Liebert CHALLENGER 3000 user manual

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Precision Cooling
For Business-Critical Continuity
™
Liebert Challenger 3000
Operation & Maintenance Manual - 3 & 5 Ton, 50 & 60Hz

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TABLE OF CONTENTS 1.0 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 1.1 System Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.1.1 Compressorized Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.1.2 GLYCOOL™ (Chilled Glycol Cooling) Systems . . . . . . . . .

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3.7.1 Setup Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 3.7.2 Select Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 3.7.3 Calibrate Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 3.7.4 Calibrate Valve Actuator . . . . . . . . . . . . .

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4.4.2 Sequential Load Activation Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 4.5 Additional Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 4.5.1 Connecting the Analog Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 4.5.2 Water Detection Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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6.5 Humidifier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 6.5.1 Infrared Humidifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 6.5.2 Steam Generating Humidifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 7.0 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . .

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FIGURES Figure 1 Advanced microprocessor control panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Figure 2 Advanced microprocessor (A) control for Challenger 3000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Figure 3 Advanced microprocessor with graphics (G) control panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Figure 4 Advanced microprocessor with graphics control menu. . . . . . . . . . . . . . . .

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Introduction 1.0 INTRODUCTION 1.1 System Descriptions ™ Challenger 3000 Liebert environmental control systems are available in several configurations. Each configuration can operate with either Advanced Microprocessor Controls (A), or Advanced Microprocessor Controls with Graphics (G). A brief description of each, including operational differ- ences, are listed below. Check model numbers to see what is supplied with your unit. 1.1.1 Compressorized Systems NOTE Compressorized systems may be a s

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Introduction 1.2 Start-Up Procedure Before beginning start-up, make certain that unit was installed according to the instructions in the Installation Manual. 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. All exterior panels must be in place with the front panel open. Locate the start-up form supplied with your unit documents. Complete the form during your start-u

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Operation with Advanced Microprocessor Controls 2.0 OPERATION WITH ADVANCED MICROPROCESSOR CONTROLS The advanced microprocessor (A) control for your Liebert Challenger 3000 unit features an easy-to- use menu driven LCD display. The menus, control features, and circuit board details are described in this section. For more control details, refer to 4.0 - System Performance with Advanced Micro- processor Controls, and for more alarm information, refer to 5.0 - Alarm Descriptions. 2.1 Basics Contro

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Operation with Advanced Microprocessor Controls Figure 2 Advanced microprocessor (A) control for Challenger 3000 Main Menu 72°F 50%RH Normal Display Status/Alarm Data Cooling Setpoints/Setup Dehumidifying Date and Time No Alarms Present Status Display Status Alarm Data Setpoints/Setup Date and Time Status Display View Setpoints Active Alarms 15-APR-2004 09:30:00 75°F 59%RH Setup System Operating Status Cooling Run Diagnostics Alarm History Log ENTER to change Dehumidifying Change Passwords Run

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Operation with Advanced Microprocessor Controls 2.2 Status Display The display normally shown includes the present room temperature, humidity, active status func- tions (cooling, heating, dehumidifying, humidifying), and active alarms. If no keys are pressed within 5 minutes, the system automatically returns to the Status Display. The Status Display may also be selected from the Main Menu. 2.3 Main Menu

Press the MENU/ESC key to display the Main Menu. The Menu selections include: •

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Operation with Advanced Microprocessor Controls 2.4.4 Run Hours Log The total operating hours of all major components in the unit can be monitored from the display and are retained in nonvolatile memory. Run times are available for the following: • Compressor • GLYCOOL Coil (or CW Coil as used on Dual Cooling Unit) •Fan • (HUM) humidifier • (RH1) reheat 1 (or Hot Water or SCR Reheat) • (RH2) reheat 2 The component run hours for each individual component can be reset by selecting the run hours d

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Operation with Advanced Microprocessor Controls 2.5.2 Setup System The Setup System menu includes the following selections: • SETUP OPERATION • SELECT OPTIONS • CALIBRATE SENSORS • SHOW DIP SWITCHES • SELECT CONTROL TYPE (Chilled Water or SCR Reheats only) • SETUP ALARMS • HUM CONTROL METHOD • ANALOG SETUP • SET STATUS DISPLAY • CALIBRATE ACTUATOR Setup Operation The Setup Operation menu permits the review and/or adjustment of the unit configuration. This may include: Cold Start—This feature, a

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Operation with Advanced Microprocessor Controls Table 2 lists the setup functions, their factory default values and the allowable programming ranges. Table 2 Setup functions, default values and ranges Function Default Range Cold Start Time Delay* 3 0 to 3 min (0 = no delay) Restart Time Delay 0.1 0 to 9.9 min (0 = manual restart) Infrared Fill Rate 150 110 to 500% Chilled/Hot Water Coil Flush 24 0 to 99 hrs (also Econ-O-Coil) C/F Degrees F C or F *Factory set to 0 for water cooled, glycol, and G

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Operation with Advanced Microprocessor Controls Select Control Type • Intelligent (Chilled Water only) • Proportional (all unit types) • Tunable PID (Chilled Water or SCR Reheats only) The type of system control method used by the microprocessor can be selected from the front panel. The default setting is Intelligent, which approximates the actions that a human operator would take to maintain precise, stable control. The control logic uses Artificial Intelligence techniques including “fuzzy

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Operation with Advanced Microprocessor Controls Enable Alarms—Each individual alarm can be selected to be ENABLED (annunciated audibly, visu- ally, and communicated to a Site Products System) or DISABLED (ignored). Enable Common Alarm—Each individual alarm can be selected to energize or to not energize the common alarm relay. If the energize common alarm function is set to YES, the relay is energized immediately as the alarm is annunciated and de-energized when the alarm condition goes away (o

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Operation with Advanced Microprocessor Controls Analog Setup For installation of analog sensors, see 4.5.1 - Connecting the Analog Sensors. After selecting a compatible sensor and properly wiring it to the terminals, set up the control to mon- itor the sensor as follows: Slope—The slope is a multiplier used to scale the input signal. The slope can be positive (rising) or negative (falling) and can range from 0 (resulting in a horizontal line) to ±999. The slope for a 0-5 volt input is per 1 vo

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Operation with Advanced Microprocessor Controls 2.5.3 Run Diagnostics By selecting Run Diagnostics, maintenance personnel can check system inputs, outputs, and complete a test of the microcontroller circuit board, all from the front panel. Review of the system inputs and the microcontroller test can be done without interrupting normal operation. To test the system out- puts, the normal system control is temporarily suspended. DO NOT leave the unit in the diagnostics mode any longer than is ne