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Liebert Challenger ITR User's Manual

1. 0 cece eee 46 Indoor centrifugal condensing unit oo 48 Airflow GEM CMH dedere i De aiana e a bode wedoh a dod eee deg Oa eR GAN Gard lawedne ad 49 Water and glycol cooled unit connection sizes 6 ee eee enn eens 53 Water and glycol cooled condensing unit data ccc ee eens 53 R407C pressure temperature chart for operation and superheat discharge hot gas ANA SUCEIONH EAS ii A A o A a Morden a 56 R407C pressure temperature chart for subcooling only liquid measurements 57 iv Introduction 1 0 INTRODUCTION 1 1 System Descriptions Liebert Challenger ITR environmental control systems are available in three main system configu rations 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 horizontal flow configurations Each model requires three phase power Units are available in 208 230 460 or 575 V 60 Hz and 200 230 or 380 415 V 50 Hz The following features are included as standard in all room units regardless of the type of system V frame coil infrared humidifier finned tubular stainless steel electric reheat 2 filter individual high voltage fused protection and fan assembly Each configuration can operate with either Advanced Microprocessor Controls A or Advanced Microprocessor Controls with Graphics G A brief description
2. SES AA Fusible a ESA a Plug yo Il J Inverted Traps on discharge A A Z and return lines to extend A E above base of coil by a ha Za minimum of 7 1 2 190mm lI Il Traps every 25 ft 7 6m Coil ofrse _ f L Hot Gas Bypass alve I Liquid Return 1 Solenoid Valves Sensing Shutoff Bulb Valve l I K ED IES Filter A External Dryer Equalizers Il Service Hot Gas a Il Bypass Scroll Compressor Check Valve Hot Gas lt Shipped Loose for Discharge Field Installation i we SINGLE CIRCUIT SHOWN Components are not supplied by Liebert but FACTORY are recommended for proper circuit operation PIPING and maintenance l ZZZ O Ey lt PIPING SL 11897 PG 5 19 Air Cooled Models 3 4 3 Charging 3 5 3 5 1 1 Make sure unit is OFF Open all disconnect switches and on units supplied with circuit breakers open all breakers Replace all fuses for the Fan and Compressors or close breakers 2 Removejumper on the Fan Safety Switch and reconnect the system wire connections Ensure that all operational components are clear of debris Turn unit ON Fan operation is required Check the evaporator fan for proper rotation and correct if necessary 3 Connect the refrigerant gauge charging hose to the drum of refrigerant and to the suction and discharge service valves of the compressor 4 Calculate the amount of
3. 25 4mm Flange 7 8 22 2mm Flange for Duct or Plenum Connection UNIT DIMENSIONAL DATA REAR VIEW Shaded area indicates a recommended clearance of 34 864mm for component access UNIT DIMENSIONAL DATA FRONT VIEW DPNO001523 Pg 2 Rev 1 Installation Figure 3 Optional floor stand dimensions q 30 1 2 25 4mm 30 4 2 rro gt 775mm a A See Specification Sheet for height of floor stand ordered SL 11897 Pg 7 Installation 2 5 2 5 1 Piping Considerations Consideration should be given before installing refrigerant and liquid lines next to under or above electronic equipment Drain Line A 3 4 19 1 mm female pipe thread FPT connection is provided for the evaporator coil condensate drain This drain line also drains the humidifier if applicable The drain line must be located so it will not be exposed to freezing temperatures The drain should be at least the full size of the drain connec tion and pitched a minimum of 1 8 per ft 11 mm per meter NOTE This line may contain boiling water Select appropriate drain system materials The Challenger ITR comes standard with a condensate pump will require a field supplied trap downstream from the pump The drain line must comply with all applicable codes Table 2 Piping connection size Air Cooled Unit Connection Sizes in Model No BR BM Liquid Line O D Copper Hot Gas Line O D Copp
4. See Cabinet and Floor Planning Dimensional Data for Piping DPN001525 Opening Sizes REVO Installation Figure 5 Piping connections for split system fan coil units nmri Piping outlet locations through the plenum are the same as the unit See below for descriptions and connection sizes Humidifier Water Supply Line p Hot Water Return 1 4 OD CU 5 8 OD CU optional Suction Refrigerant Line le Liquid Refrigerant Line 1 1 8 OD CU on 1 2 OD CU on Models Models BRO60E BRO59E BRO60E BRO59E Condensate Pump Line J y mnn Hot Water Supply 1 2 OD CU 5 8 OD CU optional Monitoring Panel PIPING OUTLET LOCATIONS See Cabinet and Floor Planning Dimensional Data for Piping Opening Sizes DPN001534 REV 0 Installation Figure 6 Piping connections for water glycol and GLYCOOL units mmi Piping outlet locations through the plenum are the same as the unit See below for descriptions and connection sizes Humidifier Water Supply Line p Hot Water Return 1 4 OD CU 5 8 OD CU optional Condenser Return Line 4 r Pa e as Line 1 1 8 OD CU on 1 8 on Models BRO71WG BRo7owG Models BRO71WG BRO70WG Condensate Pump Line Ej p Hot Water Supply 1 2 OD CU 5 8 OD CU optional Monitoring Panel PIPING OUTLET LOCATIONS
5. See Cabinet and Floor Planning Dimensional Data for Piping Opening Sizes DPNO001528 REV 0 Installation Figure 7 Piping connections for chilled water self contained units Piping outlet locations through PAT the plenum are the same as the unit See below for descriptions and connection sizes Humidifier Water Supply r Hot Water Return Line 1 4 OD CU 5 8 OD CU optional Chilled Water Supply Line lt m Chilled Water Return Line 1 1 8 OD CU 1 1 8 OD CU Condensate Pump Line 7 m Hot Water Supply 1 2 OD CU 5 8 OD CU optional Monitoring Panel PIPING OUTLET LOCATIONS See Cabinet and Floor Planning Dimensional Data for Piping Opening Sizes DPN001531 REV O 10 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 Liebert Chal lenger ITR in accordance with codes A factory supplied locking disconnect switch is factory mounted within the unit behind the fr
6. TYPICAL FOOTPRINT Table 3 Air cooled condenser statistics Connection Sizes Number OD Copper Net Weight A Dimension Model ofFans Hot Gas in Liquid in Ib kg in mm 083 1 7 8 5 8 295 133 8 42 1067 104 1 1 1 8 5 8 315 142 8 42 1067 15 Air Cooled Models 3 3 Refrigerant Piping All refrigeration piping should be installed with high temperature brazed joints Prevailing good refrigeration practices should be employed for piping supports leak testing dehydration and charg ing of the refrigeration circuits Unit refrigeration components and piping are shipped from the factory with a nitrogen holding charge NOTE The refrigeration piping should be isolated from the building by the use of vibration isolating supports NOTE Piping including inverted trap s must be routed to allow unobstructed access to the panel per the NEC NOTE Q When installing field piping care must be taken to protect all refrigerant lines from the atmosphere especially when using refrigerants with POE oils Do not allow the piping to stand open to air for more than 15 minutes Units designed for R407C have a compressor that contains POE oil that is very hygroscopic that is it quickly absorbs water from the air The longer the compressor piping is left open to air the harder it will be to fully evacuate If left open too long the POE oil may need to be replaced before achieving the
7. level sites with public access or areas which contribute to heavy snow or ice accumulations To assure adequate air supply it is recommended that drycoolers be located in a clean air area away from loose dirt and foreign matter that may clog the coil In addition drycoolers should not be located in the vicinity of steam hot air or fume exhausts Also drycoolers should not be located closer than 3 feet 1 meter from a wall obstruction or adjacent unit Drycooler Installation For roof installation mount drycoolers on steel supports in accordance with local codes To minimize sound and vibration transmission mount steel supports across load bearing walls For ground instal lation a concrete pad will provide adequate support Drycooler legs have mounting holes for securing the drycooler to steel supports or concrete pad Electrical Connections Refer to equipment nameplate regarding wire size and circuit protection requirements Refer to elec trical schematic when making connections Make all wiring and electrical connections in accordance with local and national codes A WARNING Risk of electric shock Can cause injury or death Disconnect all local and remote electric power before working within the unit Use a voltmeter to make sure power is turned off before making any electrical connections Line Voltage Line voltage electrical service is required for all drycoolers at the location of the drycooler This power supply does not
8. Back Head Pressure Control Condensers Lee Temp condensers require a separate power supply for the heated receivers This power supply is connected to the electrical connection box on the end of the receiver 14 Air Cooled Models Figure 9 Air cooled condensers FAN SPEED CONDENSER supplied by others Hot gas line Liquid line Secure each leg to condenser frame at all points shown using hardware provided Lee Temp heater pad connection box Electric service LEE TEMP CONDENSER xs line Hu Electric lt service supplied by others N Liquid line B Inverted traps are to be field supplied and installed typ When installing traps provide clearance for swing end of access door Traps are to extend above base of coil by a minimum of 7 1 2 190 mm SINGLE FAN AIR COOLED CONDENSERS Common to all models See Table 3 below for key to A dimension 51 7 16 _ 43 9 16 1306 5mm 1106mm lt Da Ber t AK 18 457 2mm 37 718 Le 962mm Lee sa CONDENSER MOUNTING 4 typ gt le 25 4mm 1 3 4 43 3 16 44 44 5mm 1097mm 1118mm el 9 16 14 3mm t t diameter holes 56 Ann 8 places for 25 4mm 37 11 16 1 2 12 7mm 1 1 3 4 4 1 4 957 3mm diameter bolts 25 4mm 44 5mm 108mm 4 3 4 4 fe al 44 5mm 1 3 4 1 3 4 44 5mm gt i 4 445mm 4 1 4 4 dd A gt 108mm 25 4mm
9. New systems can be coated with oil or a protective film dirt and scale are also common Any residual contaminants could adversely affect the heat transfer stability and performance of your system In many cases in both old and new systems special cleaners are needed to remove scale rust and hydrocarbon foulants from pipes manifolds and passages Clean heat transfer surfaces are important in maintaining the integrity of the heating cooling system For more information on clean ers and degreasers contact your sales representative Follow the manufacturer s instructions when using these products Calculate the internal volume of the system as closely as possible See Table 12 and Table 14 for unit volumes Use volume in Table 13 for glycol piping volumes Table 12 Indoor unit glycol volume approximate gallons liters max Model 50 Hz Glycol Cooled GLYCOOL 071WG 070WG 2 0 7 5 061G 058G 4 0 15 1 Table 13 Volume in standard Type L copper piping Diameter in Volume Outside Inside Gal Ft L M 1 2 0 123 0 008 0 01 5 8 0 555 0 012 0 15 3 4 0 666 0 018 0 22 7 8 0 785 0 025 0 31 1 1 8 1 025 0 043 0 53 29 Glycol GLYCOOL Cooled Models 5 5 2 Glycol Solutions NOTE Glycol solutions should be considered for protection of the coil When it is not used damage can occur from either freezing or corrosion from water When considering the use of any glycol products
10. Outlet Liquid Line male quick connect location Suction Line male quick conect location 7 8 22 2mm dia electrical entrance ae 2 am dla knockout for low voltage connection electrical entrance for altermate control panel low voltage routing SL 11087 PG 4 50 Split System Models Figure 25 Centrifugal air cooled condensing unit dimensional data con t Field supplied unit disconnect switch when factory unit disconnect switch is not supplied Electric service not by Emerson Optional factory installed disconnect switch AIR COOLED Connection terminal for field supplied earth Line voltage electric power grounding wire supply conduit voltage Removable access panels Heat rejection connection Field supplied 24V NEC Class 2 wiring See Note 2 Wire connections from evaporator module Low voltage electric power 1 24V GND supply conduit entrance 2 24V supply 3 High pressure alarm optional 4 Hot gas bypass connection only on units with hot gas bypass DPNO00226 Rev 0 Field supplied 24V NEC Class 2 wiring between condensing unit and fan coil unit NOTES 1 Refer to specification sheet for full load amp and wire size amp ratings 2 Control voltage wiring must be a minimum of 16 GA 1 6mm for up to 75 23m or not to exceed 1 volt drop in control line 51 Split System Models Figure 26 Split systems general arrangement Hot Gas Condenser Bypass Sol
11. Suction Line O D Ib kg Ib kg Ib kg Ib kg 1 2 7 3 3 3 0 2 0 1 6 9 2 9 5 8 11 7 5 3 0 3 0 2 11 0 4 6 0 4 0 2 7 8 24 4 11 1 0 7 0 3 23 0 9 6 1 0 0 4 1 1 8 41 6 18 9 1 2 0 6 39 3 16 3 1 7 0 7 1 3 8 63 3 28 7 1 9 0 8 59 8 24 8 2 7 1 1 Table 21 Recommended refrigerant lines R22 or R407C sizes OD copper 3 5 Tons 23 amp 33 kW 036E 035E 060E 059E Equivalent Feet m Suction Liquid Suction Liquid 0 50 0 15 7 8 1 2 1 1 8 1 2 51 100 16 30 1 1 8 1 2 1 1 8 5 8 101 150 31 45 1 1 8 5 8 1 3 8 5 8 Table 22 Line coupling sizes Line Size Coupling Torque OD Cu in Size lb ft 1 2 amp 5 8 10 35 45 1 1 8 12 50 65 40 Split System Models Table 23 Equivalent lengths feet for various pipe fittings Copper Pipe 90 Degree 90 Degree 45 Degree Gate Globe Angle OD in Elbow Copper Elbow Cast Elbow Tee Valve Valve Valve 1 2 0 8 1 3 0 4 2 5 0 26 7 0 4 0 5 8 0 9 1 4 0 5 2 5 0 28 9 5 5 0 3 4 1 0 1 5 0 6 2 5 0 3 12 0 6 5 7 8 1 45 1 8 0 8 3 6 0 36 17 2 9 5 1 1 8 1 85 2 2 1 0 4 6 0 48 22 5 12 0 1 3 8 2 4 2 9 1 3 6 4 0 65 32 0 16 0 1 5 8 2 9 3 5 1 6 7 2 0 72 36 0 19 5 Refrigerant trap 4 times equivalent length of pipe per this table Figure 19 Refrigerant piping diagram Pitch down 1 2 13mm per 10 ft 3m NOTE When remote condens
12. Table 1 Unit shipping weights Domestic Export Domestic Export Model Ib kg Ib kg Model Ib kg Ib kg 50Hz Models 60Hz Models BRO59E 650 295 750 340 BRO60E 650 295 750 340 BRO65A 745 340 845 385 BRO67A 745 340 845 385 BRO70WG 815 370 915 415 BRO71WG 815 370 915 415 BM058G 855 390 955 435 BM061G 855 390 955 435 BR101C 660 300 760 345 BR102C 660 300 760 345 Installation Figure 2 Cabinet dimensions Unit Weight 50 Hz Models 60 Hz Models lb kg BRO59E BRO60E 649 294 BRO65A BRO67A 744 337 30 1 2 775mm gt BRO70WG BRO71WG 814 369 31 1 9 UNIT BR101C BR102C 659 299 Cem TOP VIEW 8 1 2 z BM058G BM061G 854 387 216mm 9 5 8 244mm 10 1 T ink 1 5 8 43 5 16 260mm 41mm 1100mm i 30 1 2 Standard Piping Location 775mm 32 1 2 Projection of 5 8 826mm Display Bezel 16mm y l JI 4 12 5 8 5 1 2 321mm Plenum Overhang 140mm Standard Electrical Outlet Location Through Unit 45 1 8 1147mm 32 1 2 826mm 15 1 16 382mm 32 1 2 Discharge Air Opening 826mm Remove Blocker Panel for Air Discharge Left and or Right Side Panels Filter Access by Opening Door 91 1 16 2313mm Shaded area indicates a recommended clearance of 34 864mm for component access Blower Outlet with 1
13. hanging bracket 7 5 2 3 8 threaded rod field supplied 3 8 hex nut 3 8 washer Sleeve Isolator 00000000000000 3 8 fender washer 3 8 hex nut 3 8 hex nut gt Nylock yloc Unit base pan ref Ducting The total external static pressure for the inlet and outlet ducts including grille must not exceed 0 5 inches of H20 Hood intake dimensions should be the same as the condensing unit duct dimen sions If the condensing unit is located close to the outside of the building rain hoods must be installed In addition install a triple layer bird screen over rain hood openings to eliminate the possibility of insects birds water or debris entering the unit Use flexible ductwork or nonflammable cloth collars to attach ductwork to the unit and to control vibration transmission to the building Attach the ductwork to the unit using the flanges provided Locate the unit and ductwork so that the return air does not short circuit to the supply air inlet Avoid directing the hot exhaust air toward adjacent doors or windows Normal operating sound may be objectionable if the condensing unit is placed directly over quiet work areas Ductwork that runs through a conditioned space or is exposed to areas where condensation may occur must be insulated Whenever possible ductwork should be suspended using flexible hang ers Ductwork should not be fastened directly to the building structure In applications where
14. of each including operational differ ences 1s listed below Check model numbers to see what is supplied with your unit 1 1 1 Self Contained Systems Air Cooled Models Complete refrigeration system including hot gas bypass and crankcase heater with standard con denser and fan speed control for 95 F 85 C ambient at sea level Water Cooled Models Compete refrigeration system including hot gas bypass with water glycol cooled condenser and two way water regulating valve with bypass Glycol Cooled Models The water cooled model as described above plus pump package and 95 F 35 C design ambient dry cooler GLYCOOL Models Complete refrigeration system including hot gas bypass with glycol condenser and three way water reg ulating valve plus an integrally piped Econ O Coil with three way modulating control valve 1 1 2 Chilled Water Models Chilled Water models include chilled water piping three way modulating valve and actuator assembly 1 1 3 Split Systems Each Air Cooled split system consists of an evaporator section and one of the following condensing units Prop Fan Includes scroll compressor condenser coil prop fan high pressure switch and Lee Temp head pres sure control Unit is designed for outdoor location Centrifugal Fan Includes scroll compressor condenser coil centrifugal blower assembly high pressure switch head pressure control valve Lee Temp receiver and liquid line solenoid valve Unit must be mounted indoors
15. s Return to 2 aera Evaporator Pressure Porten Pump Valves Coil eed Aoi a 2 ES y Fluid Z or h AC Supply ave ee eee t3 A lt from A I Hose LA Z Pump Air Vents Bibt at Top of En Flow Regulating Sight Risers oy Valve Pressure Port Bypass Valve Scroll Equalizers Solenoid Valve Econ O Coil 3 Way Water pl Regulating Fluid Vale Valve oe t Actuator E Econ O Cycle from Comparator mu chy Isolation on Lh Valves ay ig La a oe Econ 0 Coil Pa Ly Circuit L A Z W _4 Y le Hose _ ay FACTORY PIPING BESA S Ha FIELD PIPING A toi Components are not supplied by Liebert but are recommended for proper circuit operation and maintenance SL 11901 PG 5 35 Glycol GLYCOOL Cooled Models 5 6 5 7 5 7 1 5 7 2 Condenser The condenser is designed to operate in conjunction with a drycooler The maximum coolant pressure 1s 350 psig 2413 kPa NOTE For pressures above 150 psig 1034 kPa the high pressure option for high pressure valve s is required Glycol Regulating Valve The glycol regulating valve automatically regulates the amount of coolant necessary to remove the heat from the refrigeration system permitting more fluid to flow when load conditions are high and less fluid to flow when load conditions are low The valve consists of a brass body balance spring valve sea
16. similar in properties proper safety equipment and proper refrigeration tools are required on both types Check unit nameplate for correct refrigerant type before topping off or recharging a system NOTE Refrigerant R407C uses a POE polyol ester lubricant The R407C refrigerant must be introduced and charged from the cylinder only as a liquid NOTE Q When installing field piping care must be taken to protect all refrigerant lines from the atmosphere especially when using refrigerants with POE oils Do not allow the piping to stand open to air for more than 15 minutes Units designed for R407C have a compressor which contains POE oil that is very hygroscopic that is it quickly absorbs water from the air The longer the compressor piping is left open to air the harder it will be to fully evacuate If left open too long the POE oil may need to be replaced before achieving the required vacuum level NOTE Complete all piping and evacuate lines before connecting quick connects when using an optional sweat adapter kit and field installed hard piping Follow all proper brazing practices including a dry nitrogen purge to maintain system cleanliness All split systems require two refrigerant lines an insulated copper suction line and a copper liquid line between the evaporator and the condensing unit Two possible methods exist for installing the copper suction and liquid lines 1 Using an optional Sweat Adapter Kit and hard piping be
17. the ceil ing plenum is used as the heat rejection domain the discharge air must be directed away from the condensing unit air inlet and a screen must be added to the end of the discharge duct to protect ser vice personnel For multiple unit installations space the units so that the hot condensing unit exhaust air is not directed toward the air inlet of an adjacent unit Table 29 Airflow CFM CMH 23 amp 33 kW 60Hz 3500 5947 50 Hz 3500 5947 49 Split System Models Figure 24 Centrifugal air cooled condensing unit dimensional data 812 8mm CABINET 1371 8mm DIMENSION CABINET 19 8 DIMENSION 41 1mm 15 3 4 400mm 48 8 15 16 Customer supplied 1219 2mm aarm threaded rods for module 33 8 a from ceiling 857mm 141 2 368 3mm a 610mm 21 1 4 CABINET 539 8mm DIMENSION ae 44 5mm Shaded area indicates a recommended clearance of eet ai 51 13 16 Hanger Bracket 30 762mm for component THREADED ROD 1316mm access and removal CENTERS THREADED ROD CENTERS NOTE Unit is spaced evenly in 4 2 12 7mm dia holes for reference to threaded threaded rods typ 2 each end rod centers 7 8 22 2mm amp 1 1 8 28 6mm 718 22 2mm amp 1 1 8 28 6mm pola ne D dia knockouts electrical entrance for high voltage connection Single Point Power Kit voltage connection Single Point Power Kit connection to Evaporator Air Inlet Air
18. to primary pump supplier 33 Glycol GLYCOOL Cooled Models Figure 16 Glycol general arrangement Expansion Tank Field Installed at 1a Drycooler Highest eee Electric Fill Box Pump Drycooler Coil A J Expansion l Fluid 2 Evaporator Port Return a Isolation Coil Pz Z To Pump Z Valves es Unions 24 aia 7 es nons Fluid Expansion de 27 z Suy 5 AA Zz from A IT Hose ll 7 gam Bibs gs Flow Regulating Air Vents at Top of Valve Sight Risers T Pressure Port External Equalizers Scroll yd yl Hot Gas Bypass Solenoid Hol Io l Io I II Tube I a in Tube Fug Condenser Supply to Unit E E I ui J Return f from e l Unit ft Isolation 1 Valves 2 Way Water E a Regulating 3 Way Water Ti Valve Regulating Valve Z Y optional Y Y e E Hose Fluid Bibs Ly Siol Z pply ed to Unit Fluid Z l PZA Return PAA Z FACTORY Fror PIPING Unit eg Foca Haser ee Ne re FIELD Bibs 7 PIPING ay Components are not supplied by Liebert but E are recommended for proper circuit operation SL 11898 PG 6 and maintenance 34 Glycol GLYCOOL Cooled Models Figure 17 GLYCOOL general arrangement Expansion Tank Field Installed at Highest Point in System Drycooler Electric Drycooler EJE Fluid 74 53 3 eS Pa Y
19. 0 106 0 41 1 212 1461 19 0 7 2 35 8 247 108 0 42 2 219 1507 20 0 6 7 36 9 254 110 0 43 3 225 1553 21 0 6 1 38 0 262 112 0 44 4 232 1601 22 0 5 6 39 0 269 114 0 45 6 239 1650 23 0 5 0 40 1 277 58 0 14 4 91 0 628 116 0 46 7 247 1701 24 0 4 4 41 3 284 59 0 15 0 92 9 640 118 0 47 8 254 1752 25 0 3 9 42 4 292 60 0 15 6 94 8 653 120 0 48 9 262 1804 26 0 3 3 43 6 300 61 0 16 1 96 7 666 122 0 50 0 269 1858 27 0 2 8 44 7 308 62 0 16 7 98 6 680 124 0 51 1 277 1912 28 0 2 2 45 9 317 63 0 17 2 100 5 693 126 0 52 2 285 1968 29 0 1 7 47 1 325 64 0 17 8 102 5 707 128 0 53 3 294 2025 30 0 1 1 48 4 333 65 0 18 3 104 5 721 130 0 54 4 302 2083 31 0 0 6 49 6 342 66 0 18 9 106 5 735 132 0 55 6 311 2143 32 0 0 0 50 9 351 67 0 19 4 108 6 749 134 0 56 7 320 2203 33 0 0 6 52 1 359 68 0 20 0 110 7 763 136 0 57 8 329 2265 34 0 1 1 53 5 369 69 0 20 6 112 8 778 138 0 58 9 338 2329 140 0 60 0 347 2393 NOTE Use this table for superheat and for control adjustment e g pressure switches See Table 33 for subcooling 56 R407C Refrigerant Table 33 R407C pressure temperature chart for subcooling only liquid measurements Temperature Pressure Gauge Temperature Pressure Gauge Temperature Pressure Gauge F C Psig kPa F C Psig kPa F C Psig kPa 36 0 2 2 73 500 59 0 15 0 114 786 94 0 34 4 203 1402 37 0 2 8 74 511 60 0 15 6 116 801 96 0 35 6 209 1444 38 0 3 3 76 52
20. 2 98 0 36 7 216 1488 39 0 3 9 77 533 100 0 37 8 222 1532 40 0 4 4 79 544 102 0 38 9 229 1578 41 0 5 0 81 556 104 0 40 0 236 1624 42 0 5 6 82 567 106 0 41 1 242 1671 43 0 6 1 84 579 108 0 42 2 249 1720 44 0 6 7 86 591 110 0 43 3 257 1769 45 0 7 2 87 602 112 0 44 4 264 1819 46 0 7 8 89 615 69 0 20 6 136 938 114 0 45 6 271 1870 47 0 8 3 91 627 70 0 21 1 138 954 116 0 46 7 279 1922 48 0 8 9 93 639 72 0 22 2 143 987 118 0 47 8 287 1975 49 0 9 4 95 652 74 0 23 3 148 1021 120 0 48 9 294 2029 50 0 10 0 96 664 122 0 50 0 302 2085 51 0 10 6 98 677 124 0 51 1 310 2141 52 0 11 1 100 690 126 0 52 2 319 2198 53 0 11 7 102 704 128 0 53 3 327 2256 54 0 12 2 104 717 130 0 54 4 336 2315 55 0 12 8 106 730 132 0 55 6 345 2376 56 0 13 3 108 744 134 0 56 7 354 2437 57 0 13 9 110 758 136 0 57 8 363 2500 58 0 14 4 112 772 138 0 58 9 372 2563 140 0 60 0 381 2628 NOTE Use this table for subcooling calculation ONLY See Table 32 for superheat or control adjustment 8 1 Calculating Subcooling Example Measure the liquid pressure e g 200 psig Find the liquid saturation temperature at that pressure on Table 33 e g 93 F Measure the temperature of the liquid line e g 90 F Subtract the actual temperature from the liquid saturation temperature to obtain the subcooling e g 93 90 39F If the actual temperature is greater than the liquid saturation temperature then there is no subcooling and the f
21. 4 4mm 95 2mm L_ ied Se one 1 25 4mm NPT Female Water Glycol Inlet Connection Suction Line male quick connect location Liquid Line male quick connect location 1 25 4mm NPT Female Water Glycol Outlet Connection 7 8 22 2mm dia electrical entrance 7 8 22 2mm dia knockout electrical entrance for low voltage connection for alternate control panel low voltage routing SL 11087PG 6 54 Split System Models Figure 28 Water glycol cooled condensing unit con t Electric service Field supplied unit disconnect not by Liebert switch when factory unit disconnect switch is not supplied Optional factory installed WATER GLYCOL disconnect switch Field supplied 24V NEC Class1 1 wiring to fan coil unit Field supplied 24V NEC Class wiring to drycooler glycol cooled units only Line voltage electric power supply conduit entrance Heat rejection connection Removable Field supplied 24V NEC Access Class 2 wiring Wire Panel connections from evaporator mod 1 24V ground 2 24V supply 3 High pressure alarm optional 4 Hot gas bypass connection only on units with hot gas bypass Connection terminal for field supplied earth grounding wire MA Low voltage electric power supply conduit entrance O Field supplied 24V NEC Class 1 wiring between glycol condensing unit and drycooler DPN000228 RevO NY Remote drycooler connection field supp
22. BA Check Valve Rotalock Valve 1 4 6 4mm Pressure Relief A Valve Lee Temp Receiver Traps Every 25 Ft 7 6m of rise on Hot Sas binenn Liquid Return P AA from Condenser _ A Za Expansion V an Hot Gas Zz Bypass oe Za Aa 7 Shutoff Valve Filter Drier Liquid Return 4 I 2 AA P ln Hot Gas Bypass SINGLE CIRCUIT SHOWN K Check Valve FACTORY PIPING a Hot Gas Discharge OPTIONAL PIPING if ZZ Z Z ZZZ FIELDPIPING Components ae not supplied by Liebert but are recommended for proper circuit operaton and maintenance SL 10061PG4 SL 10071PG4 Components supplied by Liebert and mustbe field installed 23 Water Cooled Models 4 0 WATER COOLED MODELS 4 1 Piping Considerations Manual shut off valves should be installed at the supply and return lines of each unit This will pro vide for routine maintenance or emergency isolation of the unit When the water source for the condenser is of poor quality it is good practice to provide cleanable fil ters in the supply line These filters will trap the particles in the water supply and extend the service life of the water cooled condenser To provide for the emergency of water leaks and the consequences of sub floor flooding floor drains should be provided with wet traps or a water detection system such as a Liqui tect sensor that is installed near the base of the unit or below the elevated floo
23. Dearborn Drive P O Box 29186 Columbus OH 43229 Europe Via Leonardo Da Vinci 8 Zona Industriale Tognana 35028 Piove Di Sacco PD Italy y 39 049 9719 111 While every precaution has been taken to ensure the accuracy Fax 39 049 5841 257 and completeness of this literature Liebert Corporation assumes no y responsibility and disclaims all liability for damages resulting from use of Asia this information or for any errors or omissions 7 F Dah Sing Financial Centre O 2008 Liebert Corporation mE 108 Gloucester Road Wanchai All rights reserved throughout the world Specifications subject to change H K without notice ong Kong Liebert is a registered trademark of Liebert Corporation 852 2572220 All names referred to are trademarks Fax 852 28029250 or registered trademarks of their respective owners SL 11956_REVO_07 08 Emerson Network Power The global leader in enabling Business Critical Continuity EmersonNetworkPower com MH AC Power HI Embedded Computing I Outside Plant I Racks amp Integrated Cabinets HI Connectivity HI Embedded Power I Power Switching 8 Controls I Services HI DC Power HF Monitoring HI Precision Cooling I Surge Protection Business Critical Continuity Emerson Network Power and the Emerson Network Power logo are trademarks and service marks of Emerson Electric Co 2008 Emerson Electric Co
24. Duct flanges are optional Water Glycol Condensing Units Each water cooled split system consists of an evaporator section and a water glycol condensing unit which includes scroll compressor coaxial condenser water regulating valve and high pressure switch Design pressure is 150 psi 1034 kPa as standard and 350 psi 2413 kPa as optional Each glycol cooled split system consists of an evaporator section a water glycol condensing unit as described above a pump package and a 95 F 35 C design ambient drycooler 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 be kept below 5 of the total air circulated in the room and be preconditioned 2 2 Equipment Inspection Upon arrival of the unit inspect all items for visible and concealed damage Damage should be imme diately reported to the carrier and a damage claim filed with a copy sent to Liebert or to your sales representative 2 3 Location Considerations The Liebert Challenger ITR can sit on top of an accessible elevated flooring sy
25. H Precision Cooling For Business Critical Continuity Liebert Challenger ITR Installation Manual Nominal Capacities 23 or 33 kW 50 amp 60Hz 4 EMERSON Network Power 1 0 1 1 2 0 2 1 2 2 2 3 2 4 2 5 2 6 2 7 2 8 3 0 3 1 3 2 3 3 3 4 3 5 4 0 4 1 4 2 4 3 5 0 5 1 TABLE OF CONTENTS INTRODUCTION gt Sheu iuar e he ee es BA ee Si wee ee ie We ees ie tee et 1 System Descriptions essan ce odd ee BE eh A PBS BEES 1 LEL Sef Contained Syst ms a NEA ee he a 1 EEZ bwled Water Models 00 cla e e e ts best alli a weed ous pt ELMS 1 E Sp SyStems ct a a ai E a da ee eth eae teens ricas 1 INSTALLATION iii A A A SR Oy ee 2 Room Prepara A Behe A A aes BRN ots E Mas Bor 2 Equipment Inspection iii dir Se ae ess BAS oa RA PRINS Ba Da ne HAS 2 Location Considerations tds hee aa a dined abivadada 2 2 3 1 Remote Sensor Installation Location 0 0 0 ssaa ce eee teeta e eens 2 Equipment Handling ass noses iw eB ee EE Soa bas Haw Pee Ga vg alae is 2 241 and aie With Skid e caci n 3 DAD Removal Gf Skid iii a e ee Dae Se energie a Oe ed Be ai 3 Piping Considerations 3 A A A he wc A A Oak ese d 6 Dede Traian aces E EN OR NR AN Seen ded 6 Electrical Connections wu laden pads Oe Ne eo Oe wee chee Pees Se ee Su 8 11 Balancing the Air Distribution 34 4 2 4 tose is OOS A Be A a ees ec 12 2 7 Ducted Applications 2 5058 a A ie we Gr td Sivas 12 2 7 2 Plenum Inst
26. IPING a la a E OPTIONAL PIPING Components are not supplied by Liebert but are recommended for proper circuit operation and maintenance NOTE Refer to installation manual for field piping guidelines Fluid Return from Unit ZY Fluid Supply IAA SL 11900 PG 5 to Unit 3 Way Water Regulating Valve optional 52 Split System Models 7 6 7 6 1 7 6 2 7 6 3 7 6 4 Water and Glycol Cooled Condensing Units For installation guidelines refer to Installing the Indoor Condensing Unit on page 48 Piping Considerations It is recommended that manual service shut off valves be installed at the supply and return line to each unit This will provide for routine service or emergency isolation of the unit When the water source for the condenser is of poor quality it is good practice to provide cleanable fil ters in the supply line These filters will trap the particles in the water supply and extend the service life of the water cooled condenser Table 30 Water and glycol cooled unit connection sizes Connection Size and Type Condenser Water Inlet 1 1 8 OD Cu Condenser Water Outlet 1 1 8 OD Cu Suction Line 1 7 16 16 male 12 quick connect Liquid Line 1 1 16 12 male 10 quick connect Table 31 Water and glycol cooled condensing unit data Net Weight Glycol Volume Model Ib kg gal liters MC_69W MC_68W 282 128 2 0 7 6 Condenser Water Requirements
27. Liebert Earth ground connection 50 60Hz Connection terminal for field supplied earth grounding wire Earth ground bar 50Hz only Connection terminals with factory ground from each high voltage component for field supplied earth grounding wire Control and monitoring section of electric box 8 Remote unit shutdown Replace existing jumper between Terminals 37 38 with normally closed switch having a minimum 75VA 24VAC rating Use field supplied Class 1 wiring Two additional contact pairs available as an option labeled as 37B 38B 37C 38C Replace existing jumper for appropriate pair as done for 37 38 O ole oO N 11 Installation 2 7 2 7 1 2 7 2 9 Special alarm connections Field supplied 24V Class 1 wiring for special alarm Connection made by adding normally open contacts between terminals 24 50 Optional additional connections available with Advanced or Advanced with Graphics controls and appropriate optional accessories connections 51 55 and 56 10 Liebert SiteScan connection Terminals 77 and 78 are for connection of a 2 wire twisted pair communication cable available from Liebert or others to optional Liebert SiteScan 11 Remote condensing unit connection Field supplied 24V Class 1 wiring to remote condensing unit terminals 1 2 3 4 from R2 relay split system only 12 Smoke detector alarm connections Field supplied 24V Class 1 wiring to remote alarm circuits Fa
28. Pa or with a high pressure Johnson Controls valve 350 psig 2413 kPa The valve may be adjusted with a standard refrigeration service valve wrench or screw driver To lower the head pressure setting turn the square adjusting screw clockwise until the high pressure gauge indicates the desired setting To raise the head pressure setting turn the adjusting screw counterclockwise until the desired set ting is obtained Figure 13 Johnson Controls valve adjustment 4 3 2 4 3 3 Range spring Valve spring Range adjustment screw retainer Insert screwdrivers underneath the valve spring guide Water Regulating Valve Manual Flushing The valve may be flushed by inserting screwdrivers or similar tools under the opposing sides of the main spring and lifting This action will open the valve seat and flush any dirt particles from the seat If this fails the valve must be disassembled for cleaning the seat Testing Valve Function When the refrigeration system has been off for 10 15 minutes the water flow should stop Should the water continue to flow the valve is either improperly adjusted or the pressure sensing capillary is not properly connected to the condenser 26 Glycol GLYCOOL Cooled Models 5 0 GLYCOL GLYCOOL COOLED MODELS 5 1 5 2 5 3 5 3 1 5 3 2 5 3 3 Drycooler Location The drycooler should be located for maximum security and maintenance accessibility Avoid ground
29. Quick Connect System 1 and System 2 on 8 Ton only Male Coupling SL 11081 PG 7 45 Split System Models Table 26 Cabinet and floor planning dimensional data prop fan condensing modules top air discharge Model Numbers Dimensional Data in mm 60 Hz 50 Hz PFCO67A _H PFCO66A _H PFHO67A _H PFCZ67A L PFCZ66A _L A 53 1343 B 36 1 4 918 38 1 2 978 Cc 5 1 2 140 Module Weight Ib kg net 488 222 Table 27 Piping and electrical connections top air discharge Model Numbers Dimensional Data in mm Piping Connections in mm 60 Hz 50 Hz PFCO67A _H PFCO66A _H PFHO67A _H PFCZ67A L PFCZ66A _L A 2 51 B Cc 6 152 8 1 2 216 D 4 3 4 121 E 7 3 4 197 F 8 1 2 216 46 Split System Models Figure 22 Electrical field connections prop fan condensing module HORIZONTAL AIR DISCHARGE MODELS Field supplied 24V NEC Class 2 wiring to evaporator module A A i Y I G N l i Electric service connection to contactor or terminal block Single or 3 phase ____ 7 electric service not by Liebert o High voltage electric power supply entrance Low voltage electric power supply entrance Earth ground connection terminal for field wiring SL 11081 PG 8 p NOTE Refer to specification sheet for full load am
30. S 26 4 3 1 Water Regulating Valve Adjustment 26 4 3 2 Water Regulating Valve Manual Flushing o ooooocrrrrroor morra 26 4 3 3 Testing Valve Function o oo eee eee een teen ene 26 GLYCOL GLYCOOL COOLED MODELS 00 cece cece ee eee 27 Drycooler A i Ses eS ese ard he Bs Soe Re Sey eae elk el ed NI BE NN NPS 27 5 2 5 3 5 4 5 5 5 6 5 7 6 0 6 1 7 0 7 1 7 2 7 3 7 4 7 5 7 6 8 0 8 1 Drycooler Installation ei ias pi Gab ewido as a GOAL apd whereas ade de weds as 27 Electrical Connections ess tai A EAE Sd IRE GEE SiG habe BP A hai 27 Dodi Lime Voltaire asiru o a Ree eo We a daa 27 Dedede VOW Volta NE ATA aaa ce ane ee AAA AN A Sil a ROO ae ote at 27 5 3 3 Pump and Drycooler 0 0 00 cece eee eens 27 Glycol Piping ese es 3G A ek oe EF es Rake OR Gee AA AE BE A 28 5 4 1 Expansion Tanks Fluid Relief Valves and Other Devices ooooooo ooo 28 Filling Instructions Ve a a ge db Paes Ba wares bab aed pa dide a 29 5 5 1 Preparing the System for Filling cc eee eee nnn 29 Doe Glycol Solutions cas is ti ne AE ror coe ada 30 5 5 3 Filling the System ee eee eee ene e eee e een nes 31 o A A AR RA 36 Glycol Regulating Valve o 36 5 7 1 Glycol Regulating Valve Adjustment 36 BD Zo Testing Valve FUNCION rwg id Ss tt ons Sonata Ri ir de 36 CHILLED WATER MODELS 0c cece ee eee ee eee eee eee eee eee eee 37 Piping Consi
31. The standard maximum water pressure is 150 psig 1034 kPa For applications above this pressure consult the factory about high pressure systems The system will operate in conjunction with a cooling tower city water or drycooler Regulating Valve Adjustment and Testing Refer to 4 3 1 Water Regulating Valve Adjustment and 4 3 3 Testing Valve Function Glycol Systems For split system glycol systems use drycooler and pump data found in 5 0 Glycol GLYCOOL Cooled Models See Table 16 Drycooler data Electrical control interconnect to drycooler is wired from water glycol condensing unit 53 Split System Models Figure 27 Water glycol cooled condensing unit dimensions al aie CABINET 6 DIMENSION DIMENSION Customer supplied threaded rods for module support from ceiling typ 4 Removable Access Panel 1 2 12 7mm dia holes for module rigging typ 2 each end 610mm CABINET DIMENSION Hanger Bracket Shaded area indicates a recommended clearance of 30 762mm for component access 29 13 16 33 5 8 and removal 757 2mm 854 1mm THREADED ROD THREADED ROD CENTERS CENTERS NOTE Unit is evenly spaced in reference to threaded rod centers 7 8 22 2mm amp 1 1 8 28 6mm Y 7 8 22 2mm 8 1 1 8 28 6mm dia knockouts electrical entrance for dia knockouts electrical entrance for line voltage connection line voltage connection Single Point 87 16 Power Kit 21
32. allation 50 006 oes ete aaa nee 12 Checklist for Completed Installation us aa 4404400 pee ea an As aaa ea eas 13 AIR COOLED MODELS 60 iia ceed edt Grease a lata aca 14 Condenser location 22 2 4 02 lt A toe RR BGR a GU RRO ER Oye Oa eS amet ee nas 14 Electrical Connectionss 2 merr aa wre Oe Sa a aaa ach es am Geers aes oe 14 SA ne Viola Ge aie enh sg sey ee NN 14 B22 Low Votare ick Witte o elias a ld fore ed tenes ese dott a cee et cena 14 3 2 3 Lee Temp Flood Back Head Pressure Control Condensers 000 c cece nee eae 14 Refrigerant Piping ess AA A A Se os as a oe ee BS as ds 16 Fan Speed Control Systems 17 SA Materials Supple rc A a ah OM 17 3 4 2 Dehydration Leak Test and Charging Procedures for R22 standard or R407C Optional 18 o AC AT Oi Oe ese ad cect ere oct al 1 Sa wat he gts Bees i nen E A se at octeh ene Tes arses etek eae ack 20 Lee Temp Flood Back Head Pressure Control Systems 0 00 cece eee ee eee 20 Bedell TRAP A RN 20 3 02 Materials Supplied ia nition Oe te ad Bt ee ed 21 3 5 3 Dehydration Leak Test and Charging Procedures for R22 Standard or R407C Optional 21 ARI LCHAPEING a eens O RH ARM RNA 22 WATER COOLED MODELS 0c cece eee eee eee eee eee ee eee eee eee 24 Piping Considerations sanie ii OGM eae Leah a Foes pare hen 24 CONGO SOR 2472 6 ire Sear a Brace ese Be wd ar Oe EA he WR A WOW RBIS Ces ORG ene Ware See 24 Water Resulating Valve unan ccs oh 8 Geen Se RE es SR Ae eS Se
33. arge models 43 Outdoor air cooled condensing unit top air discharge models 0000 ce oo 45 Electrical field connections prop fan condensing module 0 c eee eens 47 Detail of ceiling hanging bracket o oooooooorrrro ete eee nena 49 Centrifugal air cooled condensing unit dimensional data ooooooooooooooo ooo 50 Centrifugal air cooled condensing unit dimensional data con t o ooooooooooooo 51 Split systems general arrangement 0 eee ee ee eee eens 52 Water glycol cooled condensing unit dimensions 00 eee cee eee eens 54 Water glycol cooled condensing unit CON 55 iii Table 1 Table 2 Table 3 Table 4 Table 5 Table 6 Table 7 Table 8 Table 9 Table 10 Table 11 Table 12 Table 13 Table 14 Table 15 Table 16 Table 17 Table 18 Table 19 Table 20 Table 21 Table 22 Table 23 Table 24 Table 25 Table 26 Table 27 Table 28 Table 29 Table 30 Table 31 Table 32 Table 33 TABLES Unit shipping weights teatega A A A ER BAER ER AN 3 Piping conn ction SIZES ana e sete a DS Ee 6 Air cooled condenser statistics 0 ee eee tenes 15 Recommended line sizes OD copper inches 0 00 eee nee 16 Equivalent lengths feet for various pipe fittings 00 0 eee nes 17 Indoor unit refrigerant charge lb kg R22 or R407C per unit serial tag 17 Line charges refrigerant per 100 ft 30 m of Typ
34. ated storage receiver Head pressure control valve with integral check valve Adapter assembly Rotalock valve Pressure relief valve Liquid level sight glass Check valve 8 Bolts six per receiver 3 8 x 1 NOTE Lee Temp heater pad requires a separate continuous electrical source of either 115 VAC or 200 208 280 VAC Dehydration Leak Test and Charging Procedures for R22 Standard or R407C Optional Lee Temp Control Type Condenser A 4 4 4 CAUTION All local codes for handling refrigerant must be followed NOTE As R22 and R407C are similar in properties proper safety equipment and proper refrigeration tools are required on both types Check unit nameplate for correct refrigerant type and oil type before topping off or recharging a system NOTE Refrigerant R407C uses a POE polyol ester lubricant The R407C refrigerant must be introduced and charged from the cylinder only as a liquid NOTE When installing field piping care must be taken to protect all refrigerant lines from the atmosphere especially when using refrigerants with POE oils Do not allow the piping to stand open to air for more than 15 minutes Units designed for R407C have a compressor which contains POE oil that is very hygroscopic that is it quickly absorbs water from the air The longer the compressor piping is left open to air the harder it will be to fully evacuate If left open too long the POE oil may need to be replaced before achi
35. cedure You may have to bypass the LP Switch low pressure switch to start the compressors and stop short cycling Reset the Head Pressure switch es if open Add refrigerant R407C liquid or R22 vapor per unit nameplate to the suction side of the compressor until there is sufficient pressure to energize the low pressure switch NOTE When adding refrigerant to an operating system it may be necessary to add the refrigerant de through the compressor suction service valve Because the refrigerant leaving the refrigerant cylinder must be in a liquid state care must be exercised to avoid damage to the compressor It is suggested that a sight glass be connected between the charging hose and the compressor suction service valve This will permit adjustment of the cylinder hand valve so that liguid can leave the cylinder while allowing vapor to enter the compressor Then you may remove the manual bypass you applied earlier Charge the unit until the proper charge is weighed in Table 10 Refrigerant control settings psi kPa Low Pressure Cut Out Low Pressure Cut In High Pressure Cut Out 20 137 9 65 448 2 360 2482 22 Air Cooled Models Figure 11 Air cooled Lee Temp general arrangement Inverted Trap on Condenser Coil discharge line to extend abovebase of coil by a minimum of 7 1 2 190mm Va x J gt A a Head Pressure ia Control with dl Integral Check Valve Piping Assembly
36. charge for the system Weigh in as much of the system charge as possible Refer to the unit condenser and refrigerant line charge tables 5 Set the control temperature setpoint see operation manual to 60 F 15 C and set the relative humidity setpoint higher than the conditioned room ambient to ensure that solenoid valves and hot gas bypass valves are open during the charging procedure You may have to bypass the LP Switch low pressure switch to start the compressors and stop short cycling Reset the Head Pressure switch es if open 6 Add refrigerant R407C liquid or R22 vapor per unit nameplate to the suction side of the compressor until there is sufficient pressure to energize the low pressure switch NOTE Q When adding refrigerant to an operating system it may be necessary to add the refrigerant through the compressor suction service valve Because the refrigerant leaving the refrigerant cylinder must be in a liquid state care must be exercised to avoid damage to the compressor It is suggested that a sight glass be connected between the charging hose and the compressor suction service valve This will permit adjustment of the cylinder hand valve so that liquid can leave the cylinder while allowing vapor to enter the compressor Then you may remove the manual bypass you applied earlier 7 Charge the unit until the liquid line sight glass becomes clear Then add one additional pound of refrigerant 8 As head pressure builds th
37. ctory wired contacts from optional smoke detector are 91 comm 92 NO and 93 NC 13 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 14 Reheat and Humidifier Lockout Optional emergency power lockout of reheat and or humidifier connections provided for remote 24V AC source 15 Heat rejection connection Field supplied 24V Class 1 wiring to interlock heat rejection from pigtails 70 71 which are factory connected to compressor side switch self contained units only and to Glycool relay R5 Glycool units only 16 Main Fan Auxiliary Switch Optional main fan auxiliary side switch Terminals located in field wiring compartment for remote indication that the evaporator fan motor unit is on Field to connect 24V maximum 17 Optional Condensate Alarm Dual Float Condensate Pump only Relay terminals located in field wiring compartment for remote indication Located inside Liebert Challenger ITR on top NOTE Refer to specification sheet for full load amp and wire size amp ratings Balancing the Air Distribution Ducted Applications For ducted applications the duct work may be attached to the top perimeter of the Liebert Challenger ITR see Figure 2 The duct work must allow access to the motors blowers for maintenance The duct work must be designed within the capacity of the Liebert Challenge
38. derations ari ta ate De Feed Be ea AA BS a ae 37 SPLIT SYSTEM MODELS pd oic 0s eS a Be ME eS 38 Location Considerations a aS ose is in A Bie ak OS Sn Be SBR eed 38 7 1 1 Air Cooled Condensing Units 38 7 1 2 Water Glycol Cooled Condensing Units 0 0 ccc cece eens 38 Electrical Connections 2 ssa tanterna ea eka Ue a ate a Awe es bal hee seed 38 Deel A O ae Eos cock E eb ee ds ick thea ses AS 38 IEPS W VOMAB Oi tet dele seis eeo O ae a Gs araia BGS GSE at NE Pa lat we Ea Pa 38 Piping Considerations 0 ee eee eens 39 id Ls REIS Tan DOE A gh hb la MR EN E et 39 7 3 2 Quick Connect Fittings 42 Outdoor Air Cooled Condensing Units 0 0 0 oaeee eeaeee 43 Centrifugal Air Cooled Condensing Units 0 eee eens 48 7 5 1 Installing the Indoor Condensing Unit 48 eos DUCE cease ee SF eB kee aie e dara enw sn OER a atl Bea lage ee deg Be ea raed 8 49 Water and Glycol Cooled Condensing Units 0 0 0 ccc ee ees 53 7 6 1 Piping Considerations a eae abe als ae RE iw eR eae da 53 7 6 2 Condenser Water Requirements 53 7 6 3 Regulating Valve Adjustment and Testing 53 UGA Glycol Systems a Aa ae e a Aa eae oa 53 R407C REFRIGERANT e a ad ee a Pelee aa 56 Calculating Sub oolane cio cee A Pca EG a sl BAR AOE OM 57 Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 Figu
39. detection system such as a Liqui tect that is installed near the base of the unit or below the elevated floor Figure 18 Chilled water general arrangement horizontal flow BR Chilled Water Supply Water Chilled Valve Coil Water Actuator Return 3 WAY VALVE ll 3 Way Shutoff Chilled Valves gt Switch Air optional Flow 1 gt Hose PAN f Bibs ANG Chilled valve Water Actuator Supply Chilled _ 2 Way Chi f hilled Water H Chilled Water Return Water Coil Valve Sinton 4 f 2 WAY VALVE Valves W p Wii Es es SINGLE CIRCUIT SHOWN P Be FACTORY PIPING as 7 FIELD PIPING tilo E Components are not supplied by Emerson but a Dee are recommended for proper circuit operation SL 11899 Bibs and maintenance Pg 5 37 Split System Models 7 0 SPLIT SYSTEM MODELS 7 1 7 1 1 7 2 7 2 1 7 2 2 Three 3 condensing unit styles are available two 2 air cooled and one 1 water glycol cooled con densing unit Location Considerations Air Cooled Condensing Units To assure an adequate air supply it is recommended that all condensing units be located in a clean air area away from loose dirt and foreign matter that may clog the coil Condensing units must not be located in the vicinity of steam hot air or fume exhausts or closer than 18 from a wall obstruction or adjacent unit The outdoor condensing unit should be located fo
40. dling With Skid Always keep the Liebert Challenger ITR upright indoors and protected from damage Do not use the extended rear door frame to lift the unit If possible transport the unit using a fork lift otherwise use a crane with belts or cables avoid ing pressing on the top edges of the packaging If using a fork lift make sure that the forks if adjustable are spread to the widest allowable dis tance to still fit under the skid NOTICE Do not attempt to lift the Liebert Challenger ITR with the extended rear door frame Attempting to do so will damage the unit Lift the unit only from its main base NOTICE While on the skid the Liebert Challenger ITR is too tall to fit through a standard height doorway 88 inches or 2108 mm tall Any attempt to move the unit while on the skid through a standard doorway will damage the unit 2 4 2 Removal of Skid 1 Remove the plywood skirting that keeps the skid and unit in place 2 Raise the Liebert Challenger ITR off the skid Liebert recommends using a fork lift see Figure 1 or similar machine to ensure that the unit is lifted properly NOTE Lift the Liebert Challenger ITR only from its main base Do not use the extended rear door frame to lift the unit 3 Once the unit is raised the skid can be removed Figure 1 Removing Liebert Challenger ITR from skid Raise unit with fork lift or similar machine Remove plywood skirting holding unit and skid in place
41. e L copper tube ooooooooo 17 Condenser refrigerant per serial tag 6 eee een eee nes 17 Refrigerant control settings psi kPa o 20 Refrigerant control settings psi kPa 0 cee een ne ees 22 Room dew point temperatures 28 Indoor unit glycol volume approximate gallons liters max 0 eee 29 Volume in standard Type L copper pipe 29 Ethylene glycol concentrati0OS oooooor ee ee eee eee e eee enee 30 Mounting hole dimensional data 33 Drycooler data oss eich fea ake a wea ae da as 33 Glycol pump datar e a a SS tnt AS chattel Teh T 33 Refrigerant control settings psi kPa 0 cece eens 36 Unit refrigerant charge ce eee eee eee e eet eee eens 40 Line charges refrigerant per 100 ft 30 m of Type L copper tube 0 200 000 ee 40 Recommended refrigerant lines R22 or R407C sizes OD copper 0 0 02 eee eee 40 Eane couplin gsi Zes ci A A Oh Pind lia heed Sa na Be Se TS 40 Equivalent lengths feet for various pipe fittings 00 ccc cece 41 Horizontal air discharge cabinet and floor planning dimensional data 44 Horizontal air discharge piping and electrical connection data 0 0 cee eee 44 Cabinet and floor planning dimensional data prop fan condensing modules top AI CISCHAL OC ws A eb terse tate A A VTA Ges phe ARES cata TAO poned Bs 46 Piping and electrical connections top air discharge
42. e 5mm 177 8mm 4 1 25 4mm Es 1 25 4mm 101 6mm 1 2 12 7mm 8 Holes T pi 8 8 Gallon Expansion Tank 4 1 2 1 1 2 33 3 Liter 38 1mm 6 1 8 38 1mm 155 6mm 3 76 2mm SL 10065 PG 7B SL 10070 PG 6B Table 15 Mounting hole dimensional data A B Cc PUMP PACKAGE in mm in mm in mm SINGLE 0 75 7 5hp 15 1 4 387 4 2 1 2 63 5 22 1 2 571 5 DUAL 0 75 5 hp 30 1 4 768 4 2 1 2 63 5 22 1 2 571 5 DUAL 7 5 hp 39 5 16 998 5 1 3 4 44 5 26 7 8 682 6 Table 16 Drycooler data Drycooler Model No of Weight Conn Sizes A Dimension B Dimension C Dimension Coil Internal No Fans Ib kg Suct amp Disc in in mm in mm in mm Volume gal I 069 1 410 186 1 1 4 51 1 2 1308 44 1118 42 1067 2 4 9 2 092 1 430 195 1 1 2 51 1 2 1308 44 1118 42 1067 3 7 13 9 109 1 450 204 2 51 1 2 1308 44 1118 42 1067 4 9 18 6 112 1 470 213 2 51 1 2 1308 44 1118 42 1067 5 8 22 0 139 2 565 256 2 91 1 2 2324 84 2134 82 2083 4 8 18 2 197 2 605 274 2 91 1 2 2324 84 2134 82 2083 9 0 34 1 Table 17 Glycol pump data Pump Pump Suction Pump Discharge Hp Hz Connection in Connection in 1 1 2 60 1 1 4 3 4 2 60 1 1 4 3 4 3 60 1 1 2 1 5 60 1 1 2 1 1 4 1 50 1 1 4 3 4 1 1 2 50 1 1 4 3 4 2 50 1 1 4 3 4 3 50 1 1 2 1 1 4 Connection sizes apply
43. e before condensation will occur Expansion Tanks Fluid Relief Valves and Other Devices An expansion tank must be provided for expansion and contraction of the fluid due to temperature change in this closed system Vents are required at system high points to vent trapped air when fill ing the system A relief valve is a also a necessary piping component Depending on the complexity of the system various other devices may be specified Pressure gauges flow switches automatic air separator tempering valves standby pumps sensors for electrical con trols and flow switches are just a few of these devices NOTICE Immediately following the use of water for leak testing or system cleaning charge the tested system with the proper percentage of glycol and water for the application s coldest design ambient Complete system drain down cannot be assured and equipment damage could result from freezing of residual water 28 Glycol GLYCOOL Cooled Models 5 5 5 5 1 Filling Instructions Preparing the System for Filling It is important to remove any dirt oil or metal filings that may contaminate the cooling system piping in order to prevent contamination of the fresh glycol solution and fouling of the drycooler piping The system should be flushed thoroughly using a mild cleaning solution or high quality water and then completely drained before charging with glycol Cleaning new systems is just as important as clean ing old ones
44. e condenser fan starts rotating The fan becomes fully energized when sufficient head pressure is developed Fan starts to rotate at 190 psi and is full speed at 250 psi Table 9 Refrigerant control settings psi kPa Low Pressure Low Pressure High Pressure Cut Out Cut In Cut Out 20 137 9 65 448 2 360 2482 Lee Temp Flood Back Head Pressure Control Systems The Lee Temp system consists of a modulating type head pressure control valve and insulated receiver with heater pad to ensure operation at ambient temperatures as low as 30 F 34 4 C Piping Lee Temp systems have two factory supplied field installed check valves one on the discharge side of the scroll compressor and one on the inlet side of the receiver Be sure to install the check valves with the refrigerant flow in the proper direction When soldering or brazing the valves it is very important that the internal parts be protected by wrapping the valve with a damp cloth to keep the valve tem perature below 250 F 121 C 20 Air Cooled Models 3 5 2 Materials Supplied 1 Built in pre wired condenser control box 3 5 3 2 3 4 5 6 7 a b d e f g Air cooled condenser Piping access cover to be reinstalled when piping is complete Bolts four per leg 3 8 x 5 8 Terminal block for two wire 24V interlock connection between the unit and the condenser Condenser legs four on one fan models Lee Temp system Insul
45. enoid High Pressure Coil Valve Scroll Liquid Injection Compressor Valve Bulb Suction S Male Quick C AIR COOLED Connect 1 2 12 7mm NPT Pressure Relief Valve Suction Line Coupling Glass Service Female Quick es a Control with Pons oped Integral Check Lee Temp External HotGas Valve Pressure Balancing Receiver Tube in Bypass Control Receiver Heater Valve Tube Equalizer gt Liquid Injection valve imiti Condenser Valve Male Quick Pressure Limiting JE a Connect Liquid Line Switch SA Solenoid Valve y a 7 P Liquid Line Coupling High Pressure gt Female Quick Switch _ Connect Scroll y 1 RS We Z Xpansion Coupling Compressor 7 y Valve o LY Liquid Injection a Hot Gas Bypass Valve Bulb Solenoid Valve Evaporator A A A ater Glycol Coil Suction Li Q lt gt Return uenon Ene AS Line Water Glycol Male Quick A LI Sina oO WATER COOLED Connect Za fina rad yt uid Return CO GLYCOL COOLED Coupling oe Pasta Te Service Suction Line 14 a is Access Female Quick SS A Ports Connect S De External coming Pies gs Equalizer Sensing lt r ot Gas Bypass Sh f BX A gt utoff A gt ee Injection S Control Valve Valves ary A 2 Way Water Tube inTube alve Liquid Line ane Regulating Condenser y Male Quick E Liquid Line Comnect Hose Bibs Female Quick Coupling Connect Expansion Coupling Valve SINGLE CIRCUIT SHOWN Evaporator FACTORY Coil P
46. enser must be located below the level of the cooling coil Total discharge line pressure drop must not exceed 10 PSIG 69 kPa Consult your local Liebert representative when considering installations outside these guidelines Table 4 Recommended line sizes OD copper inches 23 amp 33 kW 067A 065A Equivalent Length Hot Gas Line Liquid Line 50 ft 15 m 7 8 1 2 100 ft 30 m 7 8 5 8 150 ft 45 m 7 8 5 8 Recommended vertical line sizes must be used for proper oil return at all cooling and dehumidification steps 16 Air Cooled Models 3 4 3 4 1 Table 5 Equivalent lengths feet for various pipe fittings Copper Pipe 90 Degree 90 Degree 45 Degree Gate Globe Angle O D in Elbow Copper Elbow Cast Elbow Tee Valve Valve Valve 1 2 0 8 1 3 0 4 25 0 26 7 0 4 0 5 8 0 9 1 4 0 5 25 0 28 9 5 5 0 3 4 1 0 1 5 0 6 25 0 3 12 0 6 5 7 8 1 45 1 8 0 8 3 6 0 36 17 2 9 5 1 1 8 1 85 2 2 1 0 4 6 0 48 22 5 12 0 1 3 8 2 4 2 9 1 3 6 4 0 65 32 0 16 0 1 5 8 2 9 3 5 1 6 7 2 0 72 36 0 19 5 Refrigerant trap 4 times equivalent length of pipe per this table Table 6 Indoor unit refrigerant charge Ib kg R22 or R407C per unit serial tag R22 R407C Approximate Charge Approximate Charge Model Ib kg Ib kg 67A 65A 1 5 0 68 1 4 0 6 Table 7 Line charges refrigerant per 100
47. er 60Hz 50Hz L HG 067A 065A 1 2 7 8 Split System Fan Coil Unit Connection Sizes in Model No BR BM Liquid Line Suction Line 60Hz 50 Hz L SC 060E 059E 1 2 O D Cu 1 1 8 O D Cu All Units Connection Sizes in Humidifier Line Condensate Condensate Pump Line Hot Water Reheat O D Copper Drain Line O D Copper O D Copper H C P Supply HWS Return HWR 1 4 1 2 OD Cu 1 2 5 8 5 8 Water Glycol Cooled Unit Connection Sizes in Model No BR BM Supply Line Return Line 60Hz 50 Hz S R 071WG 070WG 1 1 8 1 1 8 GLYCOOL Unit Connection Sizes in Model No BR BM Supply Line Return Line 60Hz 50 Hz S R 061G 058G 1 1 8 1 1 8 Chilled Water Unit Connection Sizes in Model No BR BM Supply Line Return Line 60Hz 50 Hz CWS CWR 102C 101C 1 1 8 1 1 8 Installation Figure 4 Piping connections for air cooled units mmi Piping outlet locations through the plenum are the same as the unit See below for descriptions and connection sizes Humidifier Water qr Hot Water Return Supply Line 1 4 OD CU 5 8 OD CU optional Hot Gas Refrigerant Line m Liquid Refrigerant Line 7 8 OD CU on Models 1 2 OD CU on Models BRO67A BRO65A BRO67A BROG5A A Condensate Pump 7 m Hot Water Supply Line 1 2 OD CU 5 8 OD CU optional Monitoring Panel PIPING OUTLET LOCATIONS
48. eving the required vacuum level 21 Air Cooled Models 3 5 4 Dehydration Leak Test 1 2 Make sure unit is OFF Open all disconnect switches and pull all fuses except control fuses On units supplied with circuit breakers open all breakers except for the transformer Add a jumper to the Fan Safety Switch between Common and Normal Open and disconnect the wire connected to the Normally Closed Turn unit disconnect ON Fan operation not required NOTE The above allows the technician to use unit 24 VAC power and controls to open liquid line solenoid valve s and hot gas bypass solenoid valve s for the dehydration process If no power is at the unit disconnect the technician is to use a separate 24 VAC source rated at 75 VA and connect to the system liquid line solenoid valve s and hot gas bypass solenoid value s directly Connect refrigeration gauges to the suction and discharge service valves of the compressor and open Attach a jumper hose from the Rotalock fitting on the outlet of the receiver and the Schrader fitting on the liquid header of the condenser Front seat the Rotalock valve approximately two turns To energize the liquid line solenoid valve s through the control system set the temperature setpoint see operation manual to 60 F 15 C and set the relative humidity setpoint higher than the conditioned room ambient to ensure that solenoid valves and hot gas bypass valves are open during the dehydra
49. f no power is at the unit disconnect the technician is to use a separate 24 VAC source rated at 75 VA and connect to the system liquid line solenoid valve s and hot gas bypass solenoid valve s directly 3 Connect refrigeration gauges to the suction and discharge service valves of the compressor Open all compressor service valves 4 To energize the liquid line solenoid valves through the control system power set the control temperature setpoint see operation manual to 60 F 15 C and set the relative humidity setpoint higher than the conditioned room ambient to ensure that solenoid valves and hot gas bypass valves are open during the dehydration process 5 Pressurize the system circuit s to 150 PSIG 1034 kPa by using dry nitrogen with a trace of refrigerant Check system for leaks with suitable leak finder 6 After completion of leak testing release the test pressure per local code and pull a deep vacuum on the system with a suitable pump 7 After four hours check the pressure readings and if they have not changed break vacuum with refrigerant Pull another vacuum to 250 microns or less Recheck the pressure after two hours After completing this step pressurize the circuits with refrigerant R407C liquid or R22 vapor per unit nameplate until suction and discharge pressures have equalized 18 Air Cooled Models Figure 10 Air cooled fan speed control general arrangement Condenser Coil Schrader Valve
50. fer to equipment nameplate regarding wire size and circuit protection requirements Refer to elec trical schematic when making connections Make all wiring and electrical connections in accordance with local and national codes A WARNING Risk of electric shock Can cause injury or death Disconnect all local and remote electric power before working within the unit Use a voltmeter to make sure power is turned off before making any electrical connections Line Voltage Line voltage electrical service is required for all condensing units at the location of the condensing unit This power supply does not have to be the same voltage as the indoor unit This separate power source may be 208 230 460 or 575 V 60 Hz or 200 230 or 380 415V 50 Hz A disconnect switch is required and must be mounted per local and national codes to isolate the unit for maintenance Low Voltage The control cable between the condensing unit and the evaporator unit is connected between termi nals 1 2 and 3 on the terminal strip in the evaporator unit and the condensing unit control box A fourth wire is required on systems with hot gas bypass NEC Class 1 wiring is required Glycol cooled units also require a two wire control connection to the drycooler and pump package 38 Split System Models 7 3 7 3 1 Piping Considerations Refrigerant Loop A CAUTION All local codes for handling refrigerant must be followed NOTE As R22 and R407C are
51. ft 30 m of Type L copper tube R22 R407C Liquid Line Hot Gas Line Liquid Line Hot Gas Line O D Ib kg Ibs kg Ib kg Ib kg 1 2 7 3 3 3 1 3 0 6 6 9 2 9 5 8 11 7 5 3 1 1 0 11 0 4 6 2 2 0 9 3 4 16 6 7 5 3 0 1 4 15 7 6 5 3 1 1 3 7 8 24 4 11 1 4 4 2 0 23 0 9 6 4 5 1 9 Table 8 Condenser refrigerant per serial tag R22 R407C Approximate Charge Approximate Charge Ib kg Ib kg Model Fan Speed Lee Temp Fan Speed Lee Temp 083 5 2 27 27 12 3 8 3 25 12 104 8 3 63 39 17 7 9 4 37 17 Charge includes the receiver charge Fan Speed Control Systems Fan Speed Control provides an infinite number of speed variations on specially designed permanent split capacitor motors The control module varies the air quantity passing over the condenser coil by monitoring refrigerant pressure Materials Supplied A IS Built in pre wired condenser control box Air cooled condenser Piping access cover to be reinstalled when piping is complete Bolts four per leg 3 8 x 5 8 Terminal block for two wire 24 volt interlock connection between unit and condenser Condenser legs four on one fan models 17 Air Cooled Models 3 4 2 Dehydration Leak Test and Charging Procedures for R22 standard or R407C Optional Fan Speed Control Type Condenser A CAUTION All local codes for handling refrigerant must be followed NOTE As R22 and R407C are similar in properties pr
52. have to be the same voltage as the indoor unit This separate power source may be 208 230 460 or 575 V 60 Hz or 200 230 or 380 415 V 50 Hz The disconnect switch is factory sup plied and mounted in the electric panel Low Voltage A control interlock between the drycooler and the indoor unit is required and is connected between 70 and 71 in the handy box of the indoor unit and the pump and drycooler control box of the drycooler NEC Class 1 wiring is required Pump and Drycooler All wiring to the pump and drycooler from the control box should be done in accordance with the elec trical schematic on the inside lid of the drycooler control box and with local and national codes 27 Glycol GLYCOOL Cooled Models 5 4 5 4 1 Glycol Piping NOTICE Galvanized pipe must not be used in or with systems or units that contain glycol The phosphates in the inhibitor can react with the zinc in the galvanized pipe precipitating an insoluble material that can eventually foul the system To help prevent piping failures supply and return lines must be supported in a way that keeps their weight from bearing on the piping of the unit drycooler or pumps To avoid the possibility of burst pipes it is necessary to install a relief valve in the system This valve may be obtained from the supplier as an option or obtained from another vendor Fluid cooled condensers have small internal flow passages To avoid clogging and other resulting sys
53. in a particular application you should review the lat est Material Safety Data Sheets and ensure that the use you intend can be accomplished safely For Material Safety Data Sheets and other product safety information contact the supplier nearest you Before handling any other products mentioned in the text you should obtain available product safety information and take necessary steps to ensure safety of use NOTICE When mishandled glycol products pose a threat to the environment Before using any glycol products review the latest Material Safety Data Sheets and ensure that you can use the product safely Glycol manufacturers request that the customer read understand and comply with the information on the product packaging and in the current Material Safety Data Sheets Make this information available to anyone responsible for operation maintenance and repair of the drycooler and related equipment No chemical should be used as or in a food drug medical device or cosmetic or in a product or pro cess in which it may contact a food drug medical device or cosmetic until the user has determined the suitability and legality of the use Since government regulations and use conditions are subject to change it is the user s responsibility to determine that this information is appropriate and suitable under current applicable laws and regulations NOTICE Automotive antifreeze is unacceptable and must NOT be used Typical inhibited fo
54. ing units are installed below the evaporator the suction gas line should be trapped with an inverted trap to the height of the evaporator This prevents refrigerant migration to the compressors during off cycles Maximum recommended vertical drop to condensing unit is15 ft 4 6m 1 I Suction Line Piping Condensing unit above evaporator Traps recommended at the base of riser and every 25 feet 7 6m of vertical rise Suction Line Piping Condensing unit below evaporator 41 Split System Models 7 3 2 Quick Connect Fittings NOTE When hard piping is used complete all piping and evacuate lines before connecting quick connects Be especially careful when connecting the quick connect fittings Read through the following steps before making the connections 1 Se 00 BO gt Remove protector caps and plugs Carefully wipe coupling seats and threaded surfaces with a clean cloth Lubricate the male diaphragm and synthetic rubber seal with refrigerant oil Thread the coupling halves together by hand to ensure that the threads mate properly Tighten the coupling body hex nut and union nut with the proper sized wrench until the coupling bodies bottom out or until a definite resistance is felt Using a marker or pen make a line lengthwise from the coupling union nut to the bulkhead Tighten the nuts an additional quarter turn the misalignment of the lines shows how much the coupling has bee
55. izontal air discharge piping and electrical connection data Model Numbers Dimensional Data in mm Piping Connections in mm 60 Hz 50 Hz PFCO67A _L PFCO66A _L PFHO67A _L A 2 51 B 6 152 Cc 8 1 2 216 D 4 3 4 121 7 3 4 197 E F G 8 1 2 216 44 Split System Models Figure 21 Outdoor air cooled condensing unit top air discharge models GUARD HEIGHT TOP AIR DISCHARGE UNIT DIMENSIONS see Table 26 LEFT AIR SHADED AREA INTAKE INDICATES A RECOMMENDED CLEARANCE OF 18 457mm FOR PROPERAIR FLOW SHADED AREA INDICATES A RECOMMENDED SHADED AREA CLEARANCE OF 18 457mm INDICATES A RECOMMENDED FOR PROPERAIR FLOW REMOVABLE FRONT PANEL FOR CLEARANCE OF 24 610mm ACCESS TO HIGH VOLTAGE amp ap COMPONENT AGELESS LOW VOTLAGE CONNECTIONS pes eres AND REFRIGERATION COMPONENTS 36 1 8 918mm 53 3 16 FOOTPRINT taimm DIMENSIONS 1 2 Bolt Down Holes 6 places 25 3 32 __ 637mm 2 46 7 32 1174mm SL 11081PG 5 System 2 23 amp 33kW 4 23 32 120mm Electrical Entrance for High Voltage Connection H PIPING amp ELECTRICAL CONNECTIONS see Table 27 O fj Electrical Entrance for Low Voltage System 1 3 Ton Suction Line Liquid Line Quick Connect Male Coupling Connection E
56. lied 24V NEC Class 1 wiring glycol cooled units only q NOTES 1 Refer to specification sheet for full load amp and wire size amp ratings 2 Control voltage wiring must be a minimum of 16 GA 1 6mm for up to 75 23m or not to exceed 1 volt drop in control line 55 R407C Refrigerant 8 0 R407C REFRIGERANT Table 32 R407C pressure temperature chart for operation and superheat discharge hot gas and suction gas Temperature Gauge Pressure Temperature Gauge Pressure Temperature Gauge Pressure F C Psig kPa F C Psig kPa F C Psig kPa 0 0 17 8 18 9 130 70 0 21 1 114 9 792 1 0 17 2 19 6 135 72 0 22 2 119 3 822 2 0 16 7 20 4 141 74 0 23 3 124 853 3 0 16 1 21 2 146 76 0 24 4 128 885 4 0 15 6 22 0 152 78 0 25 6 133 917 5 0 15 0 22 8 157 80 0 26 7 138 950 6 0 14 4 23 6 163 82 0 27 8 143 984 7 0 13 9 24 5 169 84 0 28 9 148 1019 8 0 13 3 25 4 175 86 0 30 0 153 1054 9 0 12 8 26 2 181 88 0 31 1 158 1091 10 0 12 2 27 1 187 90 0 32 2 164 1128 11 0 11 7 28 0 193 92 0 33 3 169 1167 12 0 11 1 28 9 200 94 0 34 4 175 1206 13 0 10 6 29 9 206 96 0 35 6 181 1246 14 0 10 0 30 8 213 98 0 36 7 187 1287 15 0 9 4 31 8 219 100 0 37 8 193 1329 16 0 8 9 32 8 226 51 0 10 6 78 7 543 102 0 38 9 199 1372 17 0 8 3 33 8 233 52 0 11 1 80 4 554 104 0 40 0 205 1416 18 0 7 8 34 8 24
57. luid may be a mixture of liquid and vapor Why There Are Two R407C Temperature and Pressure Tables R407C is a blend of refrigerants that exhibits a temperature glide of approximately 8 to 12 F 4 to 7 C This glide is the difference between the liquid and vapor saturation temperatures at a given pressure Use the correct table for the saturation temperature you need Table 32 is for super heat or operating controls Table 33 is for subcooling only 57 Ensuring The High Availability Of Mission Critical Data And Applications Emerson Network Power the global leader in enabling business critical Technical Support Service continuity ensures network resiliency and adaptability through _ Web Site a family of technologies including Liebert power and cooling www liebert com Monitoring technologies that protect and support business critical systems Liebert solutions employ an adaptive architecture that responds a Liebert monitoring emerson com to changes in criticality density and capacity Enterprises benefit Outside the US 614 841 6755 from greater IT system availability operational flexibility and Single Phase UPS reduced capital equipment and operating costs 800 222 5877 upstech emersonnetworkpower com Outside the US 614 841 6755 Three Phase UPS 800 543 2378 powertech emersonnetworkpower com Environmental Systems 800 543 2778 Outside the United States 614 888 0246 Locations United States 1050
58. ly mounted to the roof structure The ceiling and ceiling supports of existing buildings may require reinforcements Be sure to follow all applicable codes Use field supplied threaded suspension rods and 3 8 16 factory hardware kit Recommended clearance between ceiling grids and building structural members is unit height plus three inches Install the four field supplied rods by suspending them from suitable building structural members Locate the rods so that they will align with the four mounting holes in the flanges that are part of the unit base Using a suitable lifting device raise the unit up and pass the threaded rods through the four mount ing holes in the flanges that are part of the unit base Attach the threaded rods to the unit flanges using the supplied nuts and grommets See Figure 23 Detail of ceiling hanging bracket Threaded Rod and Hardware Kit Installation The rubber grommets provide vibration isolation 1 Use the plain nuts to hold unit in place Adjust these nuts so that the weight of the unit is supported evenly by the four rods does not rest on the ceiling grid and is level NOTE The untts must be level in order to operate properly 2 Use the Nylock nuts to jam the plain nuts Table 28 Indoor centrifugal condensing unit Mone Net Weight 60 Hz 50 Hz Ib kg MC_65A MC_64A 449 204 MC_69W MC 68W 282 128 48 Split System Models Figure 23 Detail of ceiling
59. manufacturers 31 Glycol GLYCOOL Cooled Models Figure 14 Drycoolers and pump packages DRYCOOLER PS _ 43 9 16 P 105mm GLYCOL PUMP PACKAGE za See Note 1 ees rl itn 37 7 8 ee 1095mm 19 483mm O NS B 1097mm o 16 for keys to Provided on dimensions A B and C dual pump package only PUMP PACKAGE 1 2 diameter holes MOUNTING ANGLES for mounting 4 typ Notes 1 Single pump packages are 17 1 4 488 mm wide Dual pump packages are 32 1 4 819 mm wide 2 Mounting holes are 15 1 4 887 mm apart on single pump packages and 30 1 4 768 mm apart on dual pump packages 3 Connection sizes apply to primary pump supplier Note Angles located z inside bottom of pump s package View used for mounting reference 3 4 saa EL A oer ESTA See Table 15 for keys to dimensions A B and C Cc For expansion tank dimensions see Figure 15 on page 33 1 3 4 4 1 4 25 4mm 25 4mm ash y q 25 4mm 37 11 16 957mm TYPICAL FOOTPRINT UNIT ANCHOR PLAN 1 2 12 7mm diameter anchor bolts typ 32 Glycol GLYCOOL Cooled Models Figure 15 Pump packages expansion tank 1 2 FPT Fitting g 9 228 6mm Fitting 1 2 FPT 6 13 16 17 1 4 173mm 30 1 2 774 7mm 438 2mm 2 3 4 or A 69 9mm i
60. n tightened This final quarter turn is necessary to ensure that the joint will not leak Refer to Table 22 for torque requirements Add charge for the additional piping refer to Table 20 42 Split System Models 7 4 Outdoor Air Cooled Condensing Units Figure 20 Outdoor air cooled condensing unit horizontal air discharge models UNIT DIMENSIONS See Table 24 Fan Rotation CCW REFRIGERATION COMPONENT left side A RIGHT AIR DISCHARGE LEFT AIR INTAKE HL Rp O ine Se N REMOVABLE RIGHT PANEL SHADED AREA INDICATES A MINIMUM CLEARANCE OF 18 457mm FOR PROPER AIR FLOW SHADED AREA INDICATES A RECOMMENDED REMOVABLE FRONT PANEL FOR E ENT Ad SHADED AREA INDICATES A MINIMUM CLEARANCE OF 18 457mm ACCESS TO HIGH VOLTAGE 8 AND REMOVAL FOR PROPER AIR FLOW LOW VOLTAGE CONNECTIONS i AND REFRIGERATION COMPONENTS SL 11081 PG 4 Liquid Line Quick Connect Male Coupling quis Ein ect Male Coupling Except as noted Electrical Entrance for High Voltage Connection Electrical Entrance for Low Voltage Connection SL 11081PG 6 43 Split System Models Table 24 Horizontal air discharge cabinet and floor planning dimensional data Model Numbers Dimensional Data in mm Module 60 Hz 50 Hz PFCO67A _L PFCO66A _L PFHO67A _L 53 1343 Weight Ib kg net 351 159 36 1 4 918 18 457 Table 25 Hor
61. ogen holding charge only See Table 19 for field charge required If field supplied refrigerant piping is installed refrigerant must be added to the system 39 Split System Models Once all piping is complete check for leaks and dehydrate the field piping as follows 1 Pressurize the field piping to 150 PSIG 1034 kPa using dry nitrogen with a trace of refrigerant Check system for leaks with a suitable leak detector 2 After completion of leak testing release the test pressure per local code and pull a deep vacuum on the field piping with a suitable pump 3 After 15 minutes check the pressure readings and if they have not changed break vacuum with dry nitrogen Pull a second vacuum to 250 microns or less Recheck the pressure after 15 minutes Table 19 Unit refrigerant charge R22 Charge R407C Charge R22 Charge R407C Charge Model Ib kg Ib kg Model Ib kg Ib kg 060 0 81 0 37 0 8 04 PF_Z67A L 51 69 23 45 50 1 22 7 059E 0 81 0 37 0 8 0 4 PF_Z66A L 51 69 23 45 50 1 22 7 MC_65 64A 27 00 12 25 26 1 11 8 PF 067A H 51 69 23 45 50 1 22 7 PF 067A L 26 63 12 08 25 8 11 7 PF_ 066A H 51 69 23 45 50 1 22 7 PF 066A L 26 63 12 08 25 8 11 7 MC_69 68W 5 88 2 67 n a Table 20 Line charges refrigerant per 100 ft 30 m of Type L copper tube R22 R407C Liquid Line Suction Line Liquid Line
62. ont door A WARNING Risk of electric shock Can cause injury or death Disconnect all local and remote electric power before working within the unit Use a voltmeter to make sure power is turned off before making any electrical connections NOTICE Three phase power must be connected to the Liebert Challenger ITR line voltage terminals in the proper sequence so that scroll the compressor rotates in the proper direction Figure 8 Electrical connections oe BOo ES Electrical Handy Box factory installed with cover g MES A n 7 H iH PEEL A E 4 o 0 O Terminal Block gt for customer connections 0 00 00000 2o ODO eo eJ Vovo 37C 138C 37B 38B 37 38 24 50 51 55 56 77 78 75 76 82 83 84 85 88 89 91 92 93 94 95 96 97 1 2 3 4 DADAA MA Babboa DPN001524 REVO Electric conduit knockouts on top and bottom of electric box Knockout size 1 3 4 44 5mm 2 Three phase connection Electric service connection terminals when factory disconnect switch 1s supplied Factory installed locking disconnect switch Three phase electric service not by
63. oper safety equipment and proper refrigeration tools are required on both types Check unit nameplate for correct refrigerant type before topping off or recharging a system NOTE Refrigerant R407C uses a POE polyol ester lubricant The R407C refrigerant must be introduced and charged from the cylinder only as a liquid NOTE When installing field piping care must be taken to protect all refrigerant lines from the atmosphere especially when using refrigerants with POE oils Do not allow the piping to stand open to air for more than 15 minutes Units designed for R407C have a compressor which contains POE oil that is very hygroscopic that is it quickly absorbs water from the air The longer the compressor piping is left open to air the harder it will be to fully evacuate If left open too long the POE oil may need to be replaced before achieving the required vacuum level Dehydration Leak Test 1 Make sure unit is OFF Open all disconnects and remove all fuses except control fuses On units supplied with circuit breakers open all breakers except for the transformer 2 Add a jumper to the Fan Safety Switch between Common and Normal Open and disconnect the wire connected to the Normally Closed Turn unit disconnect ON Fan operation not required O O A NOTE Q The above allows the technician to use unit 24 VAC power and controls to open liquid line solenoid valve s and hot gas bypass solenoid valve s for the dehydration process I
64. p and wire size amp ratings TOP AIR DISCHARGE MODELS 23 amp 33kW High Ambient Field supplied unit and 23 amp 33kW Quiet Line disconnect switch MN Single or 3 phase electric SL 11081PG 8A service not by Liebert Single or Field supplied 24V 3 phase NEC Class 2 wiring electric to evaporator service not module by Liebert Factory wired to components on electric panel Heat rejection connection Field supplied 24V NEC class 2 wiring Wire connections from evaporator module 1 24V GND 2 24V Supply 3 High Pressure Alarm 4 Hot Gas Bypass Connection only on units with hot gas bypass If no hot gas bypass connection is provided in the evaporator module Connect wire 4 with wire 2 to the 24V supply 47 Split System Models 7 5 7 5 1 Centrifugal Air Cooled Condensing Units Installing the Indoor Condensing Unit Refer to drawings for unit dimensions and component locations A WARNING Risk of structure collapse Can cause equipment damage injury or death Before beginning installation make sure that the supporting roof structure is capable of supporting the weight of the unit s and the accessories during installation and service See Table 28 Indoor centrifugal condensing unit Be sure to securely anchor the top ends of the suspension rods Make sure all nuts are tight The indoor condensing unit is usually mounted above the ceiling and must be secure
65. r 4 2 Condenser The condenser is designed to operate in conjunction with either a cooling tower or city water The maximum water pressure is 150 psig 1034 kPa A high pressure system rated at 350 psig 2413 kPa is available as an option 24 Water Cooled Models Figure 12 Water cooled general arrangement Equalizers Bypass Valve Scroll Service _ Bypass Valves Solenoid Valve Fluid Return Bypass Tube From Valve in Tube Fluid Te Condenser Supply To JL Shutoff Unit a Valves T d Regulating EA a Valve ii 4 Z i di A Lae IJ 4 IAS aft A So Y Y A J Y e To Fluid Hose Bibs 7 Unit Retum es co From E Unit FACTORY PIPING Components are not supplied by Liebert but o o I ELD are recommended for proper circuit operation PIPING and maintenance SL 11898 PG 5 25 Water Cooled Models 4 3 4 3 1 Water Regulating Valve The water regulating valve automatically regulates the amount of fluid necessary to remove the heat from the refrigeration system permitting more fluid to flow when load conditions are high and less fluid to flow when load conditions are low The valve consists of a brass body balance spring valve seat valve disc holders capillary tube to discharge pressure and adjusting screw Water Regulating Valve Adjustment The Liebert Challenger ITR may be equipped with either a standard Johnson Controls valve 150 psig 1034 k
66. r ITR otherwise air flow and performance will be compromised Plenum Installation A solid plenum or plenum with discharge grille s may be installed The plenum and instructions for its installation ship separately from the Liebert Challenger ITR 12 Installation 2 8 Checklist for Completed Installation 1 er wn 14 15 16 meee 18 19 20 21 22 Unpack and check received material Proper clearance for service access has been maintained around the equipment Equipment is level and mounting fasteners are tight Piping completed to refrigerant or coolant loop if required Piping has been leak checked evacuated and charged if required Check piping within the Liebert Challenger ITR and outside of the unit Remove potential of rub through or chaffing Condensate pump installed Drain line connected Water supply line connected to humidifier if required Field provided pan with drain installed under all ceiling mounted fluid condensing units if installed Ducting completed if applicable Filter s installed Line voltage to power wiring matches equipment serial tag Power wiring connections completed between disconnect switch evaporator and condensing unit including earth ground Power line circuit breakers or fuses have proper ratings for equipment installed Control wiring connections completed to evaporator and condensing unit Verify water detection is properly in
67. r maximum security and maintenance accessibility Avoid ground level sites with public access or areas that will contribute to heavy snow accumulations Do not allow the discharge air to blow into another condensing unit A solid base capable of supporting the weight of the condenser and at least 2 51 mm higher than the surrounding grade and at least 2 51 mm larger than the condensing unit base dimensions should be installed at the pre determined location In snow areas a base of sufficient height to clear snow accumulation must be installed The centrifugal fan air cooled condensing unit may be located above the dropped ceiling or any remote indoor area If noise is of concern the condensing unit should be located away from personnel Normal operating sound may be objectionable if the condensing unit is placed near quiet work areas To mount the unit in the ceiling refer to 7 5 1 Installing the Indoor Condensing Unit for hang ing guidelines and to Figure 23 Detail of ceiling hanging bracket for dimensional data Water Glycol Cooled Condensing Units The condensing unit may be located above the dropped ceiling or any remote indoor area If noise is of concern the condensing unit should be located away from personnel Normal operating sound may be objectionable if the condensing unit is placed near quiet work areas To mount the unit the in ceiling refer to 7 5 1 Installing the Indoor Condensing Unit Electrical Connections Re
68. re 18 Figure 19 Figure 20 Figure 21 Figure 22 Figure 23 Figure 24 Figure 25 Figure 26 Figure 27 Figure 28 FIGURES Removing Liebert Challenger ITR from skid nannan ccc eee eens 3 Cabinet Gimension sy istic A A AT a Re pve E BOE ones OE BGO sci 4 Optional floor stand dimensions 0 cc eee cee nee eens 5 Piping connections for air cooled units 2 0 e eee nas 7 Piping connections for split system fan coil units 0 0 0 eee eee nas 8 Piping connections for water glycol and GLYCOOL units asana naasa aeaaee 9 Piping connections for chilled water self contained units 0 cc cece eee eens 10 Electrical connections oere seoan e A a Baie ee AER Ae wise Ia dai 11 Aircooled COMES S eido ea a ae WR Bes sie Re BAY oe le Rhian HR nO A aan eles eeu ia 15 Air cooled fan speed control general arrangement 0 0 00 cc eens 19 Air cooled Lee Temp general arrangement 0 00 cee eee nee 23 Water cooled general arrangement 0 0 0 00 ee eens 25 Johnson Controls valve adjustment 26 Drycoolers and pump packages 32 Pump packages expansion tank 0 ccc cette een eee enne 33 Glycol general arrangement 0 cence eee e nee eens 34 GLYCOOL general arrangement 0 0 0 eee eee eee eens 35 Chilled water general arrangement horizontal flow BR 0 00 0 37 Refrigerant piping diagram 0 0 eee a een eens 41 Outdoor air cooled condensing unit horizontal air disch
69. required vacuum level NOTE Q Keep the evaporator unit and condenser closed with their factory charge of dry nitrogen while all field piping is installed Keep the field piping clean and dry during installation and do not allow it to stand open to the atmosphere When all the field interconnecting piping is in place vent the condenser dry nitrogen charge and connect to the field piping Finally vent the evaporator unit dry nitrogen charge and make its piping connections last Follow all proper brazing practices including a dry nitrogen purge to maintain system cleanliness Traps should be installed in the hot gas line on vertical risers at the base and every 25 feet 7 6 meters in elevation These traps will collect condensed refrigerant and refrigerant oil during the off cycle of the unit and ensure flow of refrigerant oil during operation A check valve is factory supplied with the unit to be field installed on the discharge side of the scroll compressor Be sure to install the check valve with the refrigerant flow in the proper direction When soldering or brazing the valve it is very important to protect the internal parts by wrapping the valve with a damp cloth to keep the valve temperature below 250 F 121 C Approval is required whenever a refrigerant piping run exceeds 150 ft 46 m equivalent length an R22 system condenser must be located more than 15 ft 4 6 m below the level of the cooling coil an R407C system cond
70. rmula ethylene glycol and propylene glycol manufacturers and suppliers are Union Carbide Ucartherm or Dow Chemical Dowtherm SR 1 Dowfrost These glycols are supplied with corrosion inhibitors and do not contain a silicone anti leak formula Commercial ethylene glycol when pure is generally less corrosive to the common metals of construction than water itself Aque ous solutions of these glycols however assume the corrosivity of the water from which they are pre pared and may become increasingly corrosive with use if not properly inhibited There are two basic types of additives corrosion inhibitors and environmental stabilizers The corro sion inhibitors function by forming a surface barrier that protects the metals from attack Environ mental stabilizers while not corrosion inhibitors in the strictest sense of the word decrease corrosion by stabilizing or favorably altering the overall environment An alkaline buffer such as borax is a sim ple example of an environmental stabilizer since its prime purpose is to maintain an alkaline condi tion pH above 7 The percentage of glycol to water must be determined by using the lowest design outdoor temperature in which the system is operating Table 14 indicates the solution freeze point at several concentra tion levels of ethylene glycol Propylene glycol concentrations should be 1 higher than the ethylene glycol table values to find the freeze point For example 41 propylene glycol freeze
71. s at 10 F 28 C Table 14 Ethylene glycol concentrations Glycol by Volume 0 10 20 30 40 50 Freezing Point F C 32 0 25 3 9 16 8 9 5 15 0 10 23 3 32 35 5 Apparent Specific Gravity 50 F 10 C 1 1 014 1 028 1 042 1 057 1 071 A minimal amount of glycol should be considered for inhibitive coil protection NOTICE The quality of water used for dilution must be considered because water may contain corrosive elements that reduce the effectiveness of the inhibited formulation Water classified as soft low in chloride and sulfate ion content less than 100 parts per million each should be used 30 Glycol GLYCOOL Cooled Models 5 5 3 Filling the System Installation of hose bibs at the lowest point of the system is recommended When filling a glycol sys tem keep air to a minimum Air in glycol turns to foam and is difficult and time consuming to remove Anti foam additives are available and may be considered Open all operating systems to the loop With the top vent s open fill the system from the bottom of the loop This will allow the glycol to push the air out of the top of the system minimizing trapped air Fill to approximately 80 of calcu lated capacity Fill slowly from this point checking fluid levels until full NOTE For glycol solution preparation and periodic testing follow manufacturer s recommendations Do not mix products of different
72. stalled around all units if installed All wiring connections are tight Control panel DIP switches set based on customer requirements Foreign materials have been removed from in and around all equipment installed literature shipping materials construction materials tools etc Fans and blowers rotate freely Inspect all piping connections for leaks during initial operations Correct as needed Verify that a blank start up sheet has been sent with the unit s and is ready to be completed by the installer 13 Air Cooled Models 3 0 AIR COOLED MODELS 3 1 3 2 3 2 1 3 2 2 3 2 3 Condenser Location The air cooled condenser should be located for maximum security and maintenance accessibility Avoid ground level sites with public access or areas that contribute to heavy snow or ice accumula tions Utilize centrifugal condensers whenever interior building locations must by used To assure adequate air supply it is recommended that condensers be located in a clean air area away from loose dirt and foreign matter that may clog the coil In addition condensers should not be located in the vicinity of steam hot air or fume exhausts Also condensers should be located no closer than three feet 1 meter from a wall obstruction or adjacent unit Install condensers in a level position to assure proper refrigerant flow and oil return For roof instal lation mount condensers on steel supports in accordance wi
73. stem It may be neces sary to furnish additional pedestal support below the unit to ensure maximum structural support see Table 1 A separate floor stand for the unit may be used as support independent of the elevated floor and installed prior to the flooring system Provide approximately 34 864 mm service clearance in the front and rear of the unit The unit can be installed between equipment racks or at the end of a row of racks Consideration should be given before installing refrigerant and liquid lines next to under or above electronic equip ment Avoid placing the Liebert Challenger ITR in an alcove Placing units too close together will reduce the effectiveness of the air distribution NOTE Locate and remove shipping screw on fan motor base 2 3 1 Remote Sensor Installation Location The remote temperature and humidity sensor should be installed in the cold aisle in front of the equipment to be cooled It should be mounted at the farthest point from the cooling unit that supply air needs to reach but still within the unit s area of influence The sensor should be installed at the highest point that equipment will draw in cooled air 2 4 Equipment Handling A WARNING Risk of equipment tipping over Can cause damage injury or death The instructions listed below must be adhered to when handling this unit with or without the skid There is the potential for this unit to tip over if handled improperly Installation 2 4 1 Han
74. t valve disc holders capillary tube to discharge pressure and adjusting screw Glycol Regulating Valve Adjustment The Liebert Challenger ITR may be equipped with either a standard Johnson Controls valve 150 psig 1034 kPa or with a high pressure Johnson Controls valve 350 psig 2413 kPa For details on adjust ing the valve refer to 4 3 1 Water Regulating Valve Adjustment Testing Valve Function When the refrigeration system has been off for approximately 10 15 minutes the coolant flow should stop Should the coolant continue to flow the valve is either improperly adjusted or the pressure sensing capillary is not connected properly to the condenser Table 18 Refrigerant control settings psi kPa Low Pressure Low Pressure High Pressure Cut Out Cut In Cut Out 20 137 9 65 448 2 360 2482 36 Chilled Water Models 6 0 CHILLED WATER MODELS 6 1 Piping Considerations Manual shut off valves should be installed at the supply and return lines to each unit This will pro vide for routine service and emergency isolation of the unit Consideration of the minimum water temperature to be supplied from the chiller will determine if the need exists to insulate supply and return lines Insulation will prevent condensation on the supply and return lines To provide for the emergency of water leaks and the consequences of sub floor flooding floor drains should be provided with wet traps or a water
75. tem operation problems install a 16 20 mesh filter in the fluid supply line to the indoor unit The filter should be located where it can be easily serviced or replaced Do not install unit on open loop systems Debris carried by the fluid will clog the brazed plate condenser It is recommended that manual service shut off valves be installed at the supply and return connec tions to each unit This enables routine service and or emergency isolation of the unit In addition multiple pump packages require a check valve at the discharge of each pump to prevent back flow through the standby pump s To facilitate filling installation of hose bibs at the lowest point of the system is recommended Consideration of the minimum glycol temperature to be supplied from the drycooler will determine if the need exists to insulate the glycol supply and return lines Insulation will prevent condensation on the glycol lines in low ambient conditions All fluid piping must comply with local codes Care in sizing pipes will help reduce pumping power and operating costs Table 11 Room dew point temperatures Dry Bulb Wet Bulb Relative Dew Point F C F C Humidity F C 70 21 1 57 2 14 0 45 48 0 8 9 70 21 1 58 5 14 7 50 50 5 10 3 72 22 2 58 9 24 9 45 50 0 10 0 72 22 2 60 0 15 5 50 52 4 11 3 75 23 8 61 2 16 2 45 52 4 11 3 75 23 8 62 5 16 9 50 55 0 12 7 Minimum glycol temperatur
76. th local codes To minimize sound and vibration transmission mount steel supports across load bearing walls For ground installation a concrete pad will provide adequate support Condenser legs have mounting holes for securing the con denser to the steel supports or concrete pad Electrical Connections Refer to equipment nameplate regarding wire size and circuit protection requirements Refer to elec trical schematic when making connections Make all wiring and electrical connection in accordance with local and national codes A WARNING Risk of electric shock Can cause injury or death Disconnect all local and remote electric power before working within the unit Use a voltmeter to make sure power is turned off before making any electrical connections Line Voltage Line voltage electrical service is required for all air cooled condensers at the location of the condenser This power supply does not have to be the same voltage as the indoor unit This separate power source may be 208 230 460 or 575 V 60 Hz or 200 230 or 380 415 V 50 Hz The disconnect switch may be factory supplied and mounted in the electrical panel or field supplied and mounted per local and national codes Low Voltage A control interlock between the condenser and the indoor unit is required and is connected between 70 and 71 in the handy box of the indoor unit and the electric panel of the air cooled condenser NEC Class 1 wiring is required Lee Temp Flood
77. tion process Pressurize system circuit s to 150 PSIG 1034 kPa by using dry nitrogen with a trace of refrigerant Check system for leaks with suitable leak finder After completion of leak testing release test pressure per local code and pull a vacuum on the system After 4 hours check pressure readings and if they have not changed break vacuum with refrigerant Pull a second and third vacuum of 250 microns or less Recheck pressure after 2 hours Charging 1 Zi Make sure unit is OFF Open all disconnect switches and on units supplied with circuit breakers open all breakers Replace all fuses for the Fan and Compressors or close breakers Remove jumper on the Fan Safety Switch and reconnect the system wire connections Ensure that all operational components are clear of debris Turn unit ON Fan operation is required Check the evaporator fan for proper rotation and correct if necessary Connect the refrigerant gauge charging hose to the drum of refrigerant and to the suction and discharge service valves of the compressor s Calculate the amount of charge for the system Weigh in as much of the system charge as possible Refer to the unit condenser and refrigerant line charge tables Set the control temperature setpoint see operation manual to 60 F 15 C and set the relative humidity setpoint higher than the conditioned room ambient to ensure that solenoid valves and hot gas bypass valves are open during the charging pro
78. tween the two units 2 Using optional pre charged line sets All refrigeration piping should be installed with high temperature brazed joints Prevailing good refrigeration practices should be employed for piping supports leak testing evacuation dehydration and charging of the refrigeration circuits The refrigeration piping should be isolated from the build ing by the use of vibration isolating supports It is important to handle the pre charged lines with care so they will not get kinked or damaged Use tube benders and make all bends before making connections to either end Coil any excess tubing in a horizontal plane with the slope of the tubing toward the condensing unit To prevent tube damage when sealing openings in walls and to reduce vibration transmission use a soft flexible material to pack around the tubes When installing remote condensing units mounted above the evaporator the suction gas line should be trapped at the evaporator This trap will retain refrigerant oil in the off cycle When the unit starts oil in the trap is carried up the vertical riser and returns to the compressor Refrigerant charge requirements Total refrigerant charge will be required only if units are evacuated during installation or maintenance Total refrigerant charge evaporator lines condensing unit NOTE All condensing units and 3 ton evaporator units are fully charged with refrigerant All 28 and 88 kW evaporator units include a nitr

Liebert Challenger ITR User's Manual

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