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 Introduction91.1 System Descriptions91.1.1 Self-Contained Systems9Air-Cooled Models9Water-Cooled Models9Glycol-Cooled Models9GLYCOOL Models (5-Ton Only)91.1.2 Chilled Water Models91.1.3 Split Systems10Prop Fan Air-Cooled10Centrifugal Fan Air-Cooled10Water-Cooled10Glycol-Cooled102.0 Installation (Applicable to all Models)112.1 Room Preparation112.2 Equipment Inspection112.3 Location Considerations112.4 Equipment Handling112.4.1 Handling With Skid122.4.2 Removal of Skid12Figure 1 Removing Challenger from skid12Table 1 Unit net weight12Figure 2 Upflow (BU) cabinet dimensions13Figure 3 Downflow (BF) cabinet dimensions142.5 Piping Considerations152.5.1 Drain Line15Table 2 Piping connection size15Figure 4 Piping connections for air-cooled units - Downflow models16Figure 5 Piping connections for air-cooled units - Upflow models17Figure 6 Piping connections for split system fan coil units - Downflow models18Figure 7 Piping connections for split system fan coil units - Upflow models19Figure 8 Piping connections for water/glycol and GLYCOOL units - Downflow models20Figure 9 Piping connections for water/glycol and GLYCOOL units - Upflow models21Figure 10 Piping connections for chilled water self-contained units - Downflow models22Figure 11 Piping connections for chilled water self-contained units - Upflow models232.5.2 Humidifier Supply Water—Optional Infrared242.6 Facility Fluid and Piping Maintenance242.7 Electrical Connections24Figure 12 Electrical connections25Figure 13 Electrical field connections for Liebert iCOM262.8 Balancing the Air Distribution272.8.1 Under-Floor Discharge Systems27Table 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)272.8.2 Ducted Applications272.8.3 Plenum Installation272.9 Checklist for Completed Installation283.0 Air-Cooled Models—Self-Contained Compressor293.1 Condenser Location293.2 Electrical Connections293.2.1 Line Voltage293.2.2 Low Voltage293.2.3 Liebert Lee-Temp/Flood Back Head Pressure Control Condensers29Figure 14 Air-cooled condensers30Table 4 Air-cooled condenser statistics303.3 Refrigerant Piping31Table 5 Recommended line sizes — OD copper (inches)*31Table 6 Equivalent lengths (feet) for various pipe fittings32Table 7 Indoor unit refrigerant charge lb (kg)32Table 8 Line charges - refrigerant per 100 ft. (30 m) of Type “L” copper tube32Table 9 Condenser refrigerant (per serial tag)323.4 Fan Speed Control Systems32Variable Fan Speed Control Piping32Variable Fan Speed Control Materials Supplied33Variable Fan Speed Control Leak Check and Evacuation Procedure33Variable Fan Speed Charging34Table 10 Fan speed suction pressure transducer settings34Figure 15 General arrangement—Air-cooled models with fan speed control35Figure 16 General arrangement—Air-cooled models with digital scroll and fan speed control363.5 Air-Cooled Condenser with Liebert Lee-Temp “Flooded Condenser” Head Pressure Control System37Liebert Lee-Temp Piping37Liebert Lee-Temp Controlled Materials Supplied37Lee-Temp Leak Check and Evacuation Procedure37Lee-Temp Charging38Table 11 Lee-Temp suction pressure transducer settings38Lee-Temp Receiver Refrigerant Level38Figure 17 General arrangement—Air-cooled models with Liebert Lee-Temp39Figure 18 General arrangement—Air-cooled models with digital scroll and Lee-Temp404.0 Water-Cooled Models—Self-Contained Compressor414.1 Piping Considerations414.2 Condenser41Figure 19 General arrangement—Water-cooled models with scroll compressor42Figure 20 General arrangement diagram—Water-cooled models with digital scroll434.3 Water Regulating Valve444.3.1 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)44Adjustment44Figure 21 Johnson Controls valve adjustment444.3.2 High Pressure Valve - 350 psig (2413 kPa) System for 3-Ton Units (Metrex Valve)44Adjustment44Figure 22 Metrex Valve adjustment45Table 12 Refrigerant control settings psi (kPa)45Manual Flushing454.4 Motorized Ball Valve—Digital Scroll Compressors454.4.1 Control45Control Method454.4.2 Adjustment464.4.3 Startup464.4.4 Location464.4.5 Manual Control465.0 Glycol/GLYCOOL-Cooled Models—Self-Contained Compressor475.1 Drycooler Location475.2 Drycooler Installation475.3 Electrical Connections475.3.1 Line Voltage475.3.2 Low Voltage475.3.3 Pump and Drycooler475.4 Glycol Piping48General Guidelines48Table 13 Room dew point temperatures495.4.1 Expansion Tanks, Fluid Relief Valves and Other Devices505.5 Filling Instructions505.5.1 Preparing the System for Filling50Table 14 Indoor unit glycol volume approximate gallons (liters) max.50Table 15 Volume in standard Type “L” copper piping505.5.2 Glycol Solutions51Table 16 Ethylene glycol concentrations525.5.3 Filling the System52Figure 23 Drycoolers and pump packages53Figure 24 Pump packages—expansion tank54Table 17 Mounting hole dimensional data54Table 18 Drycooler data54Table 19 Glycol pump data*54Figure 25 General arrangement—Glycol-cooled models with scroll compressor55Figure 26 General arrangement—Glycol-cooled models with digital scroll56Figure 27 General arrangement—GLYCOOL models with scroll compressor57Figure 28 General arrangement—GLYCOOL models with digital scroll compressor585.5.4 Motor Ball Valve—Digital Scroll Compressors595.6 Condenser595.7 Glycol Regulating Valve595.7.1 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)595.7.2 High Pressure Valve - 350 psig (2413 kPa) System for 3-Ton Units (Metrex Valve)595.7.3 Testing Valve Function59Table 20 Refrigerant control settings psi (kPa)596.0 Chilled Water Models606.1 Piping Considerations60Figure 29 Chilled water general arrangement - Upflow (BU)60Figure 30 Chilled water general arrangement - Downflow (BF) models617.0 Split System Models627.1 Location Considerations627.1.1 Air-Cooled Condensing Units627.1.2 Water/Glycol-Cooled Condensing Units627.2 Electrical Connections627.2.1 Line Voltage627.2.2 Low Voltage637.3 Piping Considerations637.3.1 Refrigerant Loop63Table 21 Unit refrigerant charge64Table 22 Line charges - refrigerant per 100 ft. (30 m) of Type “L” copper tube64Table 23 Recommended refrigerant lines (R407C) sizes OD copper64Table 24 Line coupling sizes65Table 25 Equivalent lengths (feet) for various pipe fittings65Figure 31 Refrigerant piping diagram657.3.2 Quick Connect Fittings657.4 Outdoor Air-Cooled Condensing Units66Figure 32 Outdoor air-cooled condensing unit—horizontal air discharge models66Table 26 Horizontal air discharge cabinet and floor planning dimensional data67Table 27 Horizontal air discharge piping and electrical connection data67Figure 33 Outdoor air-cooled condensing unit—top air discharge models68Table 28 Cabinet and floor planning dimensional data - prop fan condensing modules, top air discharge69Table 29 Piping and electrical connections - top air discharge69Figure 34 Electrical field connections, prop fan condensing module707.5 Centrifugal Air-Cooled Condensing Units717.5.1 Installing the Indoor Condensing Unit71Table 30 Indoor centrifugal condensing unit71Figure 35 Detail of ceiling hanging bracket727.5.2 Ducting72Table 31 Airflow CFM (CMH)72Figure 36 3-ton centrifugal air-cooled condensing unit dimensional data & piping connections73Figure 37 3-ton centrifugal air-cooled condensing unit (con't.)74Figure 38 5-ton centrifugal air-cooled condensing unit dimensional data75Figure 39 5-ton centrifugal air-cooled condensing unit dimensional data (con't.)76Figure 40 Split systems general arrangement777.6 Water and Glycol-Cooled Condensing Units787.6.1 Piping Considerations78Table 32 Water and glycol-cooled condensing unit data787.6.2 Condenser Water Requirements787.6.3 Regulating Valve787.6.4 Glycol Systems79Figure 41 3-ton water/glycol-cooled condensing unit79Figure 42 3-ton water/glycol-cooled condensing unit (con't.)80Figure 43 5-ton water/glycol-cooled condensing unit dimensional data81Figure 44 5-ton water/glycol-cooled condensing unit (con't.)828.0 R407C Refrigerant83Table 33 R407C pressure/temperature chart for operation and superheat (discharge/hot gas and suction gas)83Table 34 R407C pressure/temperature chart for subcooling only (liquid measurements)848.1 Calculating Subcooling84Example84Size: 2.41 MBPages: 88Language: EnglishOpen manual
