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Precision Cooling
For Business-Critical Continuity™
® ™ ®
Liebert Challenger 3000 with Liebert iCOM
Installation Manual - 3 & 5 Tons, 50 & 60Hz
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TABLE OF CONTENTS IMPORTANT SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 SAVE THESE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 1.0 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 1.1 System Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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4.3 Water Regulating Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 4.3.1 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) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 4.3.2 High Pressure Valve - 350 psig (2413 kPa) System
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7.4 Outdoor Air-Cooled Condensing Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 7.5 Centrifugal Air-Cooled Condensing Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 7.5.1 Installing the Indoor Condensing Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 7.5.2 Ducting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Figure 36 3-ton centrifugal air-cooled condensing unit dimensional data & piping connections . . . . . . . . . 69 Figure 37 3-ton centrifugal air-cooled condensing unit (con’t.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Figure 38 5-ton centrifugal air-cooled condensing unit dimensional data . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Figure 39 5-ton centrifugal air-cooled condensing unit dimensional data (con’t.) . . . . . . . . . . . . . . . . . . .
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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 manu
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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. Do not operate upflow units without installing a plenum, duct
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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. ® ™ 3Liebert Challenger 3000
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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. Units are av
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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. Centrifugal Fan Air-Cooled Centrifugal Fan units include scroll compressor, condenser coil, centrifugal blower assembly, high-pressure switch, hot g
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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. Outside air adds to the heating, cooling, humidifying and dehumidifying l
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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. Refe
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Installation (Applicable to all Models) Figure 2 Upflow (BU) cabinet dimensions 32-1/2" A (826mm) UNIT 30-1/2" STD 3 & 5T 11-3/4 (299mm) TOP VIEW (775mm) Hi Static 3T 8-5/8 (219mm) A 9-5/8" 8-1/2" Hi Static 5T 11-3/4 (299mm) (244mm) (216mm) 10-1/4" 1-5/8" 13" (260mm) (41mm) (330mm) 30-1/2" (775mm) Standard Piping Location 32-1/2" 12-1/2" 1-7/8" (826mm) (318mm) (48mm) Projection of Display Bezel 5/8" (16mm) 5-1/2" (140mm) Standard Electrical Outlet 32-1/2" 32-1/2" Location Through Unit (826mm) (
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Installation (Applicable to all Models) Figure 3 Downflow (BF) cabinet dimensions 32-1/2" 32-1/2" Projection of Display (826mm) (826mm) Overall Bezel 5/8" (16mm) Overall Dimension Dimension 30-1/2" 30-1/2" (775mm) (775mm) Optional 1-5/8" (41mm) Flange for Duct or Plenum Connection 76" (1930mm) 1" (25mm) FRONT & SIDES 3/4" (19mm) REAR Shaded area indicates a recommended clearance of 34” (864mm) for component 1" access. Right side access (25.4mm) 1" 30-1/2" suggested for GLYCOOL units 30-1/2" (25.
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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
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Installation (Applicable to all Models) Table 2 Piping connection size (continued) Chilled Water Unit Connection Sizes—in. Model No. BF/BU Supply Line Return Line (50 Hz) CWS CWR 068C (072C) 1-1/8 1-1/8 102C (101C) 1-1/8 1-1/8 Figure 4 Piping connections for air-cooled units - Downflow models Liebert iCOM Control Panel Condensate Drain 3/4" FPT Liquid Refrigerant Line Field-pitch a minimum of 1/8" (3.2mm) 3/8" OD CU on Models BF042A/BF040A per foot (305mm). The drain line 1/2" OD CU on Models
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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. Hot Water Return Humidifier Water Supply Line 5/8" OD CU (optional) 1/4" OD CU Liquid Refrigerant Line Hot Gas Refrigerant Line 3/8" OD CU on Models BU042A/BU040A 5/8" OD CU on Models BU042A/BU040A 1/2" OD CU on Models BU067A/BU065A 7/8" OD CU on Models BU067A/BU065A Hot W
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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 Condensate Drain #6 Quick Connect on Models BF036E/BF035E 3/4" FPT 1/2" OD CU on Models BF060E/BF059E Field pitch a minimum of 1/8" (3.2mm) per ft. (305mm). Suction Refrigerant Line The drainline must comply #11 Quick Connect on Models
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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 Hot Water Return 1/4" OD CU 5/8" OD CU (optional) Suction Refrigerant Line Liquid Refrigerant Line #11 Quick Connect on Models BU036E/BU035E #6 Quick Connect on Models BU036E/BU035E 1 1/8" OD CU on Models BU060E/BU059E 1/2" OD CU on Mod
