User ManualTable of ContentsCover1Essential Instructions2Table of Contents5List of Illustrations6Preface7Safety8SECTION 1 DESCRIPTION9COMPONENT CHECKLIST OF TYPICAL SYSTEM (PACKAGE CONTENTS)9OVERVIEW9Scope9System Description9System Configuration10Features10Handling the Oxygen Analyzer11System Considerations11SECTION 2 INSTALLATION13OXYGEN ANALYZER (PROBE) INSTALLATION13Selecting Location13Mechanical Installation13Service Required19HEATER POWER SUPPLY INSTALLATION21Mechanical Installation21Electrical Connections21SECTION 3 SETUP25OVERVIEW25MODELS 218, 225, AND 132 (ANALOG) ELECTRONICS SETUP25MODEL 218A ELECTRONICS SETUP26MODEL TC200 VERITRIM ELECTRONICS SETUP27EPROM Replacement27Heater Set Point Adjustment27MODEL 132 DIGITAL ELECTRONICS SETUP28SECTION 4 TROUBLESHOOTING29OVERVIEW29SYSTEM TROUBLESHOOTING29World Class 3000 Probe29HPS 3000 Heater Power Supply29Model 218 and 225 (Analog) Electronics Package29Model 218A Electronics Package29TC200 Veritrim Electronics Package29Model 132 Digital Electronics Package29SECTION 5 RETURN OF MATERIAL31SECTION 6 APPENDICES33APPENDIX A, REV. 3.6 WORLD CLASS 3000 OXYGEN ANALYZER (PROBE)35DESCRIPTION35PROBE TROUBLESHOOTING46SERVICE AND NORMAL MAINTENANCE50REPLACEMENT PARTS59APPENDIX B, REV. 2.2 HPS 3000 HEATER POWER SUPPLY61DESCRIPTION61HPS 3000 TROUBLESHOOTING64SERVICE AND NORMAL MAINTENANCE68REPLACEMENT PARTS71SECTION 7 INDEX73Warranty75Size: 1.77 MBPages: 76Language: EnglishOpen manual
User ManualTable of ContentsImportant Safety Instructions7Save These Instructions71.0 Introduction101.1 System Descriptions101.1.1 Self-Contained Systems10Air-Cooled Models10Water-Cooled Models10Glycol-Cooled Models10GLYCOOL Models (5-Ton Only)101.1.2 Chilled Water Models101.1.3 Split Systems11Prop Fan Air-Cooled11Centrifugal Fan Air-Cooled11Water-Cooled11Glycol-Cooled112.0 Installation (Applicable to all Models)122.1 Room Preparation122.2 Equipment Inspection122.3 Location Considerations122.4 Equipment Handling122.4.1 Handling With Skid132.4.2 Removal of Skid13Figure 1 Removing the Liebert Challenger 3000 from skid13Table 1 Unit net weight13Figure 2 Upflow (BU) cabinet dimensions14Figure 3 Downflow (BF) cabinet dimensions152.5 Piping Considerations162.5.1 Drain Line16Table 2 Piping connection size16Figure 4 Piping connections for air-cooled units - Downflow models17Figure 5 Piping connections for air-cooled units - Upflow models18Figure 6 Piping connections for split system fan coil units - Downflow models19Figure 7 Piping connections for split system fan coil units - Upflow models20Figure 8 Piping connections for water/glycol and GLYCOOL units - Downflow models21Figure 9 Piping connections for water/glycol and GLYCOOL units - Upflow models22Figure 10 Piping connections for chilled water self-contained units - Downflow models23Figure 11 Piping connections for chilled water self-contained units - Upflow models242.5.2 Humidifier Supply Water—Optional Infrared252.6 Facility Fluid and Piping Maintenance252.7 Electrical Connections25Figure 12 Electrical connections262.7.1 Electrical Field Connections for Liebert Challenger 3000 Models26Figure 13 Electrical field connections for Liebert iCOM®272.8 Balancing the Air Distribution282.8.1 Under-Floor Discharge Systems28Table 3 Recommended free area ft2 (m2) for grilles or perforated panels at output velocities of 550 and 600 fpm (2.8 and 3.1 m/s)282.8.2 Ducted Applications282.8.3 Plenum Installation282.9 Checklist for Completed Installation293.0 Air-Cooled Models—Self-Contained Compressor303.1 Condenser Location303.2 Electrical Connections303.2.1 Line Voltage303.2.2 Low Voltage303.2.3 Liebert Lee-Temp™/Flood Back Head Pressure Control Condensers30Figure 14 Air-cooled condensers31Table 4 Air-cooled condenser statistics313.3 Refrigerant Piping32Table 5 Recommended line sizes — OD copper, inches *33Table 6 Equivalent lengths (feet) for various pipe fittings33Table 7 Indoor unit refrigerant charge33Table 8 Line charges - refrigerant per 100 ft. (30 m) of Type “L” copper tube33Table 9 Condenser refrigerant (per serial tag)333.4 Fan Speed Control Systems34Variable Fan Speed Control Piping34Variable Fan Speed Control Materials Supplied34Variable Fan Speed Control Leak Check and Evacuation Procedure34Variable Fan Speed Charging35Table 10 Fan speed suction pressure transducer settings35Figure 15 General arrangement—Air-cooled models with fan speed control36Figure 16 General arrangement—Air-cooled models with digital scroll and fan speed control373.5 Air-Cooled Condenser with Liebert Lee-Temp™ “Flooded Condenser” Head Pressure Control System38Liebert Lee-Temp Piping38Liebert Lee-Temp Controlled Materials Supplied38Liebert Lee-Temp Leak Check and Evacuation Procedure38Liebert Lee-Temp™ Charging39Table 11 Liebert Lee-Temp suction pressure transducer settings39Liebert Lee-Temp Receiver Refrigerant Level40Figure 17 General arrangement—Air-cooled models with Liebert Lee-Temp™40Figure 18 General arrangement—Air-cooled models with digital scroll and Liebert Lee-Temp™414.0 Water-Cooled Models—Self-Contained Compressor424.1 Piping Considerations424.2 Condenser42Figure 19 General arrangement—Water-cooled models with scroll compressor43Figure 20 General arrangement diagram—Water-cooled models with digital scroll444.3 Water Regulating Valve454.3.1 Standard Valve - 150 psig (1034 kPa) System for 3 & 5-Ton Units (Johnson Controls Valve) High Pressure Valve - 350 psig (2413 kPa) System for 5-Ton Units (Johnson Controls Valve)45Adjustment45Figure 21 Johnson Controls valve adjustment454.3.2 High Pressure Valve - 350 psig (2413 kPa) System for 3-Ton Units (Metrex Valve)46Adjustment46Figure 22 Metrex Valve adjustment46Table 12 Refrigerant control settings psi (kPa)46Manual Flushing464.4 Motorized Ball Valve—Digital Scroll Compressors464.4.1 Control46Control Method474.4.2 Adjustment474.4.3 Startup474.4.4 Location474.4.5 Manual Control475.0 Glycol/GLYCOOL-Cooled Models—Self-Contained Compressor485.1 Drycooler Location485.2 Drycooler Installation485.3 Electrical Connections485.3.1 Line Voltage485.3.2 Low Voltage485.3.3 Pump and Drycooler485.4 Glycol Piping49General Guidelines49Table 13 Room dew point temperatures505.4.1 Expansion Tanks, Fluid Relief Valves and Other Devices515.5 Filling Instructions515.5.1 Preparing the System for Filling51Table 14 Indoor unit glycol volume approximate gallons (liters) max.51Table 15 Volume in standard Type “L” copper piping515.5.2 Glycol Solutions52Table 16 Ethylene glycol concentrations525.5.3 Filling the System53Figure 23 Drycoolers and pump packages54Figure 24 Pump packages—expansion tank55Table 17 Mounting hole dimensional data55Table 18 Drycooler data55Table 19 Glycol pump data*55Figure 25 General arrangement—Glycol-cooled models with scroll compressor56Figure 26 General arrangement—Glycol-cooled models with digital scroll57Figure 27 General arrangement—GLYCOOL models with scroll compressor58Figure 28 General arrangement—GLYCOOL models with digital scroll compressor595.5.4 Motor Ball Valve—Digital Scroll Compressors605.6 Condenser605.7 Glycol Regulating Valve605.7.1 Standard Valve - 150 psig (1034 kPa) System for 3 & 5-Ton Units (Johnson Controls Valve) High Pressure Valve - 350 psig (2413 kPa) System for 5-Ton Units (Johnson Controls Valve)605.7.2 High Pressure Valve - 350 psig (2413 kPa) System for 3-Ton Units (Metrex Valve)605.7.3 Testing Valve Function60Table 20 Refrigerant control settings psi (kPa)606.0 Chilled Water Models616.1 Piping Considerations61Figure 29 Chilled water general arrangement - Upflow (BU)61Figure 30 Chilled water general arrangement - Downflow (BF) models627.0 Split System Models637.1 Location Considerations637.1.1 Air-Cooled Condensing Units637.1.2 Water/Glycol-Cooled Condensing Units637.2 Electrical Connections637.2.1 Line Voltage647.2.2 Low Voltage647.3 Piping Considerations647.3.1 Refrigerant Loop64Table 21 Unit refrigerant charge65Table 22 Line charges - refrigerant per 100 ft. (30 m) of Type “L” copper tube66Table 23 Recommended refrigerant lines (R407C) sizes OD copper66Table 24 Line coupling sizes66Table 25 Equivalent lengths (feet) for various pipe fittings66Figure 31 Refrigerant piping diagram667.3.2 Quick Connect Fittings677.4 Outdoor Air-Cooled Condensing Units68Figure 32 Outdoor air-cooled condensing unit—horizontal air discharge models68Table 26 Horizontal air discharge cabinet and floor planning dimensional data69Table 27 Horizontal air discharge piping and electrical connection data69Figure 33 Outdoor air-cooled condensing unit—top air discharge models70Table 28 Cabinet and floor planning dimensional data - prop fan condensing modules, top air discharge71Table 29 Piping and electrical connections - top air discharge71Figure 34 Electrical field connections, prop fan condensing module727.5 Centrifugal Air-Cooled Condensing Units737.5.1 Installing the Indoor Condensing Unit73Table 30 Indoor centrifugal condensing unit73Figure 35 Detail of ceiling hanging bracket747.5.2 Ducting74Table 31 Airflow CFM (CMH)74Figure 36 3-ton centrifugal air-cooled condensing unit dimensional data & piping connections75Figure 37 3-ton centrifugal air-cooled condensing unit (con’t.)76Figure 38 5-ton centrifugal air-cooled condensing unit dimensional data77Figure 39 5-ton centrifugal air-cooled condensing unit dimensional data (con’t.)78Figure 40 Split systems general arrangement797.6 Water and Glycol-Cooled Condensing Units807.6.1 Piping Considerations803-Ton Connection Sizes805-Ton Connection Sizes80Table 32 Water and glycol-cooled condensing unit data807.6.2 Condenser Water Requirements807.6.3 Regulating Valve807.6.4 Glycol Systems81Figure 41 3-ton water/glycol-cooled condensing unit81Figure 42 3-ton water/glycol-cooled condensing unit (con’t.)82Figure 43 5-ton water/glycol-cooled condensing unit dimensional data83Figure 44 5-ton water/glycol-cooled condensing unit (con’t.)848.0 R407C Refrigerant85Table 33 R407C pressure/temperature chart for operation and superheat (discharge/hot gas and suction gas)85Table 34 R407C pressure/temperature chart for subcooling only (liquid measurements)868.1 Calculating Subcooling86Example86Size: 3.5 MBPages: 88Language: EnglishOpen manual
