Manuale d’uso / di manutenzione del prodotto 3000 del fabbricante Emerson
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Precision Cooling For Business -Critic al C ontinuity™ Li eber t C ha l leng er ™ 3000 with iC OM Install atio n Manu al - 3 & 5 T ons, 50 & 60Hz.
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i T ABLE OF CONTENTS I MPORT ANT S AFETY I NSTRUCTION S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.0 I NTRODUCTI ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ii 5.0 G LYCOL /GL YCOOL-C OOLED M ODELS —S ELF -C ONTA INED C OMPRESSOR . . . . . . . . . . . . 41 5.1 Drycooler Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 5.2 Drycooler Installation .
iii FIGURES Figure 1 Removing Challenger from skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Figure 2 Upflow (BU) cabinet dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . .
iv TA B L E S Table 1 Unit net weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Table 2 Piping connection size . . . . . . . . . . . . . . . . . . . . . . . . .
1 I MPORT A NT S AFETY I NSTRUCTIONS SAVE THESE INSTRUCTIONS This manual co ntains important safe ty instructions that sh ould be followe d during the installa tion and maintenance of the Liebert Challenger 3000 ™ . Read this manual thorough ly before attempting to install or opera te this unit.
2 NOTICE Risk of leaking water. Can cause equi pment and building damage. This unit requires a water drain connection. It may also require an external water supply to operate. Improper installati on, application and serv ice practice can result in water leakage from th e unit.
Introd uction 3 1.0 I NTRODUCTION 1.1 System Descriptions Challenger 30 00 ™ environmental control systems are availabl e in three main system configurations: • self-contained system with a scro l.
Introd uction 4 1.1.3 Split Sy stems Each air-cooled spli t system consists of an evaporator sect ion and one of the fo llowing condensing units. Prop Fan Air-Cooled Prop Fan units include s croll compressor, condenser coil, prop fan, high pressure switch, hot gas bypass and Liebert Lee-Temp head pressure cont rol.
Installation (Applicab le to all Models) 5 2.0 I NST ALLATION (A PPLICABLE TO ALL M ODELS ) 2.1 Room Prep aration The room should be well insulate d and must have a sealed v apor barrier. The vapor barrier in the ceiling can be a polyethylene fi lm type.
Installation (Applicab le to all Models) 6 2.4.1 Handling With Skid • Always keep the unit upright, in doors and protected from damage. • If possible, transport the unit usin g a fork lift; otherw ise, use a crane with belts or cables, av oid- ing pressing on the top edges of the packaging.
Installation (Applicab le to all Models) 7 Figure 2 Up flow (BU) cabinet dimens ions A S haded area indi c at es a rec om m ended c l earanc e of 34" (864mm ) f or c om ponent ac c es s . R i ght s i de ac c es s s ugges t ed f or G L Y C OO L unit s .
Installation (Applicab le to all Models) 8 Figure 3 Downflow (BF) cabinet dimensions Shad ed area indic ates a recommended c learance of 34” (864mm) f or component access.
Installation (Applicab le to all Models) 9 2.5 Piping Considerations All piping below the elevated floor must be located so that it offe rs the leas t resistance to air flow. Careful planning of the piping layout und er the rais ed floor is required to prevent the air flow from being blocked.
Installation (Applicab le to all Models) 10 Figure 4 Piping connections for air- cooled units - Downflow models PIPI NG OU TL ET L OCA TIO NS (See Cabi net and Floor Planning Dimensional D ata for Piping Opening Si zes.) Liebert iCOM Control Panel Condensate Drain 3/4" FP T Field-pitch a mini mum of 1/8" (3.
Installation (Applicab le to all Models) 11 Figure 5 Piping connections for ai r-cooled unit s - Upflow models Condensat e Drain 3/ 4" F P T F ield pit ch a min. of 1/ 8" ( 3. 2mm ) per f t . (305m m) . Unit s wit hout a condens at e pump hav e a f act or y- supplied t rap in t he unit , s o a f ield t rap s hould not be added.
Installation (Applicab le to all Models) 12 Figure 6 Piping connections for sp lit system fan coil unit s - Downflow models PI PI N G OUTL E T LOCA TI ONS ( S ee Cabinet and F l oor P lanning Dimens ional Dat a f or P iping O peni ng S iz es . ) DP N000376 Re v .
Installation (Applicab le to all Models) 13 Figure 7 Piping connections for split s ystem fan coil unit s - Upflow models DPN 000375 Rev . 01 Pipi ng outlet locations through the plenum are the same as the unit. See below for desc riptions and connection siz es.
Installation (Applicab le to all Models) 14 Figure 8 Piping connections for wate r/glyc ol and GL YCOOL unit s - Downflow models DP N000364 Rev . 01 Condensate Drain 3/4" FP T Field pi tch a minimum of 1/8" (3.
Installation (Applicab le to all Models) 15 Figure 9 Piping connections for wate r/glyc ol and GL YCOOL unit s - Up flow models PIPING OUTLET LOCA TIONS (See Cabinet and Floor Planning Dimensional Data for Piping Opening Sizes.) Piping outlet locations through the plenum the same as the unit.
Installation (Applicab le to all Models) 16 Figure 10 Piping connections for chilled wate r self-contained unit s - Downflow models PIPING OUTLET LOCA TIONS (See Cabinet and Floor Planning Dimensional Data for Piping Opening Sizes.) Condensate Drain 3/4" FPT Field pitch a minimum of 1/8" (3.
Installation (Applicab le to all Models) 17 Figure 1 1 Piping connections for chilled wate r self-contained unit s - Upflow models Cond ensate D rain 3/ 4" FP T Field-pitch a min. of 1/8" ( 3.2mm) per ft. (305mm ). Units without a condensa te pump h ave a factory- suppli ed tra p in the unit, so a field trap shou ld not be ad ded.
Installation (Applicab le to all Models) 18 2.5.2 Humidifier Supply W ater—Optional Infrared • 1/4" supply l ine; maximum water pressure is 150 psi (1034kPa) • Size humidifie r supply line for 1 gpm (3.8 l/m), with a minimum water pressure of 20 psi (1 38kPa) • Do not supply de-ionized water to the humidifier 2.
Installation (Applicab le to all Models) 19 Figure 12 Electrical connections 1. Electric conduit knockouts on top and bottom of electric bo x. Knockout size 1-3/4" (44.5mm). 2. Three-phase connec tion . Electric service connection termin als when fa ctory disconnect is NOT supplied.
Installation (Applicab le to all Models) 20 15. Heat rejection connection . Field-suppl ied 24V Class 1 wiring to interlock heat rejection from pigtails 70 + 71 which are factory -connected to co mpressor side switch (s elf-con tained units only) or to GLYCOOL relay (K11, GLY COOL units only).
Installation (Applicab le to all Models) 21 2.8 Balancing the Air Distribution 2.8.1 Under-Floor Discharge Systems The systems are designed for consta nt air delivery, therefore any unusual restrictions within the air circuit must be avoided.
Installation (Applicab le to all Models) 22 2.9 Checklist for Completed Inst allation ___ 1. Unpack and check received material. ___ 2. Proper clearance for service access has been maintained around the equipment. ___ 3. Equipment is level and mountin g fasteners are tight.
Air-Cooled Models—Sel f-Contained Compressor 23 3.0 A IR -C OOLED M ODELS —S ELF -C ON T AINED C OMPRESSOR 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 area s that contribute to heav y snow or ice accumula- tions.
Air-Cooled Models—Sel f-Contained Compressor 24 Figure 14 Air-cooled condensers T able 4 Air-cooled condenser st atistics Model Number of Fans Connection Sizes (OD Copper) Net Weight lb (kg) “A” Dimension in (mm) Hot Gas (in.) Liquid (in.) 083 1 7/8 5/8 295 (133.
Air-Cooled Models—Sel f-Contained Compressor 25 3.3 Refrigerant Piping All refrigeration pip ing should be installed with high temperature brazed joi nts. Prevailing good refrigeration pr actices should be employed for piping supports, le ak testing, dehydra tion and charg- ing of the refrigeration circuits.
Air-Cooled Models—Sel f-Contained Compressor 26 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).
Air-Cooled Models—Sel f-Contained Compressor 27 V ariable Fan S peed Control Materials Supplied •B u i l t - i n , p r e - w i r e d condenser control box • Air-Cooled con denser • Piping acce.
Air-Cooled Models—Sel f-Contained Compressor 28 V ariable Fan S peed Charging 1. Check un it nameplate for refriger ant type to be used. Unit contro l configurations dif fer depending on refrigerant type. 2. Refrigerant chargin g requires unit operatio n.
Air-Cooled Models—Sel f-Contained Compressor 29 Figure 15 General arrangement—Air -cooled models with fan speed co ntrol DP N000349 Rev . 3 Condenser Coil Schrader Va l v e Fusi ble Plu g Evaporator Coil Hot G as Bypas s Va l v e T raps* every 25 ft.
Air-Cooled Models—Sel f-Contained Compressor 30 Figure 16 General arrangement—Air -cooled models with digit al scroll and fan speed control Inve rted Trap * o n discharge line to extend above ba se of coil by a minimum of 7-1/2" (190mm) Condenser Coil Schr ade r Va l v e Fusi ble Plug T raps* every 25 ft.
Air-Cooled Models—Sel f-Contained Compressor 31 3.5 Air-Cooled Condenser with Lieber t Lee-T emp “Flooded Condenser” Head Pressure Control System The Liebert Lee-Temp system consis ts of a modulating type head pressure control v alve and insulated receivers with heater pa ds to ensure operation at ambient temperatures as low as -30°F ( -34.
Air-Cooled Models—Sel f-Contained Compressor 32 6. Aft er four hours, check the pres sure 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.
Air-Cooled Models—Sel f-Contained Compressor 33 Figure 17 General arrangement—Air -cooled models with Liebert Lee-T emp * C omponents are not supplied by Li ebert but ar e recommended for proper circui t operation and maintenance. * * Components suppli ed by Liebert and must be fi eld instal led.
Air-Cooled Models—Sel f-Contained Compressor 34 Figure 18 General arrangement—Air -cooled models with digit al scroll and Lee-T emp Digital Sole noid V al ve DPN 001725 Rev . 0 * Components are not s upplied by Liebert but are recommended for proper circuit operation and maintenanc e.
Water-Cooled Models—Sel f-Contained Compressor 35 4.0 W ATER -C OOLED M ODELS —S ELF -C ONT AINED C OMPRESSOR 4.1 Piping Considerations Manual shutoff valves should be installed at the supply and return li nes of each unit. This will pro- vide for routine maintenance or emergency isolation of the unit.
Water-Cooled Models—Sel f-Contained Compressor 36 Figure 19 General arrangement—W ater-cooled models with scr oll compressor Field-Supplied Reduce rs Requi red on 3-T on Units DPN0003 59 REV 02 Ev.
Water-Cooled Models—Sel f-Contained Compressor 37 Figure 20 General arrangement diagram—W a ter-coole d models with digital scroll D P N 001727 Re v .
Water-Cooled Models—Sel f-Contained Compressor 38 4.3 W ater Regulating V alve The water regulating valve automati cally regulates the a mount of flui d necessary to remove the heat from the refrigeration system, permitting more flui d to flow when load conditions are high and less fluid to flow when load conditions are low.
Water-Cooled Models—Sel f-Contained Compressor 39 Figure 22 Metrex V alve adjustment Manual Flushing The valve may be flushed by rotating the socket head screw clockwise. T h is s c r e w m u s t b e in t h e O U T position (counterclockwise) for normal valve operation.
Water-Cooled Models—Sel f-Contained Compressor 40 4.4.2 Adjustment Both pressure thresholds can be shifted simultaneously over a 50psi ( 345kPa) range (the 35psi [241kPa] differenti al remains constant).
Glycol/GL YCOOL-Cooled Mode ls —Self-Contained Compressor 41 5.0 G LYCOL /GL YCOOL-C OOLED M ODELS —S ELF -C ONT A INED C OMPRES SOR 5.1 Drycooler Location The drycooler shou ld be located for maximum secu rity and maintenance acce ssibility.
Glycol/GL YCOOL-Cooled Mode ls —Self-Contained Compressor 42 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 resul t from improper piping insta llation, leak check- ing, fluid chemistry and fluid maintenance.
Glycol/GL YCOOL-Cooled Mode ls —Self-Contained Compressor 43 NOTICE Risk of debri s or precipitate clogg ing pipes. Can cau se equipment damage. Galvanized pipe mu st not be used in or wi th systems or units that contain glycol.
Glycol/GL YCOOL-Cooled Mode ls —Self-Contained Compressor 44 5.4.1 Exp ansion T anks, Fluid Relief V alves and Other Devices An expansion tank must be provided for expansion and contraction of the fluid due to temperature change in this closed system.
Glycol/GL YCOOL-Cooled Mode ls —Self-Contained Compressor 45 5.5.2 Glycol Solutions When considering the use of any glycol products in a particular application, you should rev iew the lat- est Material Safety Data Sheets an d ensure that the use you intend can be accomplished safely.
Glycol/GL YCOOL-Cooled Mode ls —Self-Contained Compressor 46 NOTICE Risk of corrosion from water impu rities. Can cause equipment damage. The quality of water used for dilutio n must be considered because water may contain corrosive elements which reduce the effectiveness of the inhibite d fo rmulation.
Glycol/GL YCOOL-Cooled Mode ls —Self-Contained Compressor 47 Figure 23 Drycoolers and pump pa ckages Notes 1. Single pump packages are 17-1/4" (438 mm) wide. Dual pump p ackages ar 32-1/4" (819 mm) wide. 2. Mounting holes are 15-1/4" ( 387 mm) apart on single pump pa ckages and 30- 1/4" (768 mm) apa rt on dual pump packages.
Glycol/GL YCOOL-Cooled Mode ls —Self-Contained Compressor 48 Figure 24 Pump p ackages—exp ansion tank T able 17 Mounting hole dimensional dat a PUMP PACKAGE A in (mm ) B in (mm) C in (mm) SINGLE (0.75 - 7.5 Hp) 15-1/4 (387.4) 2-1/2 (63.5) 22-1/2 (571.
Glycol/GL YCOOL-Cooled Mode ls —Self-Contained Compressor 49 Figure 25 General arrangement—Glycol-c ooled models with scroll compressor Glycol Pump Pum p Housing Unions* Isolation V alves* Expans .
Glycol/GL YCOOL-Cooled Mode ls —Self-Contained Compressor 50 Figure 26 General arrangement—Glycol-cooled mode ls with digit a l scroll Digital Solenoi d Va l v e Glycol Pump Housing Unions* Isolat.
Glycol/GL YCOOL-Cooled Mode ls —Self-Contained Compressor 51 Figure 27 General arrangement—GL YC OOL models with scroll compressor Field-S upplied Reducers Required on 3-Ton Units Pum p Housi ng P.
Glycol/GL YCOOL-Cooled Mode ls —Self-Contained Compressor 52 Figure 28 General arrangement—GL YCOOL models with digita l scroll compressor r Di gi t a l S olenoi d Va l v e Pu m p H ous ing G l yc.
Glycol/GL YCOOL-Cooled Mode ls —Self-Contained Compressor 53 5.5.4 Motor Ball V alve—Digit al Scroll Compressors Refer to 4.4 - Motorized Ball Valv e—Digital Scroll Compressors for details on the motorized ball valve. 5.6 Condenser The condenser is designed to operate in conjuncti on with a dry cooler.
Chilled Wa ter Models 54 6.0 C HILLED W ATER M ODELS 6.1 Piping Considerations Manual shut-off valves should be install ed at the supply and return lines to each unit.
Chilled Wa ter Models 55 Figure 30 Chilled water general arrangement - Downflow (BF) mode ls SL-11899 Pg. 6 A B Flow Switch (optional) Chilled Wat er Retu rn Chilled Water Supply Chilled Wat er Retu r.
Split System Models 56 7.0 S PLIT S YSTEM M ODELS Three condensing unit styles are available: two ai r-cooled and one wate r/gl ycol-coole d condensi ng unit.
Split System Models 57 7.2.2 Low V oltage The control cable between the cond ensing unit and the evaporator unit is connecte d between termi- nals 1,2 and 3 on the terminal strip in the evapo rat or unit and the condensing unit control box. A fourth wire is requ ired on systems with hot gas bypass.
Split System Models 58 Refrigerant charge requirements: Total refrigerant char ge wi ll be required only if units ar e evacuated during installat ion or maintenance. Total refrig er ant charge = evaporator + lines + conden sing unit. Once all piping is comp lete, check for leaks and dehydrate the field pi ping as follows: 1.
Split System Models 59 Figure 31 Refrigerant p iping diagram 7.3.2 Quick Connect Fittings Be especially careful wh en connecting the quick connect fitting s. Read through the following steps before making the connectio ns. 1. Remove protector caps and p lugs.
Split System Models 60 7.4 Out door Air-Cool ed Condensing Unit s Figure 32 Out door air-cooled condensing unit—horizon t al air discharge models A B C Shad ed area indi cates a minimum cl earance o.
Split System Models 61 T able 26 Horizonta l air discharge cabi net and floor planning dimensional dat a Model Numbers Dimensional Data in. (mm) Module Weight lb (kg) net 60 Hz 50 Hz A B C PFC042A-_L .
Split System Models 62 Figure 33 Out door air-cooled conde nsing unit—top air disch arge models C A 2" (51mm) B D 36-1/8" (918mm) 25-3/32" (637mm) 46-7/32" (1174mm) 4-23/32 " (120mm) 53-3/16" (1351mm) 4" (ty p.) (102mm) 2" (typ.
Split System Models 63 T able 28 Cabinet and floor planning dimension al dat a - prop fan condensin g modules, top air discha rge Model Numbers Dimensional Data in.
Split System Models 64 Figure 34 Electrical field connect ions, prop fan condensing module NOTE: Refer to specifi cation sheet for full load amp and wire size amp ratings SL-1 1081 Pg. 8 Factory-wired to components on electric panel. Heat rejection connection.
Split System Models 65 7.5 Centrifugal Air-Cool ed Condensing Unit s 7.5.1 Inst alling the Indoor Condensing Unit Refer to drawings for unit dime nsions and component locations. The indoor condensing unit is usual ly mounted abov e the ceiling and must be securely mounted to t he roof structure.
Split System Models 66 Figure 35 Det ail of ceiling hanging bracket 7.5.2 Ducting The total external static pressure for the inlet an d outlet ducts, including grille, must not exceed 0.5 inches of H 2 O. Hood intake dimensions should be the same as t he condensing unit d uct dimen- sions.
Split System Models 67 Figure 36 3-ton centrifugal air-cooled conde nsing unit dimensional dat a & piping connections C D B A Customer- supplied threaded rods for module supp ort from ceiling ( typ.
Split System Models 68 Figure 37 3-ton centrifugal air-coole d condensing unit (con't.) DP N000207 Rev0 Si ngle- or three-phase electri c service not by Li ebert Optional fac tory-installed disco.
Split System Models 69 Figure 38 5-ton centrifugal air-coole d condensing unit dimensional dat a SL-1 1087 Pg. 4 24" (610mm) Cabinet Dimens ion 32" (812.8mm) Cabinet Dimens ion 3-3/8" (85.7mm) 14-1/2" (368.3mm) 8-15/16" (227mm) 15-3/4" (400mm) 1-5/8" (41.
Split System Models 70 Figure 39 5-ton centrifugal air-cooled conde nsing unit dimensional dat a (con't.) DPN000226_Rev0 Fiel d-Suppl ied Uni t Di sconnec t Switch whe n F actor y Unit Dis connec.
Split System Models 71 Figure 40 Split sys tems general arrang ement Conden ser Coil 1/2" (1 2.7mm) NP T Pressure Re lief V alve Pressure Balancing Va l v e Sigh t Glass Check Va l v e Lee- T emp.
Split System Models 72 7.6 W ater and Glycol-Cooled Con densing Unit s For installation gu idelines, refer to Installing the Indoor Condensing Unit on page 65. 7.6.1 Piping Considerations It is recommended that manual serv ice shut-off va lves be installed at the supply and return line to each unit.
Split System Models 73 7.6.4 Glycol Systems For split system glycol syst ems, use drycooler and pump data found in 5.0 - Glycol/GLYCOOL- Cooled Models—Self-Contained Compressor . See Table 18 - Drycooler data . Electrical control interconnect to drycooler is wired from water/glycol condensing unit.
Split System Models 74 Figure 42 3-ton water/g lycol-cooled condensing unit (con't .) DPN 000209_R ev0 Singl e- or three-phase electric service not by Liebert Field-suppli ed unit disconnect swit.
Split System Models 75 Figure 43 5-ton water/gly col-cooled condensing unit dimensional da t a 7/8" (22.2mm) & 1-1/8" (28.6mm) dia. knockouts electrical entrance for line voltage connection (S ingle Point Power Kit) Removable Acce ss Pan el 1/2" (12.
Split System Models 76 Figure 44 5-ton water/g lycol-cooled condensing unit (con't .) DPN000228_Rev0 Field-supplied uni t disconnect switch when factory unit disconnect switch i s not suplied Ele.
R407C Refrigera nt 77 8.0 R407C R EFRIGERANT T able 33 R407C pressure/temperature chart for oper ation and superheat (discharge/hot gas and suction gas) Temperature Gauge Pressure Temperature Gauge Pr essure Temperature Gauge Pressure °F °C Psig kPa °F °C Psig kPa ° F °C Psig kPa 0.
R407C Refrigera nt 78 8.1 Calculating Subcooling Example Measure the liquid pressure (e.g., 200 psig). Find the liquid saturation temperature at that pressure on Table 34 (e.g., 93°F). Measure the temperature of the li quid line (e.g., 90°F). Subtract the actual temperature from the liquid saturati on temperatur e to obtain the subc ooling (e.
R407C Refrigera nt 79 NOTES.
R407C Refrigera nt 80.
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Un punto importante, dopo l’acquisto del dispositivo (o anche prima di acquisto) è quello di leggere il manuale. Dobbiamo farlo per diversi motivi semplici:
Se non hai ancora comprato il Emerson 3000 è un buon momento per familiarizzare con i dati di base del prodotto. Prime consultare le pagine iniziali del manuale d’uso, che si trova al di sopra. Dovresti trovare lì i dati tecnici più importanti del Emerson 3000 - in questo modo è possibile verificare se l’apparecchio soddisfa le tue esigenze. Esplorando le pagine segenti del manuali d’uso Emerson 3000 imparerai tutte le caratteristiche del prodotto e le informazioni sul suo funzionamento. Le informazioni sul Emerson 3000 ti aiuteranno sicuramente a prendere una decisione relativa all’acquisto.
In una situazione in cui hai già il Emerson 3000, ma non hai ancora letto il manuale d’uso, dovresti farlo per le ragioni sopra descritte. Saprai quindi se hai correttamente usato le funzioni disponibili, e se hai commesso errori che possono ridurre la durata di vita del Emerson 3000.
Tuttavia, uno dei ruoli più importanti per l’utente svolti dal manuale d’uso è quello di aiutare a risolvere i problemi con il Emerson 3000. Quasi sempre, ci troverai Troubleshooting, cioè i guasti più frequenti e malfunzionamenti del dispositivo Emerson 3000 insieme con le istruzioni su come risolverli. Anche se non si riesci a risolvere il problema, il manuale d’uso ti mostrerà il percorso di ulteriori procedimenti – il contatto con il centro servizio clienti o il servizio più vicino.
