A-_H PFC066A-_H PFH067A-_H — PFCZ67A-_L PFCZ66A-_L Table 29 Dimensional Data in.
Split System Models Figure 34 Electrical field connections, prop fan condensing module Field-supplied unit disconnect switch TOP AIR DISCHARGE MODELS (5-Ton High Ambient & 5-Ton Quiet-Line) HORIZONTAL AIR DISCHARGE MODELS Field-supplied 24V NEC Class 2 wiring to evaporator module Single- or 3-phase electric service; not by Liebert SL-11081 Pg.
Split System Models 7.5 Centrifugal Air-Cooled Condensing Units 7.5.1 Installing the Indoor Condensing Unit Refer to drawings for unit dimensions and component locations. ! WARNING Risk of ceiling collapse and heavy unit falling. Can cause equipment and building damage, serious injury or death. Verify that the supporting roof structure is capable of supporting the weight of the unit(s) and the accessories during installation and service. (See Table 30 - Indoor centrifugal condensing unit.
Split System Models Figure 35 Detail of ceiling hanging bracket 3/8" threaded rod (field-supplied) 3/8" hex nut 3/8" washer Sleeve Isolator 3/8" fender washer 3/8" hex nut 3/8" hex nut Nylock 7.5.2 Unit base pan (ref) Ducting The total external static pressure for the inlet and outlet ducts, including grille, must not exceed 0.5 inches of H2O. Hood intake dimensions should be the same as the condensing unit duct dimensions.
Split System Models Figure 36 3-ton centrifugal air-cooled condensing unit dimensional data & piping connections 50-1/4" (1276mm) Overall Dimension Customer-supplied threaded rods for module support from ceiling (typ.
Split System Models Figure 37 3-ton centrifugal air-cooled condensing unit (con’t.
Split System Models Figure 38 5-ton centrifugal air-cooled condensing unit dimensional data 32" (812.8mm) Cabinet Dimension 54" (1371.6mm) 1-5/8" Cabinet (41.1mm) Dimension 48" (1219.2mm) Customer-supplied threaded rods for module support from ceiling (typ. 4) 15-3/4" (400mm) 8-15/16" (227mm) 3-3/8" (85.7mm) 14-1/2" (368.3mm) 24" (610mm) Cabinet Dimension 21-1/4" (539.8mm) 1-3/4" (44.5mm) 33-5/8" (854.1mm) Threaded Rod Centers 1/2" (12.7mm) dia. holes for threaded rods (typ.
Split System Models Figure 39 5-ton centrifugal air-cooled condensing unit dimensional data (con’t.
Split System Models Figure 40 Split systems general arrangement Hot-Gas Bypass Solenoid Valve Liquid Injection Valve Bulb AIR COOLED Service Access Ports External Equalizer Filter Dryer Expansion Valve 1/2" (12.
Split System Models 7.6 Water and Glycol-Cooled Condensing Units For installation guidelines, refer to Installing the Indoor Condensing Unit on page 67. 7.6.1 Piping Considerations It is recommended that manual service shutoff valves be installed at the supply and return line to each unit. This will provide for routine service or emergency isolation of the unit. When the water source for the condenser is of poor quality, it is good practice to provide cleanable filters in the supply line.
Split System Models 7.6.4 Glycol Systems For split system glycol systems, use drycooler and pump data found in 5.0 - Glycol/GLYCOOLCooled Models—Self-Contained Compressor. See Table 18 - Drycooler data. Electrical control interconnect to drycooler is wired from water/glycol condensing unit.
Split System Models Figure 42 3-ton water/glycol-cooled condensing unit (con’t.
Split System Models Figure 43 5-ton water/glycol-cooled condensing unit dimensional data 32" (812.8mm) Cabinet Dimension 32" (812.8mm) Cabinet Dimension Customer-supplied threaded rods for module support from ceiling (typ. 4). Removable Access Panel 1/2" (12.7mm) dia. holes for module rigging (typ. 2 each end) 24 " (610mm) Cabinet Dimension Hanger Bracket 33-5/8" Shaded area indicates a 29-13/16 " (854.1mm) recommended clearance of (757.
Split System Models Figure 44 5-ton water/glycol-cooled condensing unit (con’t.) Field-supplied unit disconnect switch when factory unit disconnect switch is not suplied Electric service; not by Liebert 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) Line voltage electric power supply conduit voltage Removable Access Panel Heat rejection connection.
R407C Refrigerant 8.0 R407C REFRIGERANT 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 kPa °F °C Psig kPa °F °C Psig kPa 0.0 -17.8 18.9 130 35.0 1.7 54.8 378 70.0 21.1 114.9 792 1.0 -17.2 19.6 135 36.0 2.2 56.1 387 72.0 22.2 119.3 822 2.0 -16.7 20.4 141 37.0 2.8 57.5 396 74.0 23.3 124 853 3.0 -16.
R407C Refrigerant Table 34 R407C pressure/temperature chart for subcooling only (liquid measurements) Temperature Pressure Gauge Temperature Pressure Gauge Temperature Pressure Gauge °F °C Psig kPa °F °C Psig kPa °F °C Psig kPa 36.0 2.2 73 500 59.0 15.0 114 786 94.0 34.4 203 1402 37.0 2.8 74 511 60.0 15.6 116 801 96.0 35.6 209 1444 38.0 3.3 76 522 61.0 16.1 118 815 98.0 36.7 216 1488 39.0 3.9 77 533 62.0 16.7 120 830 100.0 37.
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