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FIGURES Figure 1 Removing Challenger from skid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Figure 2 Upflow (BU) cabinet dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Figure 3 Downflow (BF) cabinet dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Figure 4 Piping connections for air cooled units . . . .
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TABLES Table 1 Unit net weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Table 2 Piping connection size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 2 2 Table 3 Recommended free area ft (m ) for grilles or perforated panels at output velocities of 550 and 600 fpm (2.8 and 3.1 m/s) . . . . . . . . . . . . . . . . . . . . . . . .
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Introduction 1.0 INTRODUCTION 1.1 System Descriptions ™ Challenger 3000 environmental control 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 avai
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Installation 2.0 INSTALLATION 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, cool- ing, humidifying and dehumidifying loads of the site. It is recommended that outside air
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Installation 2.4.2 Removal of Skid • Remove the plywood skirting that keeps the skid and unit in place. • Raise the Challenger 3000 off the skid. Liebert recommends using a fork lift (see Figure 1) or similar machine to ensure that the unit is lifted properly. • Once the unit is raised, the skid can be removed. Figure 1 Removing Challenger from skid Remove plywood skirting holding Raise unit with fork lift unit and skid in place. or similar machine. Table 1 Unit net weight Model Lbs (kg) 036E
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Installation Figure 2 Upflow (BU) cabinet dimensions 32 1/2" (826mm) A 30 1/2" (775mm) STD 3 & 5T 11-3/4 (299mm) A Hi Static 3T 8 5/8 (219mm) 8 1/2" 9 5/8" (216mm) (244mm) Hi Static 5T 11-3/4 (299mm) 10 1/4" 1 5/8" 13" (260mm) (41mm) (330mm) 30 1/2" (775mm) 32 1/2" Standard Piping Location (826mm) 12 1/2" 1 7/8" (318mm) (48mm) Projection of Display Bezel 5/8" (16mm) 5 1/2" (140mm) Standard Electrical Outlet Location Through Unit 32 1/2 " 32 1/2 " (826mm) (826mm) Overall Overall Dimension Dimen
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Installation Figure 3 Downflow (BF) cabinet dimensions 32 1/2 " 32 1/2 " (826mm) (826mm) Projection of Display Overall Overall Bezel 5/8" (16mm) 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 access. Right side access suggested for "GLYCOOL" units. 1 " (25.4mm) 1 " 30 1/2 " (25.4mm) (775mm) 30 1/2 "
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Installation 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. Condensate pumps for
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Installation Figure 4 Piping connections for air cooled units DOWNFLOW (BF) MODELS Monitoring Panel Condensate Drain, 3/4” FPT Liquid Refrigerant Line Field pitch minimum of 3/8" OD CU on Models BF042A/BF040A 1/8” (3.2mm) per foot (305mm). 1/2" OD CU on Models BF067A/BF065A The drain line must comply with Hot Gas Refrigerant Line all applicable codes 5/8" OD CU on Models BF042A/BF040A 7/8" OD CU on Models BF067A/BF065A Hot Wa ter Re tu rn 5/8" OD CU (optional) Hot Water Supply Humidifier Water S
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Installation Figure 5 Piping connections for split system fan coil units Piping outlet locations through the plenum are the same as the unit. See below for UPFLOW (BU) MODELS descriptions and connection sizes. Hu mi difier Wa ter S upply Line Hot Water Return 1/4" OD CU 5/8" OD CU (optional) Suction Refrigerant Line Liquid Refrigera nt 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 Models BU060E/BU059E C
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Installation Figure 6 Piping connections for water/glycol and GLYCOOL units DOWNFLOW (BF, BE) MODELS Monitoring Panel Condensate Drain 3/4” FPT Condenser S upply Line Field pitch a min. of 1/8" (3.2mm) per ft. (305mm). 7/8" OD CU on Models BF046WG/BF045WG The drain line must comply 1 1/8" OD CU on Models BF071WG/BF070WG with all applicable codes. Condenser Re turn Line 7/8" OD CU on Models BF046WG/BF045WG 1 1/8" OD CU on Models BF071WG/BF070WG Hot Wa ter Re tu rn 5/8" OD CU (optional) Hot Water
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Installation Figure 7 Piping connections for chilled water self-contained units Piping outlet locations through the plenum are the same as the unit. See below for descriptions and connectoin sizes UPFLOW (BU) MODELS Humidifier Water Supply Hot Water Return Line Line 1/4" OD CU 5/8" OD CU (optional) Condenser Re turn Line 7/8" OD CU on Models Condenser Supply Line BU046WG/BU045WG 7/8" OD CU on Models 1 1/8" OD CU on Models BU046WG/BU045WG BU071WG/BU070WG 1 1/8" OD CU on Models BU071WG/BU070WG
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Installation 11
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Precision Cooling
For Business-Critical Continuity
™
Liebert Challenger 3000
Installation Manual - 3 & 5 Tons, 50 & 60Hz
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TABLE OF CONTENTS 1.0 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 1.1 System Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.1.1 Self Contained Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.1.2 Chilled Water Models. . . . . . . . . . . . . . . . . . .
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5.2 Drycooler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 5.3 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 5.3.1 Line Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 5.3.2 Low Voltage . . . . . . . . . . . . . . . . . . . . . . . . . .
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Installation 2.6 Electrical Connections Three-phase electrical service is required for all models in either 208, 230, 460, or 575 V, 60 Hz; or 200, 230, or 380/415 V, 50 Hz. Electrical service shall conform to national and local electrical codes. Refer to equipment nameplate regarding wire size and circuit protection requirements. Refer to elec- trical schematic when making connections. A manual electrical disconnect switch should be installed within 5 feet (1.6 m) of the unit in accor- dance
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Installation 13. Smoke detector alarm connections. Field-supplied 24V. Class 1 wiring to remote alarm circuits. Factory-wired contacts from optional smoke detector are #91 -comm., #92-NO, and #93-NC. 14. Common alarm connection. Field-supplied 24V. Class 1 wiring to common alarm terminals 75 + 76 (and optional 94 + 95, and 96 + 97), which are factory connected to common alarm relay (R3). 15. Heat rejection connection. Field-supplied 24V Class 1 wiring to interlock heat rejection from pigtails
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Installation 2.7.2 Ducted Applications For ducted applications on units, the duct work may be attached to the top perimeter of the unit. Refer to Figure 2 for information on upflow units and to Figure 3 for downflow units. The duct work on upflow units must allow access to the motors/blowers for maintenance. The duct work on upflow units must be designed within the capacity of the unit, otherwise air flow and perfor- mance will be compromised. 2.7.3 Plenum Installation A solid plenum or plenum
