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Liebert 3000 Air Conditioner User Manual

1. Switch Off On 1 No Part Coil Part Coil Chilled Water 2 Electric Hot Gas Reheat Hot Water Reheat 3 All Not Used 4 No GLYCOOL GLYCOOL 5 No Dual Cooling Dual Cooling 6 Not Used Not Used 78 Tight Control Standard Control 2 SCR reheats only with special software otherwise not used The selections shown in Table 4 should match options installed on your unit and should not need to change during normal operation Switches 1 through 7 are self explanatory DIP switch 8 not shown in the table enables the password feature when set to ON and disables the password feature when set to OFF Operation with Advanced Microprocessor Controls Select Control Type Intelligent Chilled Water only Proportional all unit types Tunable PID Chilled Water or SCR Reheats only The type of system control method used by the microprocessor can be selected from the front panel The default setting is Intelligent which approximates the actions that a human operator would take to maintain precise stable control The control logic uses Artificial Intelligence techniques including fuzzy logic and expert systems methods to maintain precise stable control and increase reliability by reducing component cycles Proportional is a standard control method that uses one gain factor temperature sensitivity adjustment Tunable PID Proportional Integral and Derivative uses three gain factors selected by the operator PID allo
2. ooooo o o oo 40 51 9 Humidifier Problem toi hn ARA EN Ba a ee Bde ER OE SA NN Dd 40 DTI Loss oF Air FLOW erenn ove nd A a ag a a he Goatees eee ee a aed 40 Dal Loss ot Power ta gta hate ae we a ea gta Roe os Ge We ee ea 40 Dekel 2 how Humidity 9g scoters Sete oe Bae A AEA bo es WA Ss Se 40 5 1 18 Low Suction Pressure 40 5 14 Low Temperature aa Se Rea wn GE ee Ba eae Ba GONE se bbs BAM EE ia 40 51519 Man Fan Overloads v4 tnn a aioe aa nti abies Sede me ae a a BU 40 RS pats ah os a UR hace Iwan 41 Optional Custom Alarms 0 na 41 DZT Koss ot Water Flow 3 045 esse ciate ata TS EGA GA RN EGA POSE A LEAN 41 52125 Smoke Detecta iaa Ba ARI LAN Tea LAN RR era dd E A NAN ad 41 5 2 3 Standby GC Pump Ont a Bea EN Ea A Bs So Os a SNS Da 41 524 Standb WUnit Oh it RE PAs nm Ra BN GER Ne ak 41 5 215 Water Under Floor iia SEA BEN Ed BR LG E E Pd FORA SIN 41 COMPONENT OPERATION AND MAINTENANCE ccccococcocooooocooocccorc 42 System Testing 2 2 2 2554 BEA Ana Aa ee BB TA RN Mek aja DL AE SSB ba tes 42 6 1 1 Environmental Control Functions cc een eee nes 42 PUTO Li PR cea A ee PL SE SAE EAS Mg SGN le ES toh nian 44 Blower Package aii a eo eae Mun Bee OR eS Pe a es Cas Doe aan 45 6 3 1 Fan Impellers and Bearings ih 45 O Belt Boece totes Peay aa an aan aan A te Ang 45 6 3 3 Ate Distribution Sat ea ds eases een ia Ben nan Sa na BU Ger eek pag T 45 Refrigeration System enerne 4
3. Worn bearings Replace pump Noisy operation Worn motor bearings Replace pump Low discharge head Throttle discharge improve suction conditions Debris lodged in impeller Remove cover and clean out Cavitating pumps Adjust system pressures Table 26 Infrared humidifier troubleshooting Symptom No humidification Possible Cause Humidifier pan not filling Check or Remedy Check water supply Check fill valve operation Check drain stand pipe adjustment Check for clogged waterline Control not calling for humidity Check monitor status Humidity contact not pulling in Check visually If contact is made check line voltage after contactor and fuses or CBs Check for open humidifier safety stat Jumper between terminals P35 6 and P35 15 If contactor pulls in replace safety Remove jumper Humidifier bulb burned out Replace bulb Loosen lead on old bulb Trim excess lead length on new bulb to avoid shorts 61 Troubleshooting Table 27 Steam generating humidifier troubleshooting Symptom False canister full indication Possible Cause Check or Remedy Check drain valve to ensure that it drains freely Check and replace if defective Foaming Check water supply If commercially softened reconnect to raw water supply If connected to hot water reconnect to cold water Main 24 VAC fuse or circuit
4. High Temperature If the return air temperature has increased to the High Temperature Alarm setpoint check for proper setpoints Is the room load more than the unit can handle is the unit capacity too small Run diag nostics to make sure all cooling components are operating compressor and or valves 39 Alarm Descriptions 5 1 8 5 1 10 5 1 11 5 1 12 5 1 13 5 1 14 5 1 15 High Temperature and Low Temperature Simultaneously If these two alarms are displayed at the same time the temperature input signal is lost or the humidity is out of sensor range 15 to 85 RH Dashes will be displayed for the temperature reading The control system will initiate 100 cooling Check for a disconnected cable or a failed sensor Humidifier Problem Infrared Humidifiers This alarm is activated by the high water float switch in the humidifier pan assembly The high water float switch is normally closed and opens upon alarm condition Check for drain clog and if present clean drain Check for float switch stuck high replace the switch as necessary Check for proper oper ation of the humidifier water makeup valve Steam Generating Canister Humidifiers This alarm is activated by a signal from the humidifier control indicating that the canister needs to be replaced Loss of Air Flow A differential air pressure switch is used to indicate loss of air flow in Challenger 3000 units Check for blockage of unit air outl
5. Select Options Heating Humidifier Dehumidifier Heat Stages Calibrate Sensors Show DIP Switches 1 7 Select Control Type Intelligent Proportional Tunable PID Proportional Gain Derivative Gain Integral Gain Setup Alarms Set Time Delays Enable Alarms Enable Common Alarm Set Custom Alarm Select Alarm Change Custom TXT 1 2 Hum Control Method Relative Absolute Analog Setup A D Input 1 2 3 4 Slope Text Intercept Set Status Display Calibrate Actuator Change Password Setpoint Password Setup Password Operation with Advanced Microprocessor Controls 2 2 2 3 2 4 2 4 1 2 4 2 2 4 3 Status Display The display normally shown includes the present room temperature humidity active status func tions cooling heating dehumidifying humidifying and active alarms If no keys are pressed within 5 minutes the system automatically returns to the Status Display The Status Display may also be selected from the Main Menu Main Menu lt MENU ESC gt Press the MENU ESC key to display the Main Menu The Menu selections include Status alarm data Setpoints setup Date and time Status display Status Alarm Data Selecting STATUS ALARM DATA from the Main Menu will display the following selections Active alarms Operating status Alarm history log Run hours log Analog sensors Active Alarms This screen displays any active alarm The alarms are numbered 1 being the m
6. Heating GLYCOOL Chilled Water Valve Dehumidification Humidification View Set Alarms Active Alarms Alarm History Setup Alarms High Temperature Low Temperature High Humidity Low Suction Pressure Short Cycle Compressor Overload Main Fan Overload Loss of Power Humidifier Problem High Head Pressure Change Filters Loss of Air Flow Custom Alarm 1 Custom Alarm 2 Custom Alarm 3 Custom Alarm 4 Setup Custom Alarms Setup Custom Alarm Text Change Custom Text 1 Change Custom Text 2 Change Custom Text 3 Change Custom Text 4 View Water Detect Floor Plan Setup Water Detect Floor Plan Use to locate file Use ENTER to define file xx optional Himod units only kkk View Set Control Setup System View Set Setpoints Temperature Setpoint Sensitivity Setpoint Humidity Setpoint Sensitivity High Temperature Alarm Low Temperature Alarm High Humidity Alarm Low Humidity Alarm Run Diagnostics Date and Time Set Clock Date and Time Run Diagnostics Setup System Setup Operation Cold Start Delay Auto Restart Delay IR Flush Overfill CW HW Coil Flush Display in Degrees F C Min Chilled Water Temp Select Options Reheat Humidify Dehumidify Hot Gas Reheat Stages of Reheat Calibrate Sensors Temperature Sensor Humidity Sensor Calibrated Reading Calibrate Valve Actuator Select Control Algorithm Proportional Intelligent Tunable PID Proportional
7. If commu nicating with a Liebert Site Product the alarm is also transmitted The display will also show a mes sage to PRESS ENTER KEY TO SILENCE the alarm After the alarm is silenced the display will return to the Normal Status Display For the Advanced Microprocessor with Graphics the bell and hammer are shown at the top of the Normal Status Display For the Advanced Microprocessor the bottom line will display the number of Active Alarms The active alarms can be reviewed on the Advanced Microprocessor Controls by selecting ACTIVE ALARMS The alarms can also be silenced through communications with a Liebert Site Products unit Most alarms will reset automatically when the alarm condition is no longer present and only after it has been acknowledged by being Silenced The exceptions are 1 The three software alarms Loss of Power Low Suction Pressure and Short Cycle which reset automatically 90 minutes after being Silenced or acknowledged 2 Some alarms such as overloads and high pressure switches may require a manual reset depending on your model A history of 10 alarms for Advanced see 2 4 3 Alarm History Log and 60 alarms for Advanced with Graphics see 3 4 2 Alarm History Log is retained in nonvolatile memory This section provides a definition of each available alarm Troubleshooting suggestions are included Refer to 7 0 Troubleshooting for more details If you need assistance with your environmenta
8. of free area Perforated Panels are usually 2 x 2 61 cm x 61 cm and have a nominal free area of approximately 108 to 144 in 697 to 929 cm NOTE Absolutely avoid any under floor restrictions such as clusters of cables or piping Whenever possible cables and pipes should be run parallel to the air flow Never stack cables or piping 45 Component Operation and Maintenance 6 4 6 4 1 6 4 2 6 4 3 Refrigeration System Each month the components of the refrigeration system should be inspected for proper function and signs of wear Since in most cases evidence of malfunction is present prior to component failure peri odic inspections can be a major factor in the prevention of most system failures Refrigerant lines must be properly supported and not allowed to vibrate against ceilings floors or the unit frame Inspect all refrigerant lines every six months for signs of wear and proper support Also inspect capillary and equalizer lines from the expansion valve and support as necessary Each liquid line has a sight glass that indicates liquid refrigerant flow and the presence of moisture Bubbles in the sight glass indicate a shortage of refrigerant or a restriction in the liquid line The moisture indicator changes from green to yellow when moisture is present in the system Suction Pressure Suction pressure will vary with load conditions The low pressure switch will shut the compressor down if suction pressure f
9. turn ON the main unit disconnect switch 11 Push ON button putting the unit into operation 12 Check the current draw on all line voltage components and match with serial tag 13 Verify that the scroll compressor is rotating in the proper direction CAUTION The scroll compressor must rotate in the proper direction Rotation in the wrong direction will result in poor performance and compressor damage 14 Check for unusual noises and vibration 15 Check all refrigerant and fluid lines for leaks 16 Test all functions of your unit for proper operation 17 Close high voltage dead front cover and latch 18 Close front accent panel and latch Return completed start up form to Liebert Corporation Warranty Registration 1050 Dearborn Drive P O Box 29186 Columbus OH 43229 Operation with Advanced Microprocessor Controls 2 0 OPERATION WITH ADVANCED MICROPROCESSOR CONTROLS 2 1 The advanced microprocessor A control for your Liebert Challenger 3000 unit features an easy to use menu driven LCD display The menus control features and circuit board details are described in this section For more control details refer to 4 0 System Performance with Advanced Micro processor Controls and for more alarm information refer to 5 0 Alarm Descriptions Basics Control keys include ON OFF Menu ESCape Enter Increase UP arrow and Decrease DOWN arrow Refer to Figure 1 These keys are used to move throu
10. via Liebert Site Products This communication directly out of the control uses a proprietary protocol Your unit can have a variety of different Site Product devices wired to this port depending on the monitoring system you are using Consult the user manual of the appropriate device for specific installation and operation information Liebert Monitoring Devices and Software SiteScan Centralized Monitoring System Stand alone facility monitoring system SiteLink BMS Interface Module For Modbus or BACnet communication to a third party moni toring system OpenComms Network Interface Card For Ethernet connection using SNMP protocol OpenComms Nform Software package to monitor SNMP devices Environmental DO Interface Card For discrete outputs of status and alarm conditions Mini Remote Stand alone individual unit remote monitor ECA2 Communication Adapter For remote service monitoring directly or via a modem 37 Alarm Descriptions 5 0 ALARM DESCRIPTIONS 5 1 5 1 1 The Advanced Microprocessor A and the Advanced Microprocessor with Graphics G Control sys tems will audibly and visually annunciate all ENABLED alarms including the four custom alarms With the Advanced amp Advanced with Graphics Controls the customer alarms can be from the optional alarm list and or can have their own fully custom text Two alarms may be selected as cus tom for the Advanced Microprocessor and four can be custom for Advanced Mic
11. Bind 32 4 211 Proportional Control cfd va eek cite E BG SG oN ES SI Re EE LG I EAS Sk 32 4 3 2 PID Control Chilled Water or SCR Reheats only ees 32 4 3 3 Intelligent Control Chilled Water only inna 33 Load Control Features oia ge eiae aE y gov ee ae ie sawed spare NAN ANU aa Sa A nata yen 34 441 Short Cycle Control ss daa btn bea ot ccs eres danas sree esas ste ke teres at ces ni 34 4 5 4 6 5 0 5 1 5 2 6 0 6 1 6 2 6 3 6 4 44 2 Sequential Load Activation Control hn 34 Additional Features abs sa bana ben an Ane Agel SNN RN PA obras 34 4 5 1 Connecting the Analog Sensors eee ene 34 4 5 2 Water Detection Display na 35 Corona AS NPL LS PLAN LA eae ee ee aa ae Un Bana 31 ALARM DESCRIPTIONS our renen Ra erate na a an nba ad 38 Standard Alamis ls presagi alte age neha ad en Kena AN Bee iia 38 Sell Changes Kalbe acia oa dent ut aon aide are San os e bce ata ai an adat hes dicas 38 5 172 Compressor Overload reo ta a anna LAN a RN Lea BN eee ana 39 Salza CUStOMA LAS eta se oon ap an ba Na dade San E A ita Saw brete Bi 39 SLA High Head Pressure aed ce Sie A A HBR asn 39 Baco Hish Humidity ys 5 acts A in BNN MOR ates eRe let cts 39 5 1 6 High Humidity and Low Humidity Simultaneously 0 00 39 5 17 High Temperature A A BNN ti BTA RE A SREY 39 5 1 8 High Temperature and Low Temperature Simultaneously
12. Infrequently a fault in the motor insulation may result in a motor burn but burnouts rarely occur in a properly installed system Of those that do most are the effects of mechanical or lubrication fail ures resulting in the burnout as a secondary consequence If problems that can cause compressor failures are detected and corrected early a large percentage can be prevented Periodic maintenance inspections by alert service personnel on the lookout for abnormal operation can be a major factor in reducing maintenance costs It is easier and far less costly to take the steps necessary to ensure proper system operation than it is to allow a compressor to fail and require replacement When troubleshooting a compressor check all electrical components for proper operation 1 Check all fuses and circuit breakers 2 Check Hi Lo Pressure switch operation 3 Ifa compressor failure has occurred determine whether it is an electrical or mechanical failure Mechanical Failure A mechanical compressor failure will be not be indicated by a burned odor The motor will attempt to run If you have determined that a mechanical failure has occurred the compressor must be replaced If a burnout does occur correct the problem that caused the burnout and clean the system It is important to note that successive burnouts of the same system are usually caused by improper clean ing 51 Component Operation and Maintenance Electrical Failure An e
13. Pull bulb straight down 9 Replace bulb Wrap wires once loosely around bulb This will support the bulb and also allow for thermal expansion Make sure lamp wires are secure in the junction block CAUTION Do not touch the quartz lamps with your bare hands Oily deposits such as fingerprints will severely shorten bulb life Use clean cotton gloves at all times 10 Reverse Steps 1 through 6 to reassemble 53 Component Operation and Maintenance 6 5 2 Autoflush Infrared Humidifier Cleaning System NOTE To operate properly the Autoflush Humidifier requires a water source that can deliver at least 1 gpm 0 068 l s with a minimum pressure of 20 psig 138 kPa The autoflush system will periodically flush the humidifier pan with water to prevent the buildup of water minerals due to saturation Because water conditions vary the amount of water flushing through the system may be programmed to match local needs Water amounts between 110 and 500 of the amount needed for humidification may be selected Operation of the flushing system is then automatic and no further adjustments need to be made Autoflush Operation The operation of the autoflush is divided into four steps beginning with a call for humidification 1 Ifthe humidifier has not been activated for over 30 hours the autoflush will flow water into the pan for about 30 seconds This will provide a minimum amount of water in the pan and prevent heat damage to the
14. access fittings 3 Recover refrigerant using standard recovery procedures and equipment Use a filter drier when charging the system with recovered refrigerant A CAUTION Do not loosen any refrigeration or electrical connections before relieving pressure NOTE Release of refrigerant to the atmosphere is harmful to the environment and is unlawful Refrigerant must be recycled or discarded in accordance with federal state and local regulations 4 Front seat service valves to isolate the compressor Reclaim charge from compressor 5 Remove service valves pressure switch capillaries and disconnect all electrical connections 6 Remove failed compressor CAUTION A scroll compressor must rotate in the proper direction Record compressor motor connections when removing failed compressor Wire the replacement compressor motor the same way to maintain proper rotation direction Install replacement compressor and make all connections Pressurize and leak test the system at approximately 150 PSIG 1034 kPa pressure Follow manufacturer s instructions for clean out kits 10 Follow charging instructions as stated in the installation manual Liebert part number SL 11925 SPA 52 Component Operation and Maintenance 6 5 6 5 1 Humidifier Infrared Humidifier During normal humidifier operation deposits of mineral solids will collect in the humidifier pan This should be cleaned out periodically to ensure efficient oper
15. action above the normal 150 rate Also if the supply water pressure is low the flush rate adjustment can be increased so that sufficient water level is maintained during humidification Chilled Water Hot Water Econ O Coil Flush This feature will flush the respective coil for 3 minutes after the programmed number of hours of non use For example if the flush time is pro grammed with 24 hours on a hot water reheat type system and heating is not required for a 24 hour period the hot water valve will be open for 3 minutes to allow the coil to be flushed The programmed value can be from 0 no flush to 99 99 hours of non use C F Degrees The control can be selected to show readings and setpoints in either degrees Fahren heit F or Celsius C Operation with Advanced Microprocessor Controls Table 2 lists the setup functions their factory default values and the allowable programming ranges Table 2 Setup functions default values and ranges Function Default Range Cold Start Time Delay 3 0 to 3 min 0 no delay Restart Time Delay 0 1 0 to 9 9 min 0 manual restart Infrared Fill Rate 150 110 to 500 Chilled Hot Water Coil Flush 24 0 to 99 hrs also Econ O Coil C F Degrees F CorF Factory set to 0 for water cooled glycol and GLYCOOL units Select Options The following table lists options which should match the options installed with your unit and should not need to be changed during
16. be more efficient and precise for most applications but system performance based on room conditions is not as predictable as standard approaches that use a fixed equation 33 System Performance with Advanced Microprocessor Controls 4 4 4 4 1 4 4 2 4 5 4 5 1 Load Control Features Short Cycle Control The control system monitors the compressor and prevents it from turning on within 3 minutes of being turned off If this on off on occurs too often 10 times in one hour a Short Cycle alarm could occur Sequential Load Activation Control The control allows only one load output to be energized at a time on a restoration of power or micro controller reset Each additional load output will be activated at one second intervals until desired operating conditions have been met Additional Features Connecting the Analog Sensors The sensor inputs are factory set to accept a 4 20 mA signal However the inputs can be changed by removing the appropriate jumpers on the control circuit board See Table 14 Figure 5 and Figure 6 The user supplied analog sensors MUST have their own power supply To reduce the effects of inter ference from any noise source the sensor input wiring should be shielded twisted pair and the shield tied to earth ground at one end Analog input terminals for field connections are factory wired to the microprocessor board if specified when ordered Eight terminals are located in the field wiring c
17. board Fan Safety Switch The Fan Safety Switch is located in the low voltage compartment and consists of a diaphragm switch and interconnecting tubing to the blower scroll The Fan Safety switch is wired directly to the control circuit to activate the alarm system if the airflow is interrupted 42 Component Operation and Maintenance Firestat The optional firestat is a bimetal operated sensing device with a normally closed switch This device will shut down the entire unit when the inlet air temperature exceeds a preset point It is connected between terminals 1 and 2 at plug P39 Smoke Detector The optional smoke detector power supply is located on the base of the upflow units and at the top of downflow units It is constantly sampling return air through a tube No adjustments are required Water Detection Sensor CAUTION Do not use near flammable liquids or for flammable liquid detection The optional water detection devices available are a point leak detection sensor and a zone leak detec tion kit Figure 7 Liebert leak detection units E 2 LT460 Zone Leak Detection Kit Liqui tect Sensor LT460 e System De Remar Alarm E O rom m Liquitect Point Leak Detection Sensor The point leak detection sensor provides leak detection at a critical point A simple two wire connec tion signals the alarms at a Liebert environmental unit or at a monitoring panel Run wires to the Liebert un
18. compressor Optional Custom Alarms Loss of Water Flow Available only with 3 way valves and occurs when no water flow is detected in the chilled water or condenser water supply line An optional flow switch is required for this alarm Check for service valves closed pumps not working etc Smoke Detected Smoke is detected in the return air by an optional Liebert Smoke Detector Check for source of smoke or fire and follow appropriate emergency procedures Standby GC Pump On The primary pump has failed and the standby pump is activated glycol cooled and GLYCOOL units only Check for problems with the primary pump fuses blown motor burnout service valve shut stuck check valve impeller damage etc Standby Unit On The primary environmental control system has had an alarm condition and the standby system is activated Water Under Floor Water is detected by an optional Liebert Water Detection System Check under the raised floor for water or other leaks NOTE The alarms are specified by the customer at the time of order All alarms will report to a Liebert remote monitoring unit Additional devices and wiring may be required at the factory for some of the alarms 41 Component Operation and Maintenance 6 0 COMPONENT OPERATION AND MAINTENANCE 6 1 System Testing 6 1 1 Environmental Control Functions The performance of all control circuits can be tested by actuating each of the main functions This i
19. control is automatically adjusted approximately 2 RH for each degree difference between the return air temperature and the temperature setpoint With relative humidity control unnecessary dehumidification can result when overcooling occurs dur ing a dehumidification cycle This is because a higher than normal RH reading is caused by overcool ing the room about 2 RH for each degree of overcooling This extends the dehumidification cycle Later when the dehumidification ends and the temperature rises to the setpoint the RH reading falls The final RH reading will then be lower than actually desired If the overcooling was significant enough the RH could be low enough to activate the humidifier If absolute humidity control is selected over dehumidification is avoided When overcooling occurs causing an increase in the RH reading the humidity control program predicts what the RH will be when the dehumidification cycle ends and temperature returns to the setpoint This allows the dehu midification cycle to end at the proper time The predictive humidity control can reduce energy con sumption by minimizing compressor and reheat operation and eliminating unnecessary humidifier operation 10 Operation with Advanced Microprocessor Controls Analog Setup For installation of analog sensors see 4 5 1 Connecting the Analog Sensors After selecting a compatible sensor and properly wiring it to the terminals set up the contro
20. downflow units Figure 13 Steam generating humidifier Liebert P N 136798P1 54 Component Operation and Maintenance Operation 1 During start up when the humidity control calls for humidification the fill valve opens and allows water to enter the canister When the water level reaches the electrodes current flows and the water begins to warm The canister fills until the amperage reaches the setpoint and the fill valve closes As the water warms its conductivity increases and the current flow in turn rises If the amperage reaches 115 of the normal operating amperage the drain valve opens and flushes some of the water out of the canister This reduces electrode contact with the water and lowers the current flow to the amperage setpoint Boiling soon commences and the canister operates normally If the conductivity of the water is low the canister fills and the water level reaches the canister full electrode before the amperage setpoint is reached The humidifier stops filling to prevent overflow Boiling should commence in time As water is boiled off the mineral concentration in the canister increases and current flow also increases The canister eventually reaches full output and goes to normal operation No drain is permitted until then When full output is reached the circuit board starts a time cycle which is factory set at 60 seconds During this repeating time cycle the fill valve will open periodically to re
21. humidifier pan Humidifier lamps are OFF 2 Ifthe humidifier has been activated within the last 30 hours Step 1 is bypassed The autoflush will flow water into the pan for about 4 minutes The humidifier lamps are on and the humidifier is operational during this period When the pan is filled the fill cycle has timed out the water make up valve is closed 3 The water make up valve remains OFF and the humidifier lamps are ON for a maximum of 9 1 2 minutes 4 After the 9 1 2 minute delay the autoflush adds water to the pan to replenish the water used in humidification and flush the pan of mineral solids This amount of water is adjustable from 110 to 500 in increments of 10 At the end of this cycle the make up valve is closed Steps 3 and 4 repeat as long as humidification is required Autoflush Controls Use the LCD display menu and keys on the front control panel to program the autoflush controls Steam Generating Humidifier Steam generating humidifiers are designed to operate in voltage ranges from 200 to 575 volts and generate 11 pounds 5 kg of steam per hour These humidifiers operate efficiently over a wide range of water quality conditions and automatically adjust to changes in the conductivity of water The humidifiers drain and refill to maintain an amperage setpoint and alert the operator when the humidifier canister needs to be replaced The humidifier is in the lower section of upflow units it is in the middle section of
22. integral and derivative The proportional term is figured in a manner similar to the previously described proportional control The integral term sometimes called reset action is figured by measuring how much and for how long the temperature has been above or below the setpoint If the temperature is above the setpoint the cooling requirement is slowly but continuously increased until the total is sufficient to bring the temperature back to the setpoint The derivative term provides an anticipation control for rapid changes in temperature If the temperature is rising the cooling is increased temporarily until the temperature begins to stabilize The heating requirement is increased if temperature is falling The proportional integral and derivative terms are all adjustable through the control selection menu and should be set or tuned to the characteristics of the room being controlled see 4 3 Control Types Intelligent Control Chilled Water only If intelligent control is selected the return air temperature is controlled at or near the temperature setpoint The cooling heating required is calculated based on a set of logical rules that are pro grammed into the control These rules simulate the actions that an expert human operator would take if manually controlling the system see 4 3 Control Types 29 System Performance with Advanced Microprocessor Controls 41 3 Cooling Operation 1 St
23. of unit entire unit in front of unit Li 2 ft clearance 2 ft clearance ES paa in front in front 6 ft clearance 6 ft clearance in front in front Distance From Unit Distance In back 2 ft No cable behind 1 ft No cable behind On sides 2 ft 2 ft 1 ft 1 ft In front 2 ft 2 ft 6 ft 6 ft Unit Part Number footprint in Challenge LT460 Z30 LT460 Z20 LT460 Z30 LT460 Z25 r 32 5 x 32 5 Remote Shutdown A connection point is provided for customer supplied remote shutdown devices This terminal strip is located at the top of upflow units and at the base of downflow units Terminals 37 and 38 on the ter minal strip are jumpered when no remote shutdown device is installed Filters Filters are usually the most neglected item in an environmental control system To maintain efficient operation they should be checked monthly and changed as reguired Because replacement intervals vary with environmental condition and filter type each unit is eguipped with a filter clog switch This warns of restricted airflow through the filter compartment by activating the Change Filter alarm Turn power off before replacing filters Challenger 3000 filters are 28 1 2 by 29 1 2 either 2 or 4 thick plus an optional 2 thick pre filter The filter is replaced from the front of the unit On upflow units the filter is vertical in front of the lower compartment Pull the filter out t
24. system is either low on charge or there is a flow blockage in the system 5 Ifsuction pressure does not drop and discharge pressure does not rise to normal levels reverse any two of the compressor power leads and reapply power to make sure compressor was not wired to run in reverse direction If pressures still do not move to normal values system is properly charged and solenoid valves function the compressor is faulty Reconnect the compressor leads as originally configured and use normal diagnostic procedures to check operation of the reversing valve 6 To test if the compressor is pumping properly the compressor current draw must be compared to published compressor performance curves using the operating pressures and voltage of the system If the measured average current deviates more than 15 from published values a faulty compressor may be indicated A current imbalance exceeding 15 of the average on the three phases should be investigated further 7 Before replacing or returning a compressor Be certain that the compressor is actually defective At a minimum recheck a compressor returned from the field in the shop or depot for Hipot winding resistance and ability to start before returning More than one third of compressors returned for warranty analysis are determined to have nothing wrong They were misdiagnosed in the field as being defective Replacing working compressors unnecessarily costs everyone Compressor Replacement
25. the distance from the LT750 to the position of the detected water measured length is the length of the cable which is calculated automatically when the layout is defined The units for these values are in floor tiles The intercept value read from Analog Input 1 is added to the measured position of a water indication to determine which tile to highlight For example if water is displayed under the seventh tile but determined to be under the fifth tile set the offset value to 2 tiles Use the intercept value to correct errors close to the start of the cable Accuracy errors farther out on the cable should be corrected using Analog Input 1 s slope value This value effectively adjusts the measured length of the cable Increasing the effective length of cable will increase the distance of the water and move the highlighted tile farther along the cable and vice versa Unlike the intercept which adjusts by the same amount for all locations on the cable the slope increases its effect for larger distances The best procedure to calibrate the cable would be to first simulate water close to the LT750 about five tiles out Adjust the intercept to get the correct reading Next simulate water five tiles from the end Adjust the slope to get the correct reading 36 System Performance with Advanced Microprocessor Controls 4 6 Communications The control system uses a two wire RS 422 channel to communicate with remote monitoring systems
26. to the setpoint the RH reading falls The final RH reading will then be lower than actually desired If the overcooling was significant enough the RH could be low enough to activate the humidifier If absolute humidity control is selected over dehumidification is avoided When overcooling occurs causing an increase in the RH reading the humidity control program predicts what the RH will be when the dehumidification cycle ends and temperature returns to the setpoint This allows the dehu midification cycle to end at the proper time The predictive humidity control can reduce energy con sumption by minimizing compressor and reheat operation and eliminating unnecessary humidifier operation Set Status Display The Status Display can be set to display the return air temperature and humidity SENSOR READ INGS or the temperature and humidity control SETPOINTS through this selection When setpoints are selected the status display indicates so by also displaying SETPOINTS If SENSOR READ INGS is selected the Status Display will show the return air sensor readings Change Passwords Selecting CHANGE PASSWORDS will prompt the user to select one of the following SETPOINT PASSWORD SETUP PASSWORD The display prompts you to enter a three digit password when making changes The system includes two 2 passwords one for setpoints and one for system setup The system allows the passwords to be changed by first entering the present pa
27. unless the actual valve travel time is not correct The full valve travel time is used by the control to determine the appropriate valve position For example if the valve travel time is 165 sec onds and 50 cooling is being called for the valve will open for 83 seconds to achieve 50 open To change the valve travel time first enter the CALIBRATE ACTUATOR screen The display will show the present period used by the control for valve actuator full travel Press ENTER and adjust the time using the UP DOWN arrows When the correct time is displayed press ENTER to store the new time to memory Select Control Algorithm Chilled Water and SCR Reheats only The type of system control method used by the microprocessor can be selected from the front panel The default setting is INTELLIGENT which approximates the actions that a human operator would take to maintain precise stable control The control logic uses Artificial Intelligence techniques including fuzzy logic and expert systems methods to maintain precise stable control and increase reliability by reducing component cycles PROPORTIONAL is a standard control method that uses one gain factor temperature sensitivity adjustment TUNABLE PID Proportional Integral and Derivative uses three gain factors selected by the operator PID allows precision tuning but requires an experienced operator and seasonal adjustments Note that if PID is selected it is used for temper ature co
28. 150 rate Also if the supply water pressure is low the flush rate adjustment can be increased so that sufficient water level is maintained during humidification Chilled Water Hot Water Econ O Coil Flush This feature will flush the respective coil for 3 minutes after the programmed number of hours of non use For example if the flush time is programmed with 24 hours on a hot water reheat type sys tem and heating is not required for a 24 hour period the hot water valve will be opened for 3 minutes to allow the coil to be flushed The programmed value can be from 0 no flush to 99 99 hours of non use Display in Degrees The control can be set to display readings and setpoints in either degrees Fahrenheit F or Celsius C Default Settings and Ranges The following table lists the setup functions their factory default values and the allowable ranges for which they can be programmed Table 9 Setup functions default values and ranges Function Default Range Cold Start Time Delay 3 0 to 3 min 0 no delay Restart Time Delay 0 1 0 to 9 9 min 0 manual restart Infrared Fill Rate 150 110 to 500 Chilled Hot Water Coil Flush 24 0 to 99 hrs also Econ O Coil C F Degrees F CorF Factory set to 0 for water cooled glycol and GLYCOOL units 21 Operation with Advanced Microprocessor with Graphics Control 3 7 2 3 7 3 3 7 4 3 7 5 Select Options The following table is a list of opti
29. 2 1 3 12 2 3 13 3 13 1 View 24 Hour Run Time History The history of each load for every hour during the past 24 hours is displayed in the run hour history The percentage of each hour that the load was on is displayed from 0 to 100 in increments of 5 or 3 minutes Loads with a variable output are displayed as a percentage of their capacity for an hour For example a variable load that is 50 on for 1 2 of the hour will be displayed as 25 on for that hour View Total Run Hours The total operating hours of all major components in the unit can be monitored from the display and are retained in nonvolatile memory Run times are available for the following Compressor GLYCOOL Coil or Chilled Water Coil as used on Dual Cool Units e Fan Humidifier Reheat 1 or Hot Water Reheat or SCR Reheats Reheat 2 Heat Rejection The component run hours for each individual component can be reset by selecting the run hours dis play screen for the desired component then pressing ENTER within 5 minutes of applying power to the control The user will then be prompted to press ENTER to clear the selected component s run hours NOTE Run hours for a component should be reset ONLY when the component has been replaced Control Circuit board The control circuit board is located inside the unit behind the LCD display and control key panel Open the front panel for access to the board The control board includes an adjustment for LCD contr
30. 6 Emerson Network Power The global leader in enabling Business Critical Continuity IM ACPowerSystems IM Embedded Computing IM Outside Plant IM Connectivity IM Embedded Power IM Power Switching amp Control IM DCPowerSystems IM Integrated Cabinet Solutions IM Precision Cooling 39 049 9719111 Fax 39 049 5841 257 Asia 7 F Dah Sing Financial Centre 108 Gloucester Road Wanchai Hong Kong 852 2572220 Fax 852 28029250 EmersonNetworkPower com IM Services IM Site Monitoring IM Surge Protection Business Critical Continuity Emerson Network Power and the Emerson Network Power logo are trademarks and service marks of Emerson Electric Co 2006 Emerson Electric Co
31. 6 GAT 1 Suction Pressure ies ec naa eee Ph BRA an ie re eg RAE A 46 6 4 2 Discharge Pressure ica ia EN PR RNG BC a ee ee Bs Pa Daa BN Bee hal Sep RT 46 6413 Superheat 00533 BERAS Fecha ce LOR A tac 46 6 4 4 Thermostatic Expansion Valve na 47 6 4 5 Hot Gas Bypass Valve Wi Gir whee AS ene he a eee ae 47 6 4 6 Air Cooled Condenser ii 48 6 4 7 Water Glycol Cooled Condensers nana 49 6 4 8 Compressor Functional Check 51 6 4 9 Compressor Replacement 51 iii 6 5 7 0 8 0 9 0 Hide coe sce Bees acl ce sti tu lio Tahanan One st 53 65 1 Infrared Humidifier vcd sa ise Vote eae mhs Base aoe ide Ven akan 53 6 5 2 Steam Generating Humidifler Anna 54 TROUBLESHOOTING 05d 58 MONTHLY MAINTENANCE INSPECTION CHECKLIST 000 cece eee eee eens 64 SEMIANNUAL MAINTENANCE INSPECTION CHECKLIST 0 0000 e eee o 65 iv 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 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 FIGURES Advanced microprocessor control panel Advanced microprocessor A control for Challenger 3000 0 0 00 ccc een eens Advanced micropr
32. 80 RH Humidity Sensitivity 5 1 to 30 RH High Temperature Alarm 80 F 35 to 95 F 2 to 35 C Low Temperature Alarm 65 F 35 to 95 F 2 to 35 C High Humidity Alarm 60 15 to 85 RH Low Humidity Alarm 40 15 to 85 RH System Setup Selecting SYSTEM SETUP will step to the following menu SETUP OPERATION SELECT OPTIONS CALIBRATE SENSORS CALIBRATE VALVE ACTUATOR SELECT CONTROL ALGORITHM chilled water or SCR Reheats only SELECT HUMIDITY SENSING MODE SET STATUS DISPLAY CHANGE PASSWORDS Setup Operation The SETUP OPERATION menu permits the review and or adjustment of the unit configuration This may include Cold Start Delay This feature also referred to as Positive Start or Winter Start Kit allows for the low pressure switch to be ignored for the programmed time during a cold start of the compressor Entering a 0 for this time will bypass this feature A 1 will bypass the low pressure switch for one minute a 2 for two minutes etc The programmed value can be from O to 3 minutes This delay is factory set to O for water cooled glycol cooled and GLYCOOL units Typically only air cooled units need a Winter Start time 20 Operation with Advanced Microprocessor with Graphics Control Auto Restart Delay This feature allows for the unit to restart automatically after a loss of power The programmed value is 1 minute 6 seconds intervals A programmed value of zero 0
33. Gain Derivative Gain Integral Gain Select Humidity Sensing Mode Relative Absolute Set Status Display Sensor Reading Setpoints Change Passwords Setpoint Password Setup Password Change Passwords Select Control Algorithm available on Chilled Water only Show Inputs Air Sail Switch Custom Alarm 1 Custom Alarm 2 Custom Alarm 3 Custom Alarm 4 Humidifier Problem Filter Clog Switch Main Fan Overload Shutdown Device Low Pressure Switch Compressor Overload High Head Pressure Test Outputs Main Fan Compressor Liquid Line SV HGBP CUV CW CGV Dehumidification R5 Relay Reheat 1 Reheat 2 RH3 Dehum Damper Humidifier HMV Common Alarm Test Control Board Microcontroller Show DIP Switches Dipswitch 1 kkk Plot Graphs Analog Digital Inputs View Run Hours Log View Run Hours Log View 24 Hour Run Time History Chilled Water GLYCOOL Compressor Reheat 1 2 Humidifier Main Fan View Total Run Hours Compressor GLYCOOL Chilled Water Valve Main Fan Humidifier Reheat 1 2 Heat Rejection Slope Units Text Intercept Plot Graphs Analog Digital Inputs Read Analog Inputs Analog Input 1 Analog Input 2 Analog Input 3 Analog Input 4 Set Analog Inputs Analog Input 1 2 3 4 Read Digital Inputs Setup Digital nputs How to Text Dipswitch 2 Dipswitch 3 Dipswitch 4 Dipswitch 5 Dipswitch 6 Dipswitch 7 Temperature Plot Humidity Plot Analog Sensor 1
34. IM Precision Cooling For Business Critical Continuity Liebert Challenger 3000 Operation amp Maintenance Manual 3 amp 5 Ton 50 amp 60Hz O Liebert O Liebert W Liebert EMERSON Network Power 1 0 1 1 1 2 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 3 6 3 7 TABLE OF CONTENTS INTRODUCTION A ee eee eae SP eae tel la tee ee ds 1 System Descriptions sesine aon pen ek ek Rs SE NE BEN SI BAN BNN BE 1 1 1 1 Compressorized Systems naa 1 1 112 GLYCOOLM Chilled Glycol Cooling Systems inna 1 1 1 3 Chilled Water SyStetiS woo data a 4 Bille igs antes Ad BA ln Sr BAN Pn Pa Ta 1 Start Up Procedure o o ooooo na 2 OPERATION WITH ADVANCED MICROPROCESSOR CONTROLS c cccccc cc c 3 BiB GS ies tie ik nana as GSO ee IRA OR BANG ER ak BAS Fes Ok A Deen na 3 Status Display cu oh the ott oie des Chie ine E a A NN Nu 5 Main Menu lt MENU ESC gt ii nan 5 Status Alarm Data insti WEA AR RRR Pree BARS At DUN he ERs OM beatae aes 5 LAN ActivesAlanims le E hci ats ate Sais ota aaa a a cee aah ea at acy even ah aaa NN Bln 5 2432 Operating Stat sse AN nd a sce a IO Bone 5 2 43 A El E oie odds Me nets Ra Sue seen aa do obs Ra har Nae Peay Saw ie eS and cuca she 5 2 4 4 Run Hours hot is eile AA ABU NA DA Slay Be Galea Belge Bae eh 6 21415 FAN AlOS SCMSOLS eS iy sas bon telde sha shes eRe Sana Ta NU Jaa Undue Daddy ans Ta Apa a
35. Plot Analog Sensor 2 Plot Analog Sensor 3 Plot Analog Sensor 4 Plot Modify Plot Scales Modify Temp Scales Modify Humidity Scales Modify Analog Sensor 1 Scale 2 Scale 3 Scale 4 Scale 16 Operation with Advanced Microprocessor with Graphics Control 3 2 3 3 3 4 3 4 1 3 4 2 Status Display The normal status screen is divided into two sections a right half and a left half The left half displays the return air temperature and humidity readings in large characters NOTE The display can also be set to display the temperature and humidity setpoints See 3 7 7 Set Status Display The right half of the screen is divided into four guadrants top to bottom In the four guadrants six different graphic symbols may be displayed depending on the unit status At the top there will be a moving hammer striking a bell that appears when an alarm is present The word Alarm also appears next to the hammer and bell The second guadrant down displays a rotating fan as long as the unit is turned on and the fan is running The words Unit on appear next to the fan symbol The third guadrant may display one of two symbols relating to heating or cooling If the control is calling for cooling a growing snowflake is shown next to the word Cooling If the control is calling for heat ing three moving heat rays are displayed next to the word Heating In the bottom guadrant there may be one of two s
36. S or the temperature and humidity control SETPOINTS through this selection When SET POINTS is selected the status display indicates so by displaying SETPTS If SENSOR READINGS is selected the Status Display will show the return air sensor readings Calibrate Actuator For systems that use a valve actuator for chilled water or GLYCOOL cooling the actuator timing may be calibrated or adjusted This is the time it takes for the valve to travel from full closed to full open It is programmable from 0 to 255 seconds The factory default time is 165 seconds and should not be changed unless the actual valve travel time is not correct The full valve travel time is used by the control to determine the appropriate valve position For example if the valve travel time is 165 sec onds and 50 cooling is being called for the valve will open for 83 seconds to acheive 50 open To change the valve travel time first enter the CALIBRATE ACTUATOR screen The display will show the present period used by the control for valve actuator full travel Press ENTER and adjust the time using the UP DOWN arrows When the correct time is displayed press ENTER to store the new time to memory 11 Operation with Advanced Microprocessor Controls 2 5 3 Run Diagnostics By selecting Run Diagnostics maintenance personnel can check system inputs outputs and complete a test of the microcontroller circuit board all from the front panel Review of the syst
37. a ase Na an Terang 6 Setpoints Setup wt ee a eka Se E ee Sas toes adie Ue eae wheat 6 A View SCtPOIMNUS srs r pw Ba ae a nl owe Sioa elec ak eee ng ead a ea Ba 6 2 5 2 Setup Syste sek fix a a Seis Aes EO eh a a ion shalt er oes Gilat ben eae eh ed 7 Zod Ran Didsnostics e 20 A Ba BS oe eke Ss ATS 12 254 Change Passwords beta se weeks Mtge Wells Boe he ate Aw a ds le eee WA whet 13 Date and Time oa fences sc Lie fh he a ba een tam de is Lay a ioe bathe ty oon E NAN Dan 13 Status Display ies ee Seale ME ee oh PP REE SO EES CREO EAE OEE OL ES ORIG 13 Control Circuit Board 13 234 TOD Display Contras tss tears ea ena a Bu UB dr 13 2 82 Non Volatile Memory A a PES SE as 14 2 8 3 DIP Switches ista Dti Ga eh A Aa a i n Sa Pa BB 14 ZE Contra de IS ANA 14 OPERATION WITH ADVANCED MICROPROCESSOR WITH GRAPHICS CONTROL 15 Basics it SA A A ha al as 15 Status 1s player es ae ses A a PE O PUES a canos 17 Mam Menu SMENU BSES 0030004 ei A DEA ti 17 View Set Alarms 2 naa a A eo 17 BAN ACUSA A A A A A dc 17 2425 Alarm History OS A A A A AA Ad FA CO Da 17 24 35 Setup ALAS A A A ia SNN a a el WEEN 18 34 4 Setup Custom Alarims k ss A A A Ad A A is 8 19 3 4 5 View Water Detect Floor Plan for Optional LTM1000 LT 750 o ooooooooooo oo 19 3 4 6 Setup Water Detect Floor Plan en eee ene teens 19 Operating Status La oten 4 cGy A e a Eo dane ane 20 View Set Control Setpoints ii 20 Sy
38. ace connections incorrect Check connection on component plate in humidifier cabinet Terminal 1 on the square block interface device must be connected to L2 of the power terminal block L2 must also be connected to the electrode closest to the steam outlet port Verify that the red wire from terminal 2 on the interface connects to the red top terminal on the canister This is the one farthest from the steam outlet port and is the high water sensor probe Full isolation has broken down Remove red canister full wire from canister If normal operation resumes canister must be replaced Remove the wire from terminal 3 on the interface If normal operation resumes canister full interface must be replaced Drain assembly not operating freely Check and replace coil or valve if necessary Faulty circuit board Replace circuit board Canister fills but overflows Canister full circuit does not activate Check wiring of canister full interface Replace circuit board 62 Troubleshooting Table 27 Steam generating humidifier troubleshooting continued Symptom Excessive arcing in the canister Possible Cause Drain valve clogged or defective Check or Remedy Verify that drain valve operates freely when activated Clean valve and replace coil or valve if defective Flush canister several times and replace if arcing persists Improper water supply If water is commercial
39. ai been ena Se he Week Base aah Siew othe Shae sew an bee Ge Dn we een es 26 3 11 3 Read Digital Inputs ccc A BS Ss OEE BES EBA 26 3 11 Setup Digital Inputs sive a EL A Sin ells ae a raed Sas eet Ses ees 26 View Run Hours T g n reri RR tdo weds Aes 26 3 12 1 View 24 Hour Run Time History 27 3 122 View Total Run Hours jos Rb aa DAS Rite le Piha RR Hara NB 27 Control Ciretiit board aa facie PENA EN eee EA RS BA a Se thd RN BN Bun NN 27 3 19 11 LOD Contrast own be hee APA Reet Bek Boeck eae By GIRS aed REE De Ree oa 27 821332 Nonivolatile Me mi ory ii A A A Rose E iu OE ON Ra 28 3 19 23 DIP SWItCheS bt ea be eee Pe RE eek eed eee hae ein eek REE Run 28 2113145 Control Outputs Si E een td A Ie sens 28 SYSTEM PERFORMANCE WITH ADVANCED MICROPROCESSOR CONTROLS 29 Temperature Control 24 sss A A Se Ha mna 29 41 1 Cooling Heating Required in Percent eee eens 29 4 1 2 Response to Control Types 29 42153 Cooling Operations s iii ea ei os eee ee vere eae Gel eS WRN a aa Ee it dig Nu 30 41 4 Heating Op ration See an A aa Beate A a balk iti ie Beek eh ah 31 Humidity Controles hea etek a a Wee eae ioe Nm NN Ma Sas he hese 31 4 2 1 Dehumidification Humidification Required in Percent eens 31 4 2 2 Response to Control Types 31 42 3 Dehumidification Operation Wi 31 42 4 Humidification Operation ence eee nets 32 Control Types nt iets o ve DAA A utd testo ana debs
40. alls below the cut out setting High suction pressure reduces the ability of the refrigerant to cool compressor components and can result in compressor damage Minimum pres sure switch cut out setting and maximum design operating suction pressures are in Table 18 Table 18 Suction pressures Minimum Maximum PSIG kPa PSIG kPa System R 22 R 22 Air w FSC 15 103 90 620 Fan Speed Control Air w Lee Temp Control 20 137 90 620 Floodback head pressure control Water Cooled 20 137 90 620 Glycol Cooled 20 137 90 620 Discharge Pressure Discharge Pressure can be increased or decreased by load conditions or condenser efficiency The high pressure switch will shut the compressor down at its cut out setting Refer to Table 19 below Table 19 Discharge pressures Discharge Pressure System Design PSIG kPa Air Cooled 260 1795 Water Glycol Cooled 65 75 F 18 24 C fluid 210 1450 85 F 29 C fluid 225 1550 115 F 46 C fluid 295 2035 Maximum 330 2275 High Pressure Cut Out 360 2482 Superheat Superheat can be adjusted by the Thermostatic Expansion Value TEV To determine superheat Measure the temperature of the suction line at the point the TEV bulb is clamped Obtain the gauge pressure at the compressor suction valve Add the estimated pressure drop between bulb location and suction valve Convert the sum of the two pressures to the equivalent tem
41. and blinking The UP and DOWN arrow keys are used to position the cursor tile The UP key will move the cursor tile up and then it wraps around to the bottom of the next column to the right The DOWN arrow key moves the cursor down then to the top of the next column to the left The cursor will also wrap around from the right top tile to the left bottom tile and back There are three different types of tiles to be defined the environmental unit the LT750 and sensor cable tiles To set up the cable layout first move the cursor to the location of the environmental unit and press the ENTER key A rectangular box will be drawn at that location Then move the cursor to the location of the LT750 and press the ENTER key A solid circle will be drawn on the display No tile can have two definitions so if the LT750 is physically directly under the unit it must be defined at least one tile away The sensor cable should not be defined one tile at a time The only sensor cable tiles that need to be defined are the tiles where the cable is going to change direction and the last tile The display will automatically define any tiles between two consecutively defined sensor tiles to be sensor tiles The ENTER key is also used to undo tile definitions If a tile is defined in the wrong place position the cursor on that tile and press the ENTER key It will undefine the tile under the cursor and move the cursor back to the last defined tile The entire layout can b
42. are modulated to provide temperature control On units equipped with SCR Reheats unit operation can be controlled even further with DIP switch 7 on the control board With DIP switch 7 in the OFF position or Tight Control the compressor is locked on and the SCR Reheats are modulated for very tight temperature control In the event of a malfunction of the SCR Reheats the compressor will be turned off if the temperature drops to the Low Temperature Alarm Setpoint With DIP switch 7 in the ON position or Standard Control the compressor will cycle on and off as required to satisfy the requirements for cooling and dehumidi fication in a similar manner as a standard unit without SCR Reheats i e Temperature Setpoint PLUS Temperature Sensitivity PLUS 1 F The SCR Reheats are modulated from 0 to 100 as required to satisfy the requirements for heating over a control band from the Temperature Setpoint MINUS the Temperature Sensitivity MINUS 1 F Humidity Control Dehumidification Humidification Required in Percent The humidity control program for the Advanced Microprocessor is based on a calculated require ment for dehumidification humidification Response to Control Types Proportional Control The requirement is determined only by the difference between the return air humidity and the humidity setpoint As the return air humidity rises above the humidity setpoint the dehumidifica tion required increases p
43. ast nonvolatile memory DIP switches which should not reguire customer changes control output LEDs and jumpers for board configuration The jumpers should be placed as follows e P5 removed P12 removed e P19 installed on Pins 1 and 2 P47 installed on Pins 1 and 2 e P48 installed on Pins 1 and 2 P50 all jumpers installed for 4 20 mA analog inputs See 4 5 1 Connecting the Analog Sen sors for other configurations P51 removed LCD Contrast The level of contrast due to the viewing angle of the LCD can be adjusted using a small thumb wheel at the upper left of the control board just under the cable going to the display The control is labeled RAI NOTE The LCD backlighting will turn on when any key is pressed and will go off 5 minutes after the last key is pressed 27 Operation with Advanced Microprocessor with Graphics Control 3 13 2 3 13 3 3 13 4 Nonvolatile Memory All critical information is stored in nonvolatile memory Setpoints setup parameters and component run hours are kept inside the microcontroller in EEPROM Information retained for data logging 24 hour component run hour graphs alarm history and the water detection floor plan is kept in non volatile RAM DIP Switches Equipment options are selected and enabled using DIP switches 1 to 7 These are located at the upper left of the control board and are labeled SW1 Switch 1 is at the top These switches are facto
44. ath Only qualified service and maintenance personnel should work with this equipment 1 Disconnect all power to the environmental control unit Tighten all electrical wiring connections that may have loosened during shipping on electric panel and at all major components such as compressor reheats humidifier and motor 3 Remove all line voltage fuses except the main fan fuses at the far right of the electric panel and the Control Voltage fuses at the far left of the electric panel For units supplied with circuit breakers open them instead of removing fuses 4 Turn on power and check line voltage on main unit disconnect switch Line voltage must be within 10 of nameplate voltage 5 Turn ON main unit disconnect switch and check secondary voltage at transformer T1 Voltage at T1 must be 24 VAC 2 5 VAC check at TB1 1 and TB1 8 T1 voltage must not exceed 28 VAC Change primary tap if necessary 6 Push ON button Blower will start 7 Ifyou do not want your unit to operate at factory default settings set temperature and humidity setpoints and sensitivity alarms and other control functions Refer to 2 0 Operation with Advanced Microprocessor Controls or 3 0 Operation with Advanced Microprocessor with Graphics Control 8 Stop unit by depressing ON OFF button on the front display Turn OFF main unit disconnect and main breaker 9 Replace all fuses or reset circuit breakers that were removed in Step 3 10 Restore power to unit
45. ation Each water supply has different char acteristics so the time interval between cleanings must be determined locally A monthly check and cleaning if necessary is recommended Removing the Pan To remove humidifier pan first open disconnect switch and open front panel Allow time for pan and water to cool Unlatch front retainer clip or remove screw from bracket on some units Pull pan for ward Remove stand pipe to allow pan to drain Disconnect drain line Pull pan forward to remove it CAUTION Before removing pan be sure power to unit is disconnected and water in the humidifier pan is no hotter than lukewarm Cleaning the Pan An autoflush system can greatly increase the time between cleanings but does not eliminate the need for periodic checks and maintenance Scale on the side and bottom can be loosened with a stiff brush Flush with water and replace pan in humidifier Changing Humidifier Lamps 1 Open disconnect switch 2 Open front panel 3 Remove screws securing line voltage compartment cover then remove the cover 4 In line voltage compartment disconnect one end of the purple jumpers then locate the burned out bulb with a continuity meter Remove humidifier pan Refer to Removing the Pan on page 53 6 Remove lamp brackets 2 under lamps a Figure 12 Infrared humidifier lamps Humidifier Lamps 7 Loosen two screws securing bulb wires to junction block 8
46. breaker trips Shorts or loose connections Check the wiring connections of the 24 VAC circuit Faulty circuit board Replace the circuit board Main fuses blow approximately 15 seconds after unit is activated Faulty solenoid Check for magnetic field at coil Conductivity too high Check amp draw of humidifier on startup If it exceeds rated amps increase setting of the pot on the circuit board Main fuses blow when drain valve is activated Mineral deposits obstruct drain valve Check drain valve for obstructions and clean if necessary Faulty solenoid Check for magnetic field at coil Faulty circuit board Replace circuit board Unit ON humidifier will not operate Verify that RUN DRAIN switch is in the RUN position Humidifier not receiving power Check fuses or CBs and replace or reset if necessary Make sure molex connector is securely plugged into circuit board and that no wires are loose Contactor pulled in but no water enters canister No water available to unit Check external shut off valves Clogged fill line strainer Clean or replace fill line strainer Wiring breaks or loose connections Check for faulty wiring and loose connections Faulty circuit board Replace circuit board Water enters canister but canister full circuit activates at a low water level Foaming Check drain valve and water supply Canister interf
47. ce During these last hours the mineral concentration can increase If the mineral concentration is too high arcing can occur If the electrodes start to arc turn off the humidifier immediately and replace the canister with the identical part Controls The humidifier RUN DRAIN switch is located at the upper right of the humidifier assembly This switch should be in the RUN position when the humidifier is in normal operation and in the DRAIN position when a manual drain sequence is required The electronic control board for the humidifier is located on the right side of the humidifier assembly When the main unit is energized power is avail able to the humidifier circuits 55 Component Operation and Maintenance Replacing the Canister Over a period of operation the humidifier electrodes become coated with mineral solids This coating insulates the electrodes and decreases the current flow To maintain humidifier capacity the water level slowly rises to expose fresh electrode Eventually the entire electrode becomes coated and the water level reaches the top At this point the canister full alarm is activated and the output begins to fall When this happens it is necessary to replace the full canister To replace the canister 1 Turn off the humidifier by lowering the humidity setpoint below the ambient humidity level Record the original setpoint 2 Place the RUN DRAIN switch in the DRAIN position to drain the water from
48. cluding Liebert power and cooling technologies that protect and support business critical systems Liebert solutions employ an adaptive architecture that responds to changes in criticality density and capacity Enterprises benefit from greater IT system availability operational flexibility and reduced capital equipment and operating costs monitoring upstech powertech Web Site www liebert com Monitoring 800 222 5877 emersonnetworkpower com Outside the US 614 841 6755 Single Phase UPS 800 222 5877 emersonnetworkpower com Outside the US 614 841 6755 Three Phase UPS 800 543 2378 emersonnetworkpower com Environmental Systems 800 543 2778 Outside the United States 614 888 0246 Locations United States 1050 Dearborn Drive P O Box 29186 Columbus OH 43229 Europe Via Leonardo Da Vinci 8 Zona Industriale Tognana 35028 Piove Di Sacco PD Italy While every precaution has been taken to ensure the accuracy and completeness of this literature Liebert Corporation assumes no responsibility and disclaims all liability for damages resulting from use of this information or for any errors or omissions 2006 Liebert Corporation All rights reserved throughout the world Specifications subject to change without notice Liebert and the Liebert logo are registered trademarks of Liebert Corporation All names referred to are trademarks or registered trademarks of their respective owners SL 11935 REVI 08 0
49. control board includes an adjustment for LCD display contrast nonvolatile memory DIP switches which should not reguire customer changes control output LEDs and jumpers for board configuration The jumpers should be placed as follows P5 removed P12 removed P19 installed on Pins 1 and 2 P47 installed on Pins 1 and 2 P48 installed on Pins 1 and 2 P50 all jumpers installed for 4 20 mA analog inputs See 4 5 1 Connecting the Analog Sen sors for other configurations P51 removed LCD Display Contrast The level of contrast due to viewing angle of the LCD display can be adjusted using a small thumb wheel at the upper left of the control board just under the cable going to the display The control is labeled R6 NOTE The LED backlighting on the text 4 x 20 display is always lit 13 Operation with Advanced Microprocessor Controls 2 8 2 2 8 3 2 8 4 Non Volatile Memory All critical information is stored in nonvolatile memory Setpoints setup parameters and component run hours are kept inside the microcontroller in EEPROM Information retained for the alarm history is kept in non volatile RAM DIP Switches Equipment options are selected and enabled using DIP switches 1 through 7 These are located at the upper left of the control board and are labeled SW1 Switch 1 is at the top These switches are factory set and should not require any user changes The setting and function of the switches can be
50. down Device Low Pressure Switch normally on if compressor circuit 1 is in operation Compressor Overload normally on unless Compressor 1 Overload Alarm is active High Head normally off unless High Head Pressure alarm is active Test Outputs When this feature is selected the unit is effectively turned off When stepping from one load to the next the previous load if on is turned off automatically The loads can also be toggled on off by select ing ENTER Once turned on the output will remain on for 5 minutes unless toggled off or the test outputs function is exited by selecting MENU ESC Compressor is limited to 15 seconds on to pre vent damage DO NOT leave the unit in the test outputs mode any longer than is necessary for trou bleshooting The outputs are as follows Main Fan main fan contactor Compressor compressor contactor LLSV liquid line solenoid valve HGBP CUV hot gas bypass or compressor unloader valve on certain units Part Coil Part Coil Solenoid Valve CWV CGV chilled water or GLYCOOL valve R5 Relay Relay 5 heat rejection Reheat 1 Reheat 1 contactor or SCR Reheats also energizes fan for safety Reheat 2 Reheat 2 contactor also energizes fan for safety HWR hot water solenoid valve Humidifier humidifier contactor also energizes humidifier makeup valve and fan for safety e HMV humidifier makeup valve Common alarm common alarm relay CAUTION Do not test a compressor ou
51. e 5 Alarm default time delays Default Time Alarm Delay seconds N Humidifier Problem High Head Pressure Change Filter 2 2 Loss of Air flow 3 Custom Alarm 1 0 0 0 6 Custom Alarm 2 Custom Alarm 3 Custom Alarm 4 High Temperature 30 Low Temperature 30 High Humidity 30 Low Humidity 30 Low Suction Pressure 0 Short Cycle 0 Compressor Overload 2 Main Fan Overload 5 Loss of Power 0 Operation with Advanced Microprocessor Controls Enable Alarms Each individual alarm can be selected to be ENABLED annunciated audibly visu ally and communicated to a Site Products System or DISABLED ignored Enable Common Alarm Each individual alarm can be selected to energize or to not energize the common alarm relay If the energize common alarm function is set to YES the relay is energized immediately as the alarm is annunciated and de energized when the alarm condition goes away only after the alarm has been recognized If the function is set to NO the alarm has no effect on the com mon alarm relay regardless of whether the alarm is ENABLED or DISABLED Set Custom Alarms The custom alarm messages can be from a list of standard alarm messages or you can write your own message NOTE A maximum of two of the alarm messages can be your own message They can be in any location s 1 through 4 The text for custom alarms can be changed at any time by select
52. e display to select the required type for CUSTOM ALARM 1 and CUSTOM ALARM 2 if not already set Next select the alarm message for CUSTOM ALARM 1 and 2 From the Main Menu select VIEW SET ALARMS Then select SETUP CUSTOM ALARMS Then select SETUP CUSTOM ALARM TEXT Define CUSTOM ALARM 1 to be CUSTOM 1 CUSTOM 1 is the default message that will be displayed if a message has never been programmed Next select the text for custom alarm 2 to be WATER UNDER FLOOR Now change the message CUSTOM 1 to LT750 CABLE FAULT This is done by selecting the CHANGE CUSTOM TEXT 1 menu item in the SETUP CUSTOM ALARMS menu Follow the instructions on the screen to change the message The slope and intercept values of Analog Input 1 are used to calculate the location of water These values should initially be set to zero The default values are zero but it may be a good idea to verify those values They can be viewed by selecting ANALOG DIGITAL INPUTS from the Main Menu then SETUP ANALOG INPUTS See 3 4 6 Setup Water Detect Floor Plan for more information Calibration Calibration should not be required for most installations The accuracy of this display is approxi mately 1 The display is calibrated by the slope and intercept values of Analog Input 1 The position of the water is calculated from the analog output of the LT750 using this formula position analog reading full scale reading x measured length slope intercept position is
53. e erased by successively pressing the ENTER key When the last tile is defined press the ESCape key to leave the setup screen For more information and detailed installation instructions see 4 5 2 Water Detection Display 19 Operation with Advanced Microprocessor with Graphics Control 3 5 3 6 3 7 3 7 1 Operating Status The Operating Status is intended to provide the user with displayed information about what the con trol is calling for the system to do NOTE There may be some time lapse before a specific component matches the displayed number For example The display indicates the chilled water valve is 68 open On a new call for cooling it takes several seconds for the valve to travel from full closed to 68 open So when the display reads 68 it may take a few seconds for the valve to actually open 68 Also if the display indicates a com pressor is operating but the compressor has not turned on yet it may be off because of the short cycle control see 4 4 1 Short Cycle Control View Set Control Setpoints Control setpoints can be reviewed and or changed through the display Refer to the following table to see the list of default setpoints and their allowable ranges Table 8 Default setpoints and ranges Setpoint Default Range Temperature Setpoint 72 F 40 to 90 F 5 to 32 C Temperature Sensitivity 2 0 F 1 to 9 9 F 0 6 to 5 6 C Humidity Setpoint 50 20 to
54. e may be flushed by rotating the socket head screw clockwise This screw must be in the OUT position counterclockwise for normal valve operation Valve Disassembly 1 Shut off the water supply by using isolating valves 2 Relieve the tension on the main spring by turning the adjusting screw or collar as far as it will go provide a container to catch water below the valve 3 Remove four screws extending through the main spring housing Remove the center assembly screws for access to all internal parts 5 Clean the seat if possible If the seat is pitted or damaged replace the valve rubber disc and valve seat 6 After valve is reassembled check for leaks 7 Readjust head pressure control e Testing Function of Valve When the refrigeration system has been off for approximately 10 to 15 minutes the water flow should stop If the water continues to flow the valve is either improperly adjusted with head pressure too low or the pressure sensing capillary is not connected properly to the condenser Glycol Solution Maintenance It is difficult to establish a specific schedule of inhibitor maintenance since the rate of inhibitor deple tion depends upon local water conditions Analysis of water samples at time of installation and every six months should help to establish a pattern of depletion A visual inspection of the solution and fil ter residue is often helpful in judging whether or not active corrosion is occurring T
55. eases the frequency of drain cycles The frequency should be increased for highly conductive water and decreased for less conductive water If adjustment is necessary and a change of three to four percent in either direction does not permit normal operation of the unit con sult your Liebert supplier The pot marked SEC controls the duration of the drain cycle The pot is clearly marked in seconds This adjustment is factory set at 60 seconds and should not be readjusted without consulting your Liebert supplier The pot marked CAP ADJ is factory set at 100 The maximum capacity is determined by a fixed resistor R4 which is factory selected based on unit voltage Drain Tempering Feature All units are equipped with a drain tempering feature which mixes cold fill water with hot drain water to protect drain piping This feature can lower drain water temperature to as low as 140 F 60 C depending on water pressure To deactivate this feature remove the diode from socket CR18 on the circuit board lower left above LED 57 Troubleshooting 7 0 TROUBLESHOOTING Use this section to assist in troubleshooting your unit Also refer to 5 0 Alarm Descriptions Sug gestions are grouped by product function for convenience WARNING Only qualified personnel should perform service on these units Lethal voltage is present in some circuits Use caution when troubleshooting with power on Disconnect and lock out power bef
56. em inputs and the microcontroller test can be done without interrupting normal operation To test the system out puts the normal system control is temporarily suspended DO NOT leave the unit in the diagnostics mode any longer than is necessary for troubleshooting The control system will return to normal oper ation in 5 minutes automatically if no key is pressed Show Inputs With the unit on and the fan running the input state for the following devices may be displayed Air sail switch normally off unless Loss of Air Alarm is active Custom alarm 1 normally off unless this alarm is active Custom alarm 2 normally off unless this alarm is active Custom alarm 3 normally off unless this alarm is active Custom alarm 4 normally off unless this alarm is active Humidifier problem normally on unless this alarm is active Filter clog normally off unless Change Filters Alarm is active Main fan overload normally on unless Main Fan Overload Alarm is active Shutdown device normally on unless unit is off through the Fire Stat or Remote Shutdown Device Low press switch normally on if compressor circuit is in operation Comp overload normally on unless Compressor Overload Alarm is active High head comp normally off unless High Head Pressure alarm Compressor is active Test Outputs When this feature is selected the unit is effectively turned off When stepping from one load to the next the previous load if o
57. ems utilize either a 2 or 3 way valve activated by a proportioning motor For cooling and dehumidification the microprocessor will respond by positioning the valve propor tionally to match the needs of the room Full travel of the valve takes place within the range of the sensitivity setting During dehumidification full travel of the valve takes place within 2 RH For hot water reheat the microprocessor will respond by positioning the hot water valve proportion ally to match the needs of the room Full travel of the valve takes place within 1 F with each 0 1 F resulting in 10 valve travel Electric Panel The electric panel should be inspected for any loose electrical connections CAUTION Be sure that power to the unit is shut down before attempting to tighten any fittings or connections Control Transformer and Fuses The control system is divided into four separate circuits The control voltage circuits are individually protected by fuses located on the transformer fuse board If any of the fuses are blown first eliminate shorts then use spare fuses supplied with unit Use only type and size of fuse specified for your unit The small isolation transformer on the board supplies 24 volts to the main control board The trans former is internally protected If the internal protector opens the transformer fuse board must be replaced Also check the control voltage fuse on the main control board before replacing the trans former fuse
58. ep Cooling Compressorized Direct Expansion DX Systems Cooling activates when the temperature control calculates a requirement for cooling of 100 It is deactivated when the cooling requirement drops below 50 The hot gas bypass is energized on a call for cooling unless there is also a call for dehumidification To aid in lubricating the compressor the hot gas bypass solenoid is delayed for 30 seconds on the ini tial call for cooling and de energized for 30 seconds during every 60 minutes of continuous operation 2 Step Cooling Compressorized Direct Expansion DX Systems with Part Coil optional Cooling activates when the temperature control calculates a requirement for cooling of 50 If the system is designed for part coil operation part coil is active and the hot gas bypass would be acti vated At 100 cooling requirement operation would be full coil and the hot gas bypass would be acti vated When the cooling requirement drops to 75 the system returns to part coil and turns off the compressor when the requirement drops to 25 Table 13 Cooling dehumidification load status response LLSV2 LLSV1 Part Coil HGBP 1 Step Cooling Only On Off On 2 Step Cooling Only On On On Dehumidifying Only On Off Off 1 Step Cooling w Dehumidifying On Off Off 2 Step Cooling w Dehumidifying On On Off GLYCOOL Cooling When GLYCOOL cooling is available the temperature control will calculate a total cooling require me
59. er to Figure 4 To turn the unit ON press the ON OFF key after power is applied To turn the unit OFF press the ON OFF key before power is disconnected Active alarms are indicated on the LCD screen by a ringing bell Alarms are also annunciated by an audible beeper To silence an alarm press the ENTER key as prompted on the display The unit stores the 60 most recent alarms for review Setpoints DIP switch settings and other selections were made on your unit before testing at the fac tory and are kept in nonvolatile memory Setpoints were chosen based on typical operating experi ence Other selections were made based on options included with your unit Make adjustments to the factory default selections ONLY if they do not meet your specifications When entering setpoints time delays etc the allowable ranges are displayed and may require a password if enabled Figure 3 Advanced microprocessor with graphics G control panel 15 Operation with Advanced Microprocessor with Graphics Control Figure 4 Advanced microprocessor with graphics control menu 72 F Unit On 50 RH Normal Display Dehumidifying Cooling Main Menu Use UP DOWN to move the cursor Hit ENTER to select the menu item ESC key moves backward through menus toward the Main Menu Any key except ON OFF ESC key View Set Operating Alarms Status Operating Status Setpoints Compressor Cooling
60. erature excursions on a load change increase the proportional setting or the derivative setting Ifa constant temperature deviation exists between the temperature and setpoint increase the integral setting Intelligent Control Chilled Water only The intelligent control operates from a set of general rules that define how the control output should be adjusted for different system conditions The rules are designed to duplicate the actions that an experienced human operator would take if manually controlling the system Just as an operator might take several things into consideration before making a temperature control decision the intelligent control can be programmed to do likewise For example not only is the cur rent temperature used in making temperature control decisions but also conditions such as How fast is the temperature changing What direction is the temperature changing What is the cooling output now What was the cooling output in the past How long ago was the cooling output changed and other factors Any number of rules can be used in an intelligent control to define the controls operation under vari ous operating conditions Hence several advantages are gained from this type of control over a more standard control approach that uses a fixed mathematical equation to define the operation of the con trol for all conditions such as a proportional or PID control You can expect intelligent control to
61. ervals A programmed value of zero 0 would require the user to manually press the ON OFF key to start the unit i e no auto restart The purpose of this feature is to prevent several units from starting at the same time after a loss of power The message Restart Delay Please Wait will be displayed when the system is in the auto restart mode Liebert suggests programming multiple unit installations with different auto restart times IR Fill Rate infrared humidifiers only An autoflush system automatically controls a water makeup valve to maintain the proper level in the infrared humidifier water pan during humidifier operation If humidification is needed and 15 hours have elapsed since the last time the humidifier was on the humidifier is held off until the valve completes an initial fill of the humidifier pan This pre fill is about 30 seconds The valve continues to fill and flush the pan for about 4 minutes During humidifier operation with the flush rate set at the default of 150 the valve is opened peri odically to add water to the pan about 40 seconds for every 9 1 2 minutes of humidifier operation This adds enough water to the pan to cause about a third of the total water used to be flushed out the overflow standpipe located in the humidifier pan This flushing action helps remove solids from the pan The flush rate is adjustable from 110 to 500 If the water quality is poor it may be desirable to increase the water flushing
62. et or inlet Check blower motor fuses and overload reset Check for broken belts Make sure blower wheels are tight to shaft Run diagnostics to see if the fan contactor is working properly Loss of Power If the unit has lost power or the disconnect switch was turned off before the unit ON switch was pressed to turn the unit Off this local alarm will occur when power is restored to the unit A Liebert remote monitoring unit optional will immediately indicate loss of power Low Humidity If the return air humidity has decreased to the Low Humidity Alarm setpoint check to make sure that the unit is setup for humidification check DIP switch Check for proper setpoints Does the room have a vapor barrier to seal it from outdoor humidity Are doors or windows open to outside air Run diagnostics to make sure the humidifier system is working properly Low Suction Pressure A pressure switch monitors the suction pressure at the compressor inlet to monitor whether pressure has dropped below a factory preset point while the compressor is in cooling operation When pressure drops below a factory preset point the switch opens After the positive start kit time delay and the switch stays open for five minutes the alarm is activated The alarm stays active for 90 minutes Look for conditions that would cause loss of refrigerant Check for piping problems such as leaks or crimped lines Check for inoperative components such as liquid line solenoid
63. frared or steam is activated when the humidity control calculates a requirement of 100 humidification and deactivated when the requirement falls below 50 Control Types Proportional Control This is a standard control method that maintains the room at a temperature proportional to the load The temperature maintained increases as the room load increases At full load the room would be con trolled at a temperature equal to the temperature setpoint plus the temperature sensitivity If propor tional control is selected the gain is factory set and cannot be adjusted by the user Operator inputs are the usual setpoint and sensitivity adjustments PID Control Chilled Water or SCR Reheats only The PID control combines three individual terms to determine the control output for a given set of conditions Note that PID control is used only for temperature If PID control is selected humidity will continue to use proportional control The proportional P term is determined by the difference between the current temperature and the control setpoint This term is expressed in cooling heating desired for each degree above below the setpoint It is adjustable from 0 to 100 per degree The purpose of this term is to adjust the control output for any deviation between the current temperature and the control setpoint The integral I term is determined by two things the difference between the temperature and control setpoint and the amount of
64. gh the menus as prompted on the LCD display refer to Figure 2 To turn the unit ON press the ON OFF key after power is applied To turn the unit OFF press the ON OFF key before power is disconnected Active alarms are displayed on the LCD screen Alarms are also annunciated by an audible beeper To silence an alarm press the ENTER key as prompted on the display The unit stores the 10 most recent alarms for review Setpoints DIP switch settings and other selections were made on your unit before testing at the fac tory Setpoints were chosen based on typical operating experience Other selections were made based on options included with your unit Make adjustments to the factory default selections ONLY if they do not meet your specifications When entering setpoints time delays etc the allowable ranges are displayed and may require a password if enabled Figure 1 Advanced microprocessor control panel Operation with Advanced Microprocessor Controls Figure 2 Advanced microprocessor A control for Challenger 3000 Normal Display lt Cooling 72 F 50 RH Dehumidifying No Alarms Present Status Alarm Data Active Alarms Operating Status Alarm History Log Run Hours Log Active Operating Alarm Run Analog View Setup Run Alarms Status History Log Hours Log Sensors Setpoints System Diagnostics No Alarms Present Alarm History Log Alarm 01 of 03 15 APR 09 20 45 High Humidity Alarm 01
65. he complexity of water caused problems and their correction makes it important to obtain the advice of a water treatment specialist and follow a regularly scheduled maintenance program It is impor tant to note that improper use of water treatment chemicals can cause problems more serious than using none Proper inhibitor maintenance must be performed in order to prevent corrosion of the glycol system Consult glycol manufacturer for testing and maintenance of inhibitors Do not mix products from dif ferent manufacturers For further details refer to filling instructions in the installation manual Lie bert part number SL 11925 50 Component Operation and Maintenance 6 4 8 6 4 9 Compressor Functional Check The following diagnostic procedure should be used to evaluate whether the compressor is working properly 1 Proper voltage to the unit should be verified 2 The normal checks of motor winding continuity and short to ground should be made to determine if the inherent overload motor protector has opened or if an internal motor short or ground fault has developed If the protector has opened the compressor must be allowed to cool sufficiently to allow it to reset 3 Proper indoor and outdoor blower fan operation should be verified Condenser glycol flow should be verified 4 With service gauges connected to suction and discharge pressure fittings turn on the compressor If suction pressure falls below normal levels the
66. he evaporator decreases the evaporator will get colder When the coil is too cold the internal pressure in the evaporator drops and allows the hot gas bypass valve to open Hot gas then mixes with the liquid coolant on the discharge side of the expansion valve raising the temperature and pressure in the evaporator The net result is a reduction in the cooling capacity of the unit to match the load To aid in lubricating the compressor the hot gas bypass solenoid is delayed for 30 seconds on the ini tial call for cooling and de energized for 30 seconds during every 60 minutes of continuous operation Adjustment Upon deciding what evaporator temperature is desired the following procedure should be used to adjust the hot gas bypass valve 1 Install the suction and discharge pressure gauge 2 Adjust the temperature setpoint to call for cooling so that the refrigeration compressor will run 3 Remove the TOP adjusting nut from the valve 4 Insert an Allen wrench in the brass hole at top of the valve in adjusting port and turn CLOCKWISE if a higher evaporator temperature is required 5 After obtaining the suction pressure required reinstall the cap tightly making sure there are no leaks 6 Let the evaporator operate for approximately 10 to 15 minutes to make sure the suction pressure is within the desired range 7 There will be a fluctuation of approximately 3 to 6 PSIG 21 to 41 kPa on the evaporator due to the differential on the
67. heck line voltage and determine location of voltage drop Compressor motor defective Check for motor winding short or ground Single phasing Check control panel for welded contactor contacts or welded overload contacts Check voltage across all 3 legs at contactor Correct source problem Replace defective components 60 Troubleshooting Table 24 Dehumidification troubleshooting Symptom No dehumidification Possible Cause Control not calling for dehumidification Check or Remedy Check monitor status Compressor contactor not pulling in See 6 4 8 Compressor Functional Check and Table 23 Compressor won t run fuse blown or CB tripped See 6 4 8 Compressor Functional Check and Table 23 Check fuses or CBs and contacts Check line voltage Table 25 Glycol pump troubleshooting Symptom Suddenly stops pumping Possible Cause Clogged strainer or impeller Check or Remedy Clean out debris Suddenly slow pumping Clogged impeller diffuser or line Clean out debris and use strainer Excessive leakage around the pump shaft while operating Worn seal or packing Replace seal or packing Performance poor Worn impeller or seal Suction lift too high Replace with new impeller or seal Relocate pump closer to supply Motor not up to speed low voltage Larger lead wires may be required Check for proper line voltage 10
68. hen making changes The system includes two 2 passwords one for setpoints and one for setup The system allows the passwords to be changed by first entering the present password factory set as 123 for setpoints and 321 for setup The pass word function provides system security so only personnel authorized to make changes should know the passwords If unauthorized changes are being made the passwords may be compromised and new ones should be selected The password function can be disabled by setting DIP switch 8 to OFF Date and Time The current date and time is available through the display This feature allows the date and time to be read or changed and is accessed by selecting DATE AND TIME from the Main Menu The DATE AND TIME is used only by the control for recording the Alarm History NOTE The clock uses the 24 hour system For example 17 00 would be 5 00 PM The date and time are backed up by battery Status Display The Status Display selected from the Main Menu is the same Status Display that is normally on the screen While the Main Menu is displayed you can press the MENU ESC key to return to the Status Display NOTE The system automatically returns to the Status Display in five minutes if no control keys are pressed Control Circuit Board The control circuit board is located inside the unit behind the LCD display and control key panel Open the front panel for access to the board The
69. hilled water temperature selected through the SETUP OPERATION menu Dual Cooling Source If dual cooling is available the sensible cooling system operates in the same manner as a GLYCOOL system except that it is assumed that 100 chilled water capacity is available any time the chilled water temperature is 3 F cooler than the return air temperature Chilled Water Cooling The chilled water control valve is adjusted proportionally as the temperature control varies the requirement for cooling from 0 to 100 30 System Performance with Advanced Microprocessor Controls 4 1 4 4 2 4 2 1 4 2 2 4 2 3 Heating Operation Electric Reheat The two heat stages are activated when the temperature control calculates a requirement of 50 and 100 respectively Each stage is deactivated when the heat requirement is 25 less than the activa tion point Hot Water Reheat The solenoid valve opens when the requirement for heating is 100 and closes when the requirement drops below 50 SCR Electric Reheat Requires Special Control Software The SCR Silicon Controlled Rectifier controller shall proportionally control the stainless steel reheats to maintain the selected room temperature The rapid cycling made possible by the SCR con troller provides precise temperature control and the more constant element temperature improves heater life During operation of the SCR control the compressor operates continuously The heaters
70. hot gas bypass 8 Return the temperature setpoint to desired number 47 Component Operation and Maintenance 6 4 6 Air Cooled Condenser Restricted airflow through the condenser coil will reduce the operating efficiency of the unit and can result in high compressor head pressure and loss of cooling Clean the condenser coil of all debris that will inhibit air flow This can be done with compressed air or commercial coil cleaner Check for bent or damaged coil fins and repair as necessary In winter do not permit snow to accumulate around the sides or underneath the condenser Check all refrigerant lines and capillaries for vibration isolation Support as necessary Visually inspect all refrigerant lines for signs of oil leaks Checking Refrigerant Charge Lee Temp Flood Back Head Pressure Control The system refrigerant level must be checked periodically To do so 1 Adjust temperature setpoint in the unit so that the compressor will run continuously 2 The refrigerant level is visible through two sight glasses on the receiver and will vary with ambient temperature a 40 F 4 4 C and lower Midway on the bottom sight glass b 40 to 60 F 4 4 to 15 6 C Bottom sight glass should be clear with liquid c 60 F 15 6 C and above Midway on the top sight glass 3 Return temperature setpoint to desired number Figure 9 Outdoor fan condenser configuration FAN SPEED CONDENSER Electric service supplied b
71. igeration secondary Heating Two stages of electric reheat standard Humidification Infrared standard steam generating optional Dehumidification Hot gas bypass locked out standard 1 1 3 Chilled Water Systems These systems utilize a central chiller and control cooling by modulating a control valve in the chilled water line Cooling Proportional in response to room needs Heating Two stages of electric reheat standard Humidification Infrared standard steam generating optional Dehumidification Chilled water valve opens proportionally in response to room needs Introduction 1 2 Start Up Procedure Before beginning start up make certain that unit was installed according to the instructions in the Installation Manual Verify that the fan shipping bolt has been removed the check valve has been installed on air cooled units and that the scroll compressor is rotating in the proper direction All exterior panels must be in place with the front panel open Locate the start up form supplied with your unit documents Complete the form during your start up and mail it to Liebert when start up is completed Contact your Liebert supplier if you have any ques tions or problems during your unit installation start up or operation WARNING Potentially lethal voltages exist within this equipment during operation Observe all cautions and warnings on unit and in this manual Failure to do so could result in serious injury or de
72. ile approximately 2 ft x 2 ft Installation LT750 DIP Switch Settings Install the LT750 following the instructions in the LT750 user manual The following additional switch selections should be made when connecting to an Advanced Microprocessor control DIP SW3 4 Off water alarm relay energizes for alarm DIP SW3 5 Off cable fault relay energizes for alarm Switch 1 Off LT750 sources power for 4 20 mA loop Figure 6 Connecting the LT750 Environmental Unit 35 System Performance with Advanced Microprocessor Controls Physical Connections Figure 6 shows the 4 20 mA output of LT750 connected to Analog Input 1 41 and 42 on the exter nal inputs terminal strip This strip is provided on units ordered with analog inputs If this strip is not installed there is a field installation kit available from your Liebert representative The 4 20 mA output of the LT750 must be connected to the first analog input as shown TB4 is the water detected relay output It can be connected to any one of the four special alarm inputs TB5 is the cable fault relay output It can also be connected to any one of the four special alarm inputs Setup The following description assumes the wiring connections as shown above First verify that special alarms 1 and 2 are ENABLED to either WARNING or URGENT type Do this by selecting VIEW SET ALARMS from the Main Menu Then select SETUP ALARMS Follow the instructions on th
73. ing SET CUSTOM ALARMS To change the text for a custom alarm select SELECT ALARM Then select the alarm you would like to change 1 through 4 Using the UP DOWN arrows will step through the list of five standard alarm messages see list below and the two custom alarms NOTE The two custom alarm messages will be shown with what was previously programmed in them and can be changed Press ENTER to make your selection To modify the two custom alarm messages go back one screen and select CHANGE CUSTOM TXT 1 or 2 Text can be up to 20 characters in length and can be any of the following characters or a blank space ABCDEFGHIJKLMNOPQRSTUVWXYZ 0123456789 Standard Custom Alarm Messages WATER UNDER FLOOR SMOKE DETECTED STANDBY GC PUMP ON LOSS OF WATER FLOW STANDBY UNIT ON For more information concerning alarms see 5 0 Alarm Descriptions Humidity HUM Control Method The user may select between relative direct and absolute predictive humidity control If relative is selected the RH control is taken directly from the RH sensor If absolute is selected the RH control is automatically adjusted as the return air temperature deviates from the desired temperature setpoint This results in a predictive humidity control The display will indicate RH for both methods of con trol but the adjusted humidity reading will be displayed if absolute is selected With absolute humid ity control the humidity
74. isplay and are retained in nonvolatile memory Run times are available for the following Compressor GLYCOOL Coil or CW Coil as used on Dual Cooling Unit e Fan HUM humidifier RH1 reheat 1 or Hot Water or SCR Reheat e RH2 reheat 2 The component run hours for each individual component can be reset by selecting the run hours dis play screen for the desired component then pressing ENTER within 5 minutes of applying power to the control The user will then be prompted to press ENTER to clear the selected component s run hours NOTE Run hours for a component should be reset ONLY when the component has been replaced Analog Sensors The four 4 analog sensor inputs can be monitored from the display The inputs are filtered then dis played along with the text label assigned during setup See Analog Setup on page 11 Setpoints Setup Selecting Setpoints Setup from the Main Menu will display the following selections e View setpoints Setup system Run diagnostics Change passwords NOTE Setpoints and system setup parameters are kept in nonvolatile memory View Setpoints Control and alarm setpoints can be reviewed and or changed through the display The following table lists the default setpoints and their allowable ranges Table 1 Default setpoints and ranges Setpoint Default Range Temperature Setpoint 72 F 40to90 F 5to32 C Temperature Sensitivity 2 0 F 1 t
75. it and connect them to terminals 24 and 51 55 or 56 Use NEC Class 2 24V wiring The sensor contains a solid state switch that closes when water is detected by the twin sensor probes The sensor is hermetically sealed in all thread PVC nipple and is to be mounted where water problems may occur The sensor should be located 6 8 feet 2 2 5m from the environmental control unit in a wet trap or near a floor drain It should not be mounted directly under the unit Figure8 Recommended liquid sensor locations Liebert unit Recommended Liquitect location Floor drain 43 Component Operation and Maintenance 6 2 The zone leak detection kit provides leak detection for a defined zone This kit is ideal for perimeter sensing or serpentine coverage of small areas A simple two wire connection signals the alarms at a Liebert environmental unit or at a monitoring panel Run wires to the Liebert unit and connect them to terminals 24 and 51 55 or 56 The sensor utilizes Liebert s LT500Y leak detection cable The kit is offered with five different lengths of cable sized specifically for the type of Liebert Environmental unit see matrix below Refer to matrix below for the recommended location of leak detection cable Table 16 Zone leak detection kit installation scenarios Scenarios Upflow Unit Upflow Unit Downflow Unit Downflow Unit Detection Detection on sides Detection Detection on sides around and around and entire unit in front
76. key changes the time scale from 90 minutes to 8 hours to 24 hours The UP arrow key toggles the display between maximum and minimum resolution 25 Operation with Advanced Microprocessor with Graphics Control 3 11 3 11 1 3 11 2 3 11 3 3 11 4 3 12 Analog Digital Inputs Selecting ANALOG DIGITAL INPUTS steps to the following menu READ ANALOG INPUTS SETUP ANALOG INPUTS READ DIGITAL INPUTS SETUP DIGITAL INPUTS Read Analog Inputs The four 4 analog sensor inputs can be monitored from the display The inputs are filtered then dis played along with the text label assigned during setup Setup Analog Inputs For installation of analog sensors see Analog Setup on page 11 After selecting a compatible sensor and properly wiring it to the terminals set the control to monitor the sensor according to the following instructions Slope The slope is a multiplier used to scale the input signal The slope can be positive rising or negative falling and can range from 0 resulting in a horizontal line to 999 The slope for a 0 5 volt input is per 1 volt input for 0 10 volt input it is per 2 volt input and for 4 20 mA it is per 4 mA input For example assuming an intercept of 0 for a 0 10 volt sensor input with a slope of 50 an input of 1 volt would be displayed as 25 1x 50 2 2 volts would be 50 2x 50 2 3 volts would be 75 3x 50 2 etc Intercept The intercept is an offset from point 0 cor
77. l con trol system contact your Liebert supplier Standard Alarms Change Filter Periodically the return air filters in the environmental units must be changed The Change Filter alarm notifies the user that filter replacement is necessary A differential air pressure switch closes when the pressure drop across the filters becomes excessive The switch is adjustable using the proce dure on the switch label 38 Alarm Descriptions 5 1 2 5 1 5 5 1 7 Compressor Overload An optional tri block overload device can be used for the compressor Compressor overload may be manual or automatic reset depending on your model Overload is located at the electric connection box on the compressor Custom Alarms Custom alarm messages are programmed at the LCD display The alarms may be specified by the customer at the time of order Additional devices and wiring may be required at the factory or by oth ers The message displayed may be included in this alphabetical list of alarms or it may be custom ized text for up to two alarms If customized text is used customer maintenance personnel should be informed of the alarm function and corrective action required High Head Pressure Compressor high head is monitored with a pressure switch One SPDT pressure switch is used for the compressor in the unit If head pressure exceeds 360 PSIG the switch opens the compressor contactor and sends an input signal to the control On a self c
78. l to mon itor the sensor as follows Slope The slope is a multiplier used to scale the input signal The slope can be positive rising or negative falling and can range from 0 resulting in a horizontal line to 999 The slope for a 0 5 volt input is per 1 volt input for 0 10 volt input is per 2 volt input and for 4 20 mA is per 4 mA input For example assuming an intercept of 0 for a 0 10 volt sensor input with a slope of 50 an input of 1 volt would be displayed as 25 1x 50 2 2 volts would be 50 2x 50 2 3 volts would be 75 3x 50 2 etc Intercept The intercept is an offset from point 0 corresponding to O volts or 0 mA input The inter cept can be positive or negative and can be a point from 0 to 999 Adding an intercept of 100 to the slope example above 1 volt would be 125 100 1x 50 2 2 volts would be 150 100 2x 50 2 3 volts would be 175 100 8x 50 2 etc NOTE For a 4 20 mA input sensor if the desired reading at 4 mA input is 0 then an intercept of 1 x slope would be required For example assuming a slope of 50 the formula would be 1 x 50 4 x 50 4 0 The intercept is 50 Text You may enter a custom label for each analog input The text label can be 20 characters in length including any of the following ABCDEFGHIJKLMNOPQRSTUVWXYZH 0123456789 or space Set Status Display The Status Display can be set to display the return air temperature and humidity SENSOR READ ING
79. lectrical failure will be indicated by a distinct pungent odor If a severe burnout has occurred the oil will be black and acidic In the event that there is an electrical failure and a complete burnout of the refrigeration compressor motor the proper procedures must be performed in order to clean the system to remove any acids that would cause a future failure CAUTION Damage to a replacement compressor caused by improper system cleaning constitutes abuse under the terms of the warranty and the WARRANTY WILL BE VOID There are two kits that can be used with a complete compressor burnout Sporlan System Cleaner and Alco Dri Kleener Follow the manufacturer s procedure CAUTION Avoid touching or contacting the gas and oils with exposed skin Severe burns will result Use long rubber gloves in handling contaminated parts Compressor Replacement Procedure Replacement compressors are available from your Liebert supplier They will be shipped in a reusable crate to the job site as required by the service contractor Upon shipping a replacement compressor the service contractor will be billed in full for the compres sor until the replacement has been returned to the factory The compressor should be returned in the same container used for shipping to the job The possible damage causes or conditions that were found should be recorded by marking the compressor return tag 1 Disconnect power 2 Attach suction and discharge gauges to
80. ly softened reconnect humidifier to raw water supply drain canister and restart If connected to hot supply reconnect to cold water Insufficient drain rate Increase drain rate by adjusting pot on circuit board above the preset 70 to roughly 80 Excessive iron content in water Analyze iron content of water If it exceeds 0 1 mg I install a filter to remove iron from water supply On cold start up canister fills high water alarm activates and humidifier fails to reach full amperage Conductivity of water too low Drain canister and add one Alka Seltzer tablet to canister Refill Turn the pot to roughly 60 Restart humidifier If amperage rises rapidly it may be necessary to dilute the water to prevent blown fuses If it rises too slowly add another Alka Seltzer tablet On cold start up canister fills high water alarm activates and humidifier fails to reach full amperage Table 28 Fill solenoid not closing tightly Reheat troubleshooting If humidifier returns to canister full condition verity that the fill solenoid closes tightly Symptom Control not calling for heat Possible Cause Check monitor status Check or Remedy Reheat will not operate contactor not pulling in Reheat safety stat open Jumper between terminals P34 1 and P34 2 If reheat operates safety is open Remove jumper Replace safety Reheat not operating contactor pulling in Heate
81. mpressor contactor pulled in but compressor will not operate Blown fuse or tripped CB Check for line voltage after fuses or CBs and after contactors Compressor runs for three minutes then stops contactor drops out Low pressure switch not closing Check for low gas pressure Compressor is running on Positive Start Kit air cooled systems only Liquid line solenoid valve not opening Check magnetic field to see if energized High discharge pressure Dirty condenser or drycooler fins Clean coil Condenser equipment not operating Check operation High refrigerant charge Check refrigerant charge Hot gas bypass valve adjusted Adjust properly improperly Water regulating valve adjusted Adjust properly improperly Low discharge pressure Excessive fluid flow through condenser Adjust fluid regulating valve Suction service valve partially closed Faulty head pressure control valve or condenser fan speed control Open the valve Replace if defective Compressor rotation in reverse direction Check for proper power phase wiring to unit and to compressor motor Low suction pressure Insufficient refrigerant in system Check for leaks repair and add refrigerant for air cooled Evacuate and recharge for water glycol unit Dirty air filters Change filters Plugged filter drier Replace filter Improper superheat adjustment Reset expansion
82. n is turned off automatically The loads can also be toggled ON OFF by selecting ENTER Once turned on the output will remain on for 5 minutes unless toggled off or the Test Outputs function is exited by selecting MENU ESC The compressor is limited to 15 seconds on to prevent damage The outputs are as follows Main fan main fan contactor Comp compressor contactor LLSV liquid line solenoid valve HGBP CUV hot gas bypass or compressor unloader valve on certain units e Part coil part coil solenoid valve CWV CGV chilled water or GLYCOOL valve R5 Relay Relay 5 heat rejection Reheat 1 Reheat 1 contactor also energizes fan for safety or SCR Reheats Reheat 2 Reheat 2 contactor also energizes fan for safety e HWR hot water solenoid valve Humidifier humidifier contactor also energizes humidifier makeup valve and fan for safety HMV humidifier makeup valve Comm alarm common alarm relay CAUTION Do not test a compressor output for more than a few seconds Compressor damage could result Test Control Board By selecting this function the microcontroller will perform a self test lasting approximately 10 sec onds At the end of the test the ROM checksum ROM part number and version number will be dis played 12 Operation with Advanced Microprocessor Controls 2 5 4 2 6 2 7 2 8 2 8 1 Change Passwords The display prompts you to enter a three digit password w
83. n air temperature rises above the temperature setpoint the cooling required increases proportionally from 0 to 100 over a temperature band equal to the temperature sensitivity plus 1 F The heating requirement is determined the same way as the temperature decreases below the setpoint With this type of control the temperature at which the room is con trolled increases as the room cooling load increases At full cooling load the room would be controlled at a temperature equal to the setpoint plus the sensitivity For systems with SCR Reheats the requirement is determined only by the difference between the return air temperature and the temperature setpoint This permits tighter temperature control The SCR Reheats are controlled in a proportional manner inversely as described above for cooling When the return air temperature is at the temperature setpoint the SCR Reheats will be on 100 As the temperature increased to the temperature setpoint plus the temperature sensitivity the SCR Reheats will be pulsed proportionally from full on to full off 0 to 100 until the return air temperature reaches the temperature setpoint plus the temperature sensitivity PID Control Chilled Water or SCR Reheats only If PID control is selected the return air temperature is controlled at or near the temperature setpoint independent of the room load The cooling heating requirement is calculated by adding together three individual terms proportional
84. normal operation Table 3 Unit options Option Selection Heating Yes or No Humidifier Yes or No Dehumidifier Yes or No Hot Gas Reheat Yes or No Heat Stages 2 1Heating cannot be disabled on units with SCR reheats 2Hot gas reheat not available on units with SCR reheats 3Heat stages not selectable on units with SCR reheats Calibrate Sensors The temperature and humidity sensors can be calibrated by selecting this menu item SENSOR shows the actual sensor reading or raw reading CALIBRATED shows the sensor reading after the calibration offset has been added The temperature sensor can be calibrated 5 degrees Fahrenheit and the humidity sensor can be calibrated 10 RH When calibrating the humidity sensor the value shown will always be RH even though absolute humidity control may be selected If absolute humidity control is selected the Normal Status Display will display the adjusted reading and may not agree with the relative humidity reading displayed while in calibration Show DIP Switches The DIP switch settings can be reviewed from the display panel Changing the DIP switches requires opening the upper panel for access to the DIP switches on the microprocessor control board NOTE Power MUST be cycled OFF then ON from the unit disconnect switch for the control system to update the DIP switch settings with the exception of switch 8 Table 4 DIP switch settings
85. ns Notes Serial Steam Generating Humidifier ___1 Check canister for deposits 2 Check condition of steam hoses __ 3 Check water make up valve for leaks __ 4 Inspect amp tighten electrical connections Infrared Humidifier 1 Check pan drain for clogs 2 Check humidifier lamps 3 Check pan for mineral deposits 4 Inspect amp tighten electrical connections Refrigeration Cycle Section 1 Check refrigerant lines 2 Check for moisture sight glass 3 Check suction pressure 4 Check head pressure 5 Check discharge pressure 6 Check hot gas bypass valve 7 Check thermostatic exp valve Air Distribution Section ___1 Restriction in grille free area Refrigerant Charge ___1 Check refrigerant level Electrical Panel __ 1 Check fuses __ 2 Inspect amp tighten electrical connections __ 3 Check operation sequence 4 Check contactor operation Reheat __ 1 Check reheat element operation __ 2 Inspect elements for cleanliness ___ 3 Inspect amp tighten electrical connections Signature Make photocopies of this form for your records 65 Semiannual Maintenance Inspection Checklist 66 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 a family of technologies in
86. nt of 200 rather than 100 Assuming that full GLYCOOL capacity is available the GLYCOOL valve opens proportionally as the requirement for cooling rises from 0 to 100 If more than 100 cooling is required then the compressor is activated at 200 If full GLYCOOL capacity is not avail able then the GLYCOOL valve will be opened proportionally over a cooling requirement band equal to the available GLYCOOL capacity The compressor would be activated at a cooling requirement of 100 above the available GLYCOOL capacity For example if the GLYCOOL capacity is 60 then the GLYCOOL valve would be full open at 60 cooling requirement and the compressor would be in full cooling at 160 In order to reduce compres sor cycling and prevent hunting GLYCOOL capacity first becomes available when the entering glycol temperature is at least 8 F 22 capacity below the return air temperature or 3 F below the return air temperature for 2 hours GLYCOOL capacity approaches 100 when the glycol temperature is 25 degrees F below the return air temperature The system will continue to Econ O Cool as necessary as long as the entering glycol temperature remains at least 3 F 0 capacity below the return air tem perature If GLYCOOL is not available the temperature control will operate the compressor in the same manner as a 1 step or 2 step system without GLYCOOL The control will not permit compressor operation if the chilled water temperature is below the minimum c
87. ntrol while humidity will continue to use proportional control For chilled water units with the optional Variable Speed Drive Intelligent is required for proper operation Refer to 4 0 System Performance with Advanced Microprocessor Controls for more details on types of control 22 Operation with Advanced Microprocessor with Graphics Control 3 7 6 3 7 7 3 7 8 3 8 Select Humidity Sensing Mode The user may select between RELATIVE direct and ABSOLUTE predictive humidity control If relative is selected the RH control is taken directly from the RH sensor If absolute is selected the RH control is automatically adjusted as the return air temperature deviates from the desired temper ature setpoint This results in a predictive humidity control The display will indicate RH for both methods of control but the adjusted humidity reading will be displayed if absolute is selected With absolute humidity control the humidity control is automatically adjusted approximately 2 RH for each degree difference between the return air temperature and the temperature setpoint With relative humidity control unnecessary dehumidification can result when overcooling occurs dur ing a dehumidification cycle This is because a higher than normal RH reading is caused by overcool ing the room about 2 RH for each degree of overcooling This extends the dehumidification cycle Later when the dehumidification ends and the temperature rises
88. o 9 9 F 0 6 to 5 6 C Humidity Setpoint 50 20 to 80 RH Humidity Sensitivity 5 1 to 30 RH High Temperature Alarm 80 F 35 to 95 F 2 to 35 C Low Temperature Alarm 65 F 35 to 95 F 2 to 35 C High Humidity Alarm 60 15 to 85 RH Low Humidity Alarm 40 15 to 85 RH Operation with Advanced Microprocessor Controls 2 5 2 Setup System The Setup System menu includes the following selections SETUP OPERATION SELECT OPTIONS CALIBRATE SENSORS SHOW DIP SWITCHES SELECT CONTROL TYPE Chilled Water or SCR Reheats only SETUP ALARMS HUM CONTROL METHOD ANALOG SETUP SET STATUS DISPLAY CALIBRATE ACTUATOR Setup Operation The Setup Operation menu permits the review and or adjustment of the unit configuration This may include Cold Start This feature also referred to as Positive Start or Winter Start Kit allows for the low pressure switch to be ignored for the programmed time during a cold start of the compressor Enter ing a 0 for this time will bypass this feature A 1 will bypass the low pressure switch for one minute a 2 for 2 minutes etc The programmed value can be from 0 to 3 minutes This delay is fac tory set to O for water cooled glycol cooled and GLYCOOL units Typically only air cooled units need a Winter Start delay time Restart This feature allows for the unit to restart automatically after a loss of power The pro grammed value is in 0 1 minute 6 seconds int
89. ocessor with graphics G control panel Advanced microprocessor with graphics control menu ee eens Analoganput Jumper a me A A A IA A E Connecting the il 150s ws sas is ites ae si at a Id ite ails Liebert leak detection units ii Recommended liquid sensor locations ee ee eee eee enna Outdoor fan condenser Configuration Johnson Controls valve adjustment Metrex valve adjustment a oe See NBA Ba Pg ory Boke a ae es od naa Pen Infrared humidifier lamps ii na Steam generating humidifier 2 0 0 0 0 na Canister replacement yete BRA gat he A Ge hee Rae os PLM A BOR Eee Default setpoints and ranges arere t aea a E eee een eee nee es Setup functions default values and ranges 0 0 0 0 ccc eee eens UNE OPS Sc na O Be oe oe one bee ete Wiles anced Sede ERE iy BAD RGSS BR ed oles DIFP Swit Setan ES ii Pid Pee ee ap BE E oe cat TEE A RS Ee ea DN ate ai Alarimidetault time delay 2 5 oa wate dam a A dal Ged ee daun ods Controkoutput LEDS 3 Ken ies oh bosen solo hoes ote eta ga Ga Btn Wa Kane BN bees We oid atte ae Alarm default timetdelaysi d ae ee of estes ade eee aes RE ote le Btw we el eee od Default setpoints and ranges cc na Setup functions default values and ranges eee teen nee Unit options in LAs e teil Beaks A AA Wek ah oe Meee Since na a Seting OPINAS Ki sea ask i wv day aller etsy Tua MOM A a a a Kan an Prstereb
90. of 01 High Head PR Setpoints Setup Date and Time View Setpoints Setup System Run Diagnostics Change Passwords Analog Sensors Analog in 1 2 3 4 xx AD 1 2 3 4 Use to Scroll Use 4to Scroll Use 4 to Scroll ESCape to exit Operating Status DX Cool Comp Heat Econo Cool Fan CW Valve Hum DX Deh Hum RH1 RH2 Alarms Available Standard Alarms Humidifier Problems High Head Pressures Change Filter Loss of Air Flow High Temperature Low Temperature High Humidity Low Humidity Short Cycle Low Suction Pressure Compressor Overload Loss of Power Custom Alarms 1 to 4 Programmed Alarm Messages Water Under Floor Smoke Detected Standby GC Pump On Loss of Water Flow Standby Unit On User Customized Alarm Messages Available for Custom Alarms Some alarms require optional equipment Optional GLYCOOL or CW Coil Run Hours Log View Setpoints Temp Setpoint Sensitivity Hum Setpoint Sensitivity High Temp Alarm Lo Temp Alarm High Hum Alarm Lo Hum Alarm Main Menu Status Alarm Data Setpoints Setup Date and Time Status Display Status Display 15 APR 2004 09 30 00 75 F 59 RH Cooling Dehumidifying No Alarms Present ENTER to change ESCape to exit Change Password Run Diagnostics Show Inputs Test Outputs Test Control Board Setup System Setup Operation Cold Start TD Restart TD IR Fill Rate F C Degrees Min CW Temp CW HW Flush
91. ompartment of the unit Wire sensors to the terminals as follows Table 14 Analog input terminals Terminal Signal 41 Input 1 42 Input 1 43 Input 2 44 Input 2 45 Input 3 46 Input 3 47 Input 4 48 Input 4 Consult your Liebert supplier for a field installation kit to add these connections after unit delivery if reguired Table 15 Additional connections available after unit delivery Input 1 Input 2 Input 3 Input 4 4 20 mA Jumper P50 1 amp 2 Jumper P50 5 amp 6 Jumper P50 9 amp 10 Jumper P50 13 8 14 and P50 3 amp 4 and P50 7 amp 8 and P50 11 amp 12 and P50 15 amp 16 0 5 VDC Jumper P50 1 amp 2 Jumper P50 5 amp 6 Jumper P50 9 amp 10 Jumper P50 13 amp 14 0 10 VDC NO Jumper NO Jumper NO Jumper NO Jumper on P50 1 8 2 on P50 5 amp 6 on P50 9 amp 10 on P50 13 amp 14 and P50 3 amp 4 and P50 7 amp 8 and P50 11 amp 12 and P50 15 amp 16 34 System Performance with Advanced Microprocessor Controls Figure 5 Analog input jumpers ENLARGED AREA Analog input jumper location Pee B5G0680088 gt 4 5 2 Water Detection Display The water detection display is designed to graphically display the location of water under a raised floor when connected to an LT750 water detection system The graphical floor plan screen shows a 30 x 16 grid Each square represents one standard floor t
92. ons which should match the options installed with your unit and should not need to change during normal operation Table 10 Unit options Option Selection Reheat YESOrNO Humidity YES or NO Dehumidify YES or NO Hot Gas Reheat YES or NO Stages of Reheat 2 Heating cannot be disabled on units with SCR reheats 2Hot gas reheat not available on units with SCR reheats 3Heat stages not selectable on units with SCR reheats Calibrate Sensors The temperature and humidity sensors can be calibrated by selecting this menu item SENSOR shows the actual sensor reading or raw reading CALIBRATED shows the sensor reading after the calibration offset has been added The temperature sensor can be calibrated 5 F and the humidity sensor can be calibrated 10 RH When calibrating the humidity sensor the value shown will always be RH even though absolute humidity control may be selected If absolute humidity control is selected the Normal Status Display will display the adjusted reading and may not agree with the relative humidity reading displayed while in calibration Calibrate Valve Actuator For systems that use a valve actuator for chilled water or GLYCOOL cooling the actuator timing may be calibrated or adjusted This is the time it takes for the valve to travel from full closed to full open It is programmable from 0 to 255 seconds The factory default time is 165 seconds and should not be changed
93. ontained system the head pressure switch located at the compressor requires a manual reset and the alarm condition to be acknowledged on the front display panel On a split system the high head pressure condition is acknowledged by pressing the alarm silence button that will clear the alarm if the high head pressure condition no longer exists On a split system if the compressor is off for 1 hour the control goes into a special cold start mode In the cold start mode on a call for cooling or dehumidification the Liquid Line Solenoid Valve LLSV is energized If the high pressure switch does NOT trip within 10 seconds the control returns to normal operation of monitoring the high head pressure switch for three occurrences in a 12 hour period It is a rolling timer and after the third high head alarm occurs and is acknowledged by the user it will lock off the compressor If while in the cold start mode the high head pressure switch DOES trip within 10 seconds of the activation of the LLSV the control does not annunciate the alarm The con trol will turn off the LLSV and delay 10 seconds The control will permit this occurrence two more times or a total of three times If on the fourth try the high head pressure switch trips within 10 sec onds the control will annunciate the alarm turn off the LLSV wait for the user to acknowledge the alarm and hold the compressor off for three minutes which is the normal short cycle control On the third occur
94. or mounts tight ___5 Check discharge pressure __ 3 Bearings in good condition ___ 6 Check hot gas bypass valve 4 Refrigerant lines properly ___ 7 Check thermostatic exp valve supported Reheat Air Distribution Section __ 1 Check reheat element operation E Restriction in grille free area __ 2 Inspect elements for cleanliness Refrigerant Charge Check refrigerant level Notes Signature Make photocopies of this form for your records 64 Semiannual Maintenance Inspection Checklist 9 0 SEMIANNUAL MAINTENANCE INSPECTION CHECKLIST Date Prepared by Model Filters __ 1 Restricted air flow ___2 Check filter switch __ 3 Wipe section clean Blower Section ___1 Impellers free of debris and move freely __ 2 Check belt tension and condition __ 3 Bearings in good condition 4 Inspect amp tighten electrical connections Compressor __ 1 Check oil leaks __ 2 Check for leaks __ 3 Inspect amp tighten electrical connections Air Cooled Condenser if applicable 1 Condenser coil clean 2 Motor mounts tight 3 Bearings in good condition 4 Refrigerant lines properly supported 5 Inspect amp tighten electrical connections Water Glycol Condenser if applicable 1 Copper tube clean 2 Water regulating valves function 3 Glycol solution 4 Check for water glycol leaks Glycol Pump ___ 1 Glycol leaks __ 2 Pump operation 3 Inspect amp tighten electrical connectio
95. ore replacing components Use caution and standard procedures when working with pressurized pipes and tubes A CAUTION When using jumpers for troubleshooting always remove jumpers when maintenance is complete Jumpers left connected could override controls and cause equipment damage Table 21 Blower troubleshooting Symptom Possible Cause Check or Remedy No main power Check L1 L2 and L3 for rated voltage Blower Willingt Stare Blown fuse or tripped circuit breaker CB Check fuses or CBs to main fan Overloads tripped Push reset button on main fan overload Check amp draw No output voltage from transformer Check for 24 VAC between P24 2 and P24 1 If no voltage check primary voltage Control fuse blown or circuit breaker tripped Check for 24 VAC between P4 4 and E1 If no voltage check for short Replace fuse or reset circuit breaker Table 22 Chilled water troubleshooting Symptom Possible Cause Check or Remedy Chilled water or hot Motor operates but valve won t open Check linkage for adjustment and be sure that it is water steam valve tight on the valve not opening No 24 VAC power to motor Check linkage for adjustment and be sure that it is Modulating Motors tight on the valve No signal from control Check DC voltage on printed circuit board in motor Terminal No 1 is grounded and No 3 is positive DC voltage should vary from 0 8 to 2 0 VDC or above as temperature control is varied below room tempe
96. ost recent If there are no active alarms then NO ALARMS PRESENT will be displayed Operating Status The Operating Status is intended to provide the user with displayed information concerning what the control is calling for the system to do NOTE There may be some time lapse before a specific component matches the displayed number For example The display indicates the chilled water valve is 68 open On a new call for cooling it takes several seconds for the valve to travel from fully closed to 68 open So when the display reads 68 it may take a few seconds for the valve to actually open 68 Also if the display indicates a com pressor is operating but the compressor has not yet turned on it may be off because of the short cycle control see 4 4 1 Short Cycle Control Alarm History Log A history of the 10 most recent alarms is kept in nonvolatile memory complete with the date and time that the alarms occurred The first alarm in the history is the most recent and the 10th is the oldest If the alarm history is full 10 alarms and a new alarm occurs the oldest is lost and the newest is saved in alarm history location 1 The rest are moved down the list by 1 Alarm history on new units may show the results of factory testing Operation with Advanced Microprocessor Controls 2 4 4 2 4 5 2 5 2 5 1 Run Hours Log The total operating hours of all major components in the unit can be monitored from the d
97. oward you to remove it On downflow units the filter is hori zontal above the electrical panel Slide the filter out toward you to remove it After replacing the filter s test the operation of the filter clog switch Turn the adjusting screw counter clockwise to trip the switch this will energize the Change Filter alarm To adjust the switch proceed as follows With the fan running set the switch to energize the light with clean filters The unit panels must all be in place and closed to accurately find this point Then turn the adjusting knob one turn clockwise or to the desired filter change point 44 Component Operation and Maintenance 6 3 6 3 1 6 3 2 6 3 3 Blower Package Periodic checks of the blower package include belt motor mounts fan bearings and impellers Fan Impellers and Bearings Fan impellers should be periodically inspected and any debris removed Check to see if they are tightly mounted on the fan shaft Rotate the impellers and make sure they do not rub against the fan housing Bearings used on the units are permanently sealed and self lubricating They should be inspected for signs of wear when the belt is adjusted Shake the pulley and look for movement in the fan shaft If any excessive movement is noticed bearings should be replaced However the cause of the wear must be determined and corrected before returning the unit to operation Belt The drive belt should be checked monthly for
98. p ti Control output EDS A FRG A vee SNe heh wie ay we ogee Penata Cooling dehumidification load status response 0 0 ccc eee teen nee Analog input terminals ec ee en ene eee eee nent a a aad Additional connections available after unit delivery 00 0000 cee nes Zone leak detection kit installation scenarios eee een ees Recommended free area ft m2 for grilles or perforated panels at output velocities of 550 and 600 fpm 2 8 and 3 1 M S oi SUCTION Pressures eirs oleae id a Ea then ele Bb gs Ur en bab ws wesw lac os bbw in Du na Kanan Discharge pressures ii Humidifier canister part numbers inn Blower troubleshooting ii Chilled water troubleshooting Wi Compressor and refrigeration system troubleshooting teenies Dehumidification troubleshooting 00 000 cc na Glycol pump troubleshooting a n Infrared humidifier troubleshooting inna Steam generating humidifier troubleshooting ii Reheat troubleshootin amp amp Kari bntn Bana MBA ENG UB Hue UPS NB RU Gears Phas vi Introduction 1 0 INTRODUCTION 11 System Descriptions Challenger 3000 Liebert environmental control systems are available in several configurations Each configuration can operate with either Advanced Microprocessor Controls A or Advanced Microprocessor Controls with Gra
99. perature Subtract this temperature from the actual suction line temperature The difference is superheat OUR Oy Ne 46 Component Operation and Maintenance 6 4 4 6 4 5 Thermostatic Expansion Valve Operation The thermostatic expansion valve performs one function It keeps the evaporator supplied with enough refrigerant to satisfy load conditions It does not effect compressor operation Proper valve operation can be determined by measuring superheat If too little refrigerant is being fed to the evaporator the superheat will be high if too much refrigerant is being supplied the superheat will be low The correct superheat setting is between 10 and 15 F 5 6 and 8 8 C Adjustment To adjust the superheat setting proceed as follows 1 Remove the valve cap at the bottom of the valve 2 Turn the adjusting stem counterclockwise to lower the superheat 3 Turn the adjusting stem clockwise to increase the superheat NOTE Make no more than one turn of the stem at a time As long as 30 minutes may be required for the new balance to take place Hot Gas Bypass Valve Operation The hot gas bypass is inserted between the compressor discharge line and the leaving side of the expansion valve through the side outlet distributor The system with normal operation when the evaporator is under full load will maintain enough pressure on the leaving side of the hot gas valve to keep the valve port closed If the load on t
100. phics G A brief description of each including operational differ ences are listed below Check model numbers to see what is supplied with your unit 1 1 1 Compressorized Systems NOTE Compressorized systems may be a self contained system with the compressor in the Challenger 3000 unit or a split system with the compressor in the separate condensing unit These systems may be air water or glycol cooled depending on the heat rejection method selected Cooling One stage standard two stages of mechanical refrigeration with optional split coil Heating Two stages of electric reheat standard SCR controlled electric reheat hot water reheat hot gas reheat on water and glycol cooled systems optional Humidification Infrared standard steam generating optional Dehumidification Hot gas bypass locked out standard part coil operation optional 1 1 2 GLYCOOL Chilled Glycol Cooling Systems GLYCOOL systems have all of the features of a compressorized water or glycol system plus a sec ond cooling coil that is connected into the water circuit When fluid temperature is sufficiently low below room temperature cooling is provided by circulating the fluid through the second cooling coil flow is controlled by a motorized valve This is then the primary cooling source and it greatly reduces the compressor operation Cooling Modulated cooling valve opens proportionally to match room needs primary one or two stages of mechanical refr
101. plenish the water being boiled off and maintain a steady state output at the set point The amperage variance will depend on the conductivity of the water After a period of time the mineral concentration in the canister becomes too high When this occurs the water boils too quickly As the water quickly boils off and less of the electrode is exposed the current flow decreases When the current crosses the low threshold point factory set at 90 before the end of the time cycle the drain valve opens draining the mineral laden water out and replacing it with fresh water This lowers the mineral concentration and returns the canister to steady state operation and prolongs canister life The frequency of drains depends on water conductivity Over a period of time the electrode surface will become coated with a layer of insulating material which causes a drop in current flow As this happens the water level in the canister will slowly rise exposing new electrode surface to the water to maintain normal output Eventually the steady state water level will reach the canister full electrode and indicate so by activating the canister full alarm At this point all of electrode surface has been used up and the canister should be replaced After the entire electrode surface has been coated the output will slowly begin to fall off This usually occurs in the last several hours of electrode life and should allow enough time to schedule maintenan
102. r burned out Turn off power and check heater continuity with Ohm meter NOTE E Reheat element sheaths and fins are manufactured with stainless steel Regular inspections are necessary to assure proper cleanliness of the reheating element Should inspection reveal corrosion particles on the reheating element or adjoining surfaces including ducts and plenums appropriate cleaning should be performed Periodic reheating element replacement may be required to meet specific application requirements 63 Monthly Maintenance Inspection Checklist 8 0 MONTHLY MAINTENANCE INSPECTION CHECKLIST Date Prepared by Model Serial Filters Steam Generating Humidifier __ 1 Restricted air flow o Check canister for deposits __ 2 Check filter switch __ 2 Check condition of steam hoses 3 Wipe section clean 3 Check water make up valve for leaks Blower Section Infrared Humidifier 1 Impellers free of debris and move freely Check pan drain for clogs __ 2 Check belt tension and condition 2 Check humidifier lamps 3 Bearings in good condition 3 Check pan for mineral deposits Compressor Refrigeration Cycle Section __ 1 Check oil leaks _ Check refrigerant lines __ 2 Check for leaks ___2 Check for moisture sight glass Air Cooled Condenser if applicable T Check suction pressure 1 Condenser coil clean ___ 4 Check head pressure 2 Mot
103. rature on cooling valve or above room temperature on heating valve Motor not working Remove wires on terminal No 1 and No 3 from the motor do not short With 24 VAC power from TR to TR jumper terminal 1 and 2 on motor to drive open Remove jumper to drive closed if motor fails to work replace it Actuator Motors No 24 VAC power to motor Check for 24 VAC between P22 3 and P22 5 open or P22 1 and P22 5 closed 58 Troubleshooting Table 23 Compressor and refrigeration system troubleshooting Symptom Compressor will not start Possible Cause Power off Check or Remedy Check main switch fuses or CBs and wiring Current overload open Re set units with overload option manually Allow compressor to cool for internal overloads to reset Loose electrical connections Tighten connections Compressor motor burned out Check and replace compressor if defective Compressor will not operate contactor not pulling in No call for cooling Check monitor status Solenoid valve not energizing Hold screwdriver over solenoid and check for magnetic field This indicates solenoid is energized Low pressure switch not making contact Check gas pressure manually energize low pressure switch Compressor will not operate contact not pulling in High pressure switch open Reset switch Refer to other refrigeration troubleshooting suggestions Co
104. re lubricated and properly seated on the bottom neck 2 Always check the fill and drain solenoids for proper operation NOTE Q When replacing the wiring connect the red wire from terminal 1 on the interface to the red top terminal on the canister It is in the middle of a group of three terminals The black wire from terminal 2 on the interface connects to the power terminal farthest from the red terminal wire The power wire to this terminal is routed through the current sensing coil 56 Component Operation and Maintenance Figure 14 Canister replacement Circuit Board Adjustments A WARNING Circuit board adjustment should be performed by qualified personnel only Hazardous voltages are present in the equipment throughout the procedure Use extreme caution If desired power may be disconnected prior to the procedure Humidifier operation is governed by the humidifier control board This board is located on the right side of the humidifier compartment There are three potentiometers mounted on the board These pots can be used to adjust for extreme water conductivity conditions and capacity The pot controls the amperage at which the drain will energize The pot is clearly marked in per centages This adjustment is factory set at 90 which indicates that the unit will drain when the amperage falls off to 90 of the capacity setpoint Raising the value increases the frequency of drain cycles Lowering the value decr
105. re switch erratic in operation Check tubing to switch to see if clogged or crimped Check for proper switch operation Insufficient refrigerant in system Check for leaks fix and add refrigerant on air cooled unit Evacuate and recharge water glycol unit Suction service valve closed Open valve Insufficient fluid flowing through condenser or clogged condenser or dirty air cooled condenser coils Adjust fluid regulating valve to condenser Flush the condenser Discharge service valve not fully open Open valve Compressor cycles continually Faulty low pressure switch Repair or replace Dirt or restriction in tubing to pressure stat Check and clean tubing Defective liquid line solenoid valve Check valve and solenoid operator replace if necessary Plugged filter drier Replace filter Compressor motor protectors tripping or cycling High discharge pressure Check for loss of condenser water or blocked condenser fan or coil Defective overload relay Replace High suction temperature Reduce suction temperature by expansion valve adjustment or provide desuperheating Loose power or control circuit wiring connection Check all power and control circuit connections Defective motor Check for motor ground or short Replace compressor if either condition is found Compressor cycles on locked rotor Motor burnout Low line voltage C
106. read from the LCD display see Show DIP Switches on page 8 or the accompanying Table 4 Control Outputs Active control outputs are indicated with LEDs on the lower section of the control board Each LED is lit if the control output is active on The LEDs assist in troubleshooting the system Refer to the fol lowing table Table 6 Control output LEDs LED Control Output R5 Heat Rejection LLSV Liquid Line Solenoid Valve HGBP Hot Gas By Pass or Compressor Unloader Valve C1 Compressor RH1 Reheat Stage 1 Hot Gas Hot Water Reheat Solenoid or SCR Reheats RH2 Reheat Stage 2 HUM Humidifier FAN Main Fan HMV Humidifier Make Up Valve LLSV2 Part Coil Solenoid Valve 14 Operation with Advanced Microprocessor with Graphics Control 3 0 OPERATION WITH ADVANCED MICROPROCESSOR WITH GRAPHICS CONTROL The advanced microprocessor with graphics G control for your Liebert Challenger 3000 unit features an easy to use menu driven LCD Graphics Display The menus control features and circuit board details are described in this section For more details on the control refer to 4 0 System Perfor mance with Advanced Microprocessor Controls for details on the alarms refer to 5 0 Alarm Descriptions 3 1 Basics Control keys include ON OFF Menu ESCape ENTER Increase UP arrow and Decrease DOWN arrow Refer to Figure 3 These keys are used to move through the menus as prompted on the LCD display ref
107. rence the control will lock the compressor off until the control power is reset On air cooled systems check for power shut off to the condenser condenser fans not working defec tive head pressure control valves closed service valves dirty condenser coils and crimped lines Also make sure that when the compressor contactor is energized the side switch on the contactor closes to energize the control circuit on the air cooled condenser On water glycol GLYCOOL systems check water regulating valves Verify water glycol flow are pumps operating and service valves open Is water tower or drycooler operating Is the coolant tem perature entering the condenser at or below design conditions Is relay R5 operating during cooling to turn on the drycooler High Humidity The return air humidity has increased to the High Humidity Alarm setpoint Is the unit setup for dehumidification check DIP switch Check for proper setpoints Does the room have a vapor barrier to seal it from outdoor humidity Are doors or windows open to outside air Run diagnostics to make sure the cooling system is working properly the cooling system dehumidifies High Humidity and Low Humidity Simultaneously If these two alarms are displayed at the same time the humidity input signal is lost Dashes will be displayed for the humidity reading The control system will deactivate humidification and dehumidi fication Check for a disconnected cable or a failed sensor
108. responding to 0 volts or 0 mA input The intercept can be positive or negative and can be a point from 0 to 999 Adding an intercept of 100 to the slope example above 1 volt would be 125 100 1x 50 2 2 volts would be 150 100 2x 50 2 3 volts would be 175 100 8x 50 2 etc NOTE For a 4 20 mA input sensor if the desired reading at 4 mA input is 0 then an intercept of 1 x slope would be required For example assuming a slope of 50 the formula would be 1 x 50 4 x 50 4 0 The intercept is 50 Text You may enter a custom label for each analog input The text label can be 20 characters in length including any of the following ABCDEFGHIJKLMNOPQRSTUVWXYZ 0123456789 or space Read Digital Inputs The four custom alarm inputs can be defined to be digital inputs Digital inputs are used to sense cus tomer devices for status display purposes only and will not activate the audible alarm Setup Digital Inputs A digital input is enabled by defining one of the four custom alarms to be STATUS ONLY type in the alarm setup screen The digital input is given a name by specifying it to be one of the optional alarms or a custom text alarm See 3 4 3 Setup Alarms and 3 4 4 Setup Custom Alarms View Run Hours Log Selecting VIEW RUN HOURS LOG will step to the following menu VIEW 24 HOUR RUN TIME HISTORY VIEW TOTAL RUN HOURS 26 Operation with Advanced Microprocessor with Graphics Control 3 1
109. roportionally from 0 to 100 over a humidity band equal to the humidity sensitivity setting The converse is true for humidification requirement PID Control Chilled Water or SCR Reheats only If PID control is selected humidity is controlled in the proportional mode with the sensitivity band being determined by the humidity sensitivity setpoint Intelligent Control Chilled Water only If intelligent control is selected the return air humidity is controlled at or near the humidity setpoint The dehumidification humidification required is calculated based on a set of logical rules that simulate the actions of an expert human operator see 4 3 3 Intelligent Control Chilled Water only Dehumidification Operation 1 Stage Dehumidification Compressorized Direct Expansion DX Systems Dehumidification with the standard configuration is accomplished by operating the compressor with out hot gas bypass active If system has part coil dehumidification is accomplished by using only part coil If the installation has a very light sensible load dehumidification will be inhibited at the point at which 125 heating would be required to prevent overcooling Dehumidification would be enabled when the temperature increases to the point where only 50 heating is required 31 System Performance with Advanced Microprocessor Controls 4 2 4 4 3 4 3 1 4 3 2 Humidification Operation System Activation The humidifier in
110. roprocessor with Graphics The custom alarm inputs are 24 VAC which is available from the Liebert unit Alarms are wired from terminal 24 through a normally open contact to locations 50 51 55 and 56 respectively for alarms 1 through 4 The Advanced and Advanced with Graphics alarms can be delayed from 0 to 255 seconds for Advanced see Setup Alarms on page 9 for Advanced with Graphics see 3 4 3 Setup Alarms The Advanced alarms can be ENABLED or DISABLED and can also be programmed to energize the Common Alarm Relay or to alarm only and not energize the Common Alarm Relay The Advanced Microprocessor with Graphics alarms can be selected as WARNING URGENT or DIS ABLED If selected to be a WARNING they are annunciated after the Time Delay but do not ener gize the Common Alarm Relay If selected as URGENT they are annunciated after the Time Delay as a WARNING alarm and then re annunciated after a user programmable period from 0 minutes to 999 hours as an URGENT alarm When annunciated as an URGENT alarm the Common Alarm Relay is activated The custom alarm inputs of the Advanced Microprocessor with Graphics can be designated to be Status Only As Status Only the custom alarm input is referenced as a digital input and is no longer treated as an alarm It is for monitoring only and can be reviewed by selecting ANALOG DIG ITAL INPUTS When a new alarm occurs it is displayed on the screen and the audible alarm is activated
111. ry set and should not require any user changes The setting and function of the switches can be read from the LCD see 3 8 4 DIP Switches Control Outputs Active control outputs are indicated with LEDs on the lower section of the control board Each LED is lit if the control output is active on Use these LEDs to assist in troubleshooting the system Table 12 Control output LEDs LED Control Output R5 Heat Rejection LLSV Liquid Line Solenoid Valve HGBP Hot Gas By Pass C1 Compressor RH1 Reheat Stage 1 or Hot Gas Hot Water Reheat Solenoid or SCR Reheats RH2 Reheat Stage 2 HUM Humidifier FAN Main Fan HMV Humidifier Make Up Valve LLSV2 Part Coil Solenoid Valve 28 System Performance with Advanced Microprocessor Controls 4 0 SYSTEM PERFORMANCE WITH ADVANCED MICROPROCESSOR CONTROLS 4 1 4 1 1 This section provides details on how your Challenger 3000 unit responds to user inputs and room con ditions Refer to this section when you need specific information This section includes details on con trol Temperature Control Cooling Heating Required in Percent The temperature control program for the advanced microprocessor is based on a calculated require ment for cooling heating Response to Control Types Proportional Control The requirement is determined by the difference between the return air temperature and the tem perature setpoint As the retur
112. s done by temporarily changing the setpoints Cooling To test the cooling function set the setpoint for a temperature of 10 F 5 C below room temperature A call for cooling should be seen and the equipment should begin to cool A high temperature alarm may come on Disregard it Return setpoint to the desired temperature Heating Reheat may be tested by setting the setpoint for 10 F 5 C above room temperature A call for heat ing should be seen and the heating coils should begin to heat Disregard the temperature alarm and return the setpoint to the desired temperature Humidification To check humidification set the humidity setpoint for an RH 10 above the room humidity reading For infrared humidifiers the infrared element should come on For steam generating humidifiers you will immediately hear the clicks as it energizes After a short delay the canister will fill with water The water will heat and steam will be produced Return the humidity setpoint to the desired humidity Dehumidification Dehumidification can be checked by setting the humidity setpoint for an RH 10 below room relative humidity The compressor should come on Return humidity setpoint to the desired humidity Proportional Heating Cooling Dehumidification On Chilled Water GLYCOOL Econ O Cycle Free Cool GLYCOOLING cycle models and models with hot water reheat the microprocessor is capable of responding to changes in room conditions These syst
113. signs of wear and proper tension Pressing in on belts midway between the sheave and pulley should produce from 1 2 to 1 12 to 25 mm of movement Belts that are too tight can cause excessive bearing wear Belt tension can be adjusted by raising or lowering the fan motor base Loosen nut above motor mounting plate to remove belt Turn nut below motor mounting plate to adjust belt tension If belt appears cracked or worn it should be replaced with a matched belt identically sized With proper care a belt should last several years NOTE After adjusting or changing the belt always be certain that motor base nuts are tightened The bottom adjustment nut should be finger tight The top locking nut should be tightened with a wrench Air Distribution All unit models are designed for constant volume air delivery Therefore any unusual restrictions within the air circuit must be avoided Refer to the following table for recommended free area for proper air flow Table 17 Recommended free area ft m for grilles or perforated panels at output velocities of 550 and 600 fpm 2 8 and 3 1 m s 550 FPM 600 FPM Model 2 8 m s 3 1 m s 60 Hz Units 3 Ton 2 5 0 22 2 3 0 21 5 Ton 3 8 0 34 3 5 0 33 50 Hz Units 3 Ton 2 9 0 27 2 6 0 24 5 Ton 3 5 0 33 3 3 0 31 Grilles used in raised floors vary in size the largest being 18 x 6 46 cm x 15 cm This type of grille has approximately 56 in 361 em
114. son Controls Valve High Pressure Valve 350 psig 2413 kPa system for 5 ton units Johnson Controls Valve Adjustment The valve may be adjusted with a standard refrigeration service valve wrench or screw driver Refer to Table 19 for recommended refrigerant pressures 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 10 Johnson Controls valve adjustment Range Adjustment Screw Top Retainer Insert screwdrivers under the valve spring guide Manual Flushing The valve may be flushed by inserting a screwdriver or similar tool under the two sides of the main spring and lifting This action will open the valve seat and flush any dirt parti cles from the seat If this fails it will be necessary to disassemble the valve and clean the seat 49 Component Operation and Maintenance High Pressure Valve 350 PSIG System 2413 kPa for 3 Ton Units Metrex Valve Adjustment The valve may be adjusted using a 1 8 diameter rod Turn adjusting collar nut coun terclockwise to raise head pressure Turn it clockwise to lower head pressure Rotation directions are as viewed from top of valve spring housing Figure 11 Metrex valve adjustment Adjusting Collar Nut RES Manual Flushing The valv
115. ssword factory set as 123 for setpoints and 321 for setup The password function provides system security so only personnel authorized to make changes should know the passwords If unauthorized changes are being made the passwords may be compro mised and new ones should be selected The password function can be disabled by setting DIP switch 8 to OFF Run Diagnostics By selecting RUN DIAGNOSTICS maintenance personnel can check system inputs outputs and complete a test of the microcontroller circuit board all from the front panel Review of the system inputs and the microcontroller test can be done without interrupting normal operation 23 Operation with Advanced Microprocessor with Graphics Control 3 8 1 3 8 2 3 8 3 Show Inputs With the unit on and the fan running the input state for the following devices may be displayed Air Sail Switch normally off unless Loss of Air Alarm is active Custom Alarm 1 normally off unless this alarm is active Custom Alarm 2 normally off unless this alarm is active Custom Alarm 3 normally off unless this alarm is active Custom Alarm 4 normally off unless this alarm is active Humidifier Problem normally on unless this alarm is active Filter Clog Switch normally off unless Change Filters Alarm is active Main Fan Overload normally on unless Main Fan Overload Alarm is active Shutdown Device normally on unless unit is off through the Fire Stat or Remote Shut
116. stem SetUp at wie O SN end 20 3 8 3 9 3 10 3 11 3 12 3 13 4 0 4 1 4 2 4 3 4 4 Sal Setup Operations ccs cere EK EL Hed wal es Eee See eos ba eke he eke 20 8202 Select OPtions es sen Me ee ws ae Benn Gene BB a a sans Saal ane ENN a 22 dik Calibrate SensOrss 8c ett A a ea a ah ae ae et BN 22 3 7 4 Calibrate Valve Actuator s aeaa pea ene cent n eee n nena 22 3 7 5 Select Control Algorithm Chilled Water and SCR Reheats only 22 3 7 6 Select Humidity Sensing Mode 23 Behl gt DEL OLALUS Display ar Saba ne Ta dt EI Henna ene Satie ape AE ala 23 2 05 Change Pass Words Anonim sede va aa aban bate ds Pon Gas above ae Ana TARUNA Yan Gaon 23 Run Diagnostics isn drein spa a BANE RS wl On WE A ERE A 23 381 Show lniputsy oserei AA Sera BPN Pe tla bean ges Bye ae Ba Da SON Darah Ban aan 24 218125 Test Outputs seco eee RARE Pn BERES hw Raha aoe ngage eae Ba eo Gre one Reb anges ca kd 24 3 8 3 Test Control Board oria won aa we ha hE aa EN ANE ERA BEAN hae 24 3 0 4 DIP Switches se Raw ni eo a te ee ONS Ae BS es lin oe RE na 25 Date and Mime icine deg to eles nae ba ea paw dae wate BSE eG na akg a ae saa 25 Plot Graph te sang Bas An Una Ge eh EN Pw E RTH Gs Ee a 25 3 10 1 Modify Plot Scale deeh c g Ida A BAE RM eben nds dt BN DR aii do 25 Analog Digital Inputs io 26 3 tl Read Analog Inputs ia tt RN dae be Ba Pike eee aa ies beans See ok 26 311 2 Setup Analog Inputs e
117. th Graphics Control 3 4 4 3 4 5 3 4 6 Setup Custom Alarms Selecting SETUP CUSTOM ALARMS will step to the following menu SETUP CUSTOM ALARM TEXT CHANGE CUSTOM TEXT 1 CHANGE CUSTOM TEXT 2 CHANGE CUSTOM TEXT 3 CHANGE CUSTOM TEXT 4 The custom alarm messages can be selected from a list of standard messages or you can write your own messages The message selected for any custom alarm can be changed at any time by selecting SETUP CUSTOM ALARM TEXT A list of five standard messages see list below and four custom messages are available to choose from To modify the custom messages press CHANGE CUSTOM TEXT 1 2 3 or 4 Each message can be up to 20 characters in length and can be any of the following characters or a blank space ABCDEFGHIJKLMNOPQRSTUVWXYZ 0123456789 Standard Custom Alarm Messages WATER UNDER FLOOR SMOKE DETECTED STANDBY GC PUMP ON LOSS OF WATER FLOW STANDBY UNIT ON For more information concerning alarms see 5 0 Alarm Descriptions View Water Detect Floor Plan for Optional LTM1000 LT750 When water is detected the alarm will sound and the WATER UNDER FLOOR alarm message will be displayed To see where the water is in the room select VIEW SET ALARMS from the main menu then VIEW WATER DETECT FLOOR PLAN A tile will be highlighted and blinking to indicate the position of the detected water Setup Water Detect Floor Plan The selected i e cursor floor tile will be highlighted
118. the canister 3 Return the RUN DRAIN switch to the RUN position after the canister has drained WARNING To avoid a shock hazard all power to the unit must be disconnected before proceeding with the canister replacement procedure 4 Turn OFF the power at the main unit 5 Remove the cover from the humidifier cabinet A CAUTION The canister and steam hose may be hot Allow time for the humidifier to cool before replacing parts 6 Locate the power wires to the steam canister They are connected to the canister with 1 4 quick connects Make note of the wiring configuration before removing any wires Refer to the schematic on the unit Slide the rubber boot back to expose the connections Remove the three power wires and the two canister full wires Do not loosen the screws that secure the electrodes 7 Loosen the steam outlet hose clamp and slide the steam hose away from the canister top fitting 8 The canister is now ready to be removed Pull the canister straight up and out of the cabinet toward you 9 Replace the canister with the part indicated in Table 20 Table 20 Humidifier canister part numbers Part Capacity Number Voltage Ibs hr kg hr 136798P1 200 460 11 5 136798P2 380 575 11 5 Can operate on 575 V unit with transformer 10 Replace the canister by reversing the above procedure Make special note of the following NOTE When replacing the canister 1 Make sure the two O rings a
119. through the display This feature allows the date and time to be read or changed and is accessed by selecting DATE AND TIME from the Main Menu The DATE AND TIME is used by the control for recording the Alarm History and plotting graphs NOTE The clock uses the 24 hour system For example 17 00 would be 5 00 PM The date and time are backed up by battery Plot Graphs Selecting PLOT GRAPHS will step to the following menu TEMPERATURE PLOT e HUMIDITY PLOT ANALOG SENSOR 1 PLOT ANALOG SENSOR 2 PLOT ANALOG SENSOR 3 PLOT ANALOG SENSOR 4 PLOT MODIFY PLOT SCALES Six different data types are recorded for graphing temperature humidity and four user defined ana log inputs Each data type can be viewed over three different time scales and two different resolu tions The three time scales are 90 minutes 8 hours and 24 hours The two resolutions are minimum and maximum With minimum resolution selected the full scale of the sensor is displayed In other words the largest and smallest possible sensor readings are shown Maximum resolution shows a range that covers two fifths of the full scale sensor range Modify Plot Scales The MODIFY PLOT SCALES menu item adjusts the layout of the graph This setup screen selects the time scale and resolution It also adjusts the center of the graph for a maximum resolution graph The time scale and resolution can also be changed while the graph is displayed The DOWN arrow
120. time this difference has existed This term is expressed in cooling heat ing desired for each minute and degree above below the setpoint It is adjustable from 0 to 100 per degree minute The purpose of this term is to force the control to maintain the temperature around the setpoint by slowly but continuously adding subtracting a small amount of cooling heat ing to the total control output until the temperature is at the setpoint The derivative D term is determined by the rate of change of temperature This term is expressed in cooling heating desired for each degree per minute rise fall in temperature It is adjustable from 0 to 100 per degree min The purpose of this term is to adjust the control output for quickly chang ing temperatures thus providing an anticipation control All three terms are adjusted through the select control type menu If PID control is selected the temperature sensitivity setting is not used by the control For optimum performance a PID control must be adjusted or tuned according to the characteristics of the particular space and load to be controlled Improper tuning can cause the control to exhibit poor response and or hunting The characteristics of the space and load may change seasonally so occa sional retuning is required for optimum performance 32 System Performance with Advanced Microprocessor Controls 4 3 3 A suggested tuning procedure is as follows 1 Initiall
121. tput for more than a few seconds Compressor damage could result Test Control Board By selecting this function the microcontroller will perform a self test lasting approximately 10 sec onds At the end of the test the ROM checksum ROM part number and version number will be dis played 24 Operation with Advanced Microprocessor with Graphics Control 3 8 4 3 9 3 10 3 10 1 DIP Switches The DIP switch settings can be reviewed from the display panel Changing the DIP switches requires opening the front panel for access to the DIP switches on the microprocessor control board NOTE Power MUST be cycled off then on from the unit disconnect switch for the control system to update the DIP switch settings except for switch 8 These selections should match options installed on your unit and should not need to change during normal operation Switches 1 through 7 are self explanatory DIP switch 8 not shown in Table 11 below enables the password feature when set to ON and disables the password feature if set to OFF Table 11 Setting options Switch Off On 1 No Part Coil Part Coil Chilled Water 2 Electric Hot Gas Reheat Hot Water Reheat 3 All Not Used 4 No GLYCOOL GLYCOOL 5 No Dual Cooling Dual Cooling 6 Not Used Not Used 7 Tight Control Standard Control 2 SCR reheats only with special software otherwise not used Date and Time The current date and time is available
122. ure Change Filter 2 2 Loss of Air flow 3 Custom Alarm 1 0 0 0 6 Custom Alarm 2 Custom Alarm 3 Custom Alarm 4 High Temperature 30 Low Temperature 30 High Humidity 30 Low Humidity 30 Low Suction Pressure 0 Short Cycle 0 Compressor Overload 2 Main Fan Overload 5 Loss of Power 0 Each individual alarm can be selected as either DISABLED WARNING or URGENT The four cus tom alarms may also be selected to be a Status Only input If the alarm is DISABLED it is ignored If the alarm is WARNING or URGENT it will be annunciated audibly visually and communicated to a Site Products System if appropriate When the alarm is selected to be a WARNING the alarm will NOT activate the common alarm relay When the alarm is selected to be URGENT the alarm is first annunciated as a WARNING and then annunciated again after the programmed time delay When the alarm becomes URGENT the control will activate the common alarm relay The common alarm relay is de energized after the alarm has been recognized and when the alarm no longer exists When the alarm type has been selected to be URGENT the allowable range for the time delay from warning to urgent is 0 minutes to 999 hours When any of the four custom alarm inputs have been selected as Status Only they become digital inputs for monitoring only and are no longer treated as alarms 18 Operation with Advanced Microprocessor wi
123. valve low pressure switch expansion valve and head pressure control valve Check for closed service valves in the liquid line or at the condenser or receiver Low Temperature If the return air temperature has decreased to the Low Temperature Alarm setpoint check for proper setpoints Run diagnostics to make sure all heating components are operating contactors and reheats Are reheats drawing the proper current See nameplate for amp rating Main Fan Overload An optional tri block overload is required for this alarm and may or may not replace internal motor overload depending on your model The overload device is located next to the main fan contactor in the line voltage section The alarm is activated when the overload is tripped 40 Alarm Descriptions 5 1 16 Short Cycle 5 2 5 2 1 5 2 2 5 2 3 5 2 4 5 2 5 On compressorized systems if the compressor has exceeded 10 cooling starts in one hour or if the compressor has cycled five times in 10 minutes on the low pressure switch during non cooling the Short Cycle alarm will occur This can be caused by low refrigerant level but not low enough to acti vate Low Suction Pressure alarm or room cooling load is small compared to capacity of the unit Check for leaks crimped lines and defective components If room load is low increase sensitivity to reduce cycling proportional control On GLYCOOL units dirty filters can cause the coil freeze stats to cycle the
124. valve for 10 15 F 6 8 C Defective expansion valve sensing element Replace element Poor air distribution Check duct work for closed dampers Check for under floor restrictions at or near the unit Low condensing pressure Slipping belts Check head pressure control device Inspect and adjust 59 Troubleshooting Table 23 Compressor and refrigeration system troubleshooting continued Symptom Possible Cause Check or Remedy Defective or improperly set expansion Increase superheat or replace valve Flooding valve Evaporator fan motor or belt Correct problem or replace fan motor and or belts Low condensing pressure Check head pressure control device Slipping belts Inspect and adjust Low compressor capacity or inability to pull down system Compressor rotation in reverse direction Check for proper power phase wiring to unit and to compressor motor Leaking liquid line solenoid valve or dirt in valve Replace valve if clean clean out valve if dirty Compressor noisy Loose compressor or piping support Tighten clamps Pipe rattle Loose pipe connections Check pipe connections Compressor running hot Compression ratio too high Check setting of high and low pressure switches Check condenser is it plugged Check that all evaporator and condenser fans are operating properly Compressor cycles intermittently Low pressu
125. w alarm occurs the oldest is lost and the newest is saved in alarm history location 1 The rest are moved down the list by 1 Alarm history on new units may show the results of factory testing 17 Operation with Advanced Microprocessor with Graphics Control 3 4 3 Setup Alarms The list of alarms may be reviewed using the UP DOWN keys Any alarm may be selected to have it s parameters modified by pressing the ENTER key All alarms have a time delay and alarm type parameter The high low temperature and humidity alarms also have a programmable Trip Point The Trip Point is the point at which the alarm is activated By programming a time delay for an alarm the system will delay the specified amount of time before recognizing the alarm The alarm condition must be present for the amount of time programmed for that alarm before it will be annun ciated If the alarm condition goes away before the time delay has timed out the alarm will not be rec ognized For software alarms such as Loss of Power Short Cycle and Low Suction Pressure a time delay will only delay the annunciation of that alarm The condition of the alarm is not applicable because the condition has already occurred For these alarms the time delay should be left at the fac tory default of 0 The following table shows the default time delays for each alarm Table 7 Alarm default time delays Default Time Alarm Delay seconds Humidifier Problem 2 High Head Press
126. would require the user to manually press the ON OFF switch to start the unit i e no auto restart The purpose of this feature is to pre vent several units from starting at the same time after a loss of power The message Restart Delay Please Wait will be displayed when the system is in the auto restart mode Liebert suggests pro gramming multiple unit installations with different auto restart times IR Flush Overfill infrared humidifiers only An autoflush system automatically controls a water makeup valve to maintain proper level in the infrared humidifier water pan during humidifier operation If humidification is needed and 30 hours have elapsed since the last time the humidifier was on then the humidifier is held off until the valve completes an initial fill of the humidifier pan This pre fill is about 15 seconds The valve continues to fill and flush the pan for about 4 minutes During humidifier operation with the flush rate set at the default of 150 the valve is opened peri odically to add water to the pan about 40 seconds for every 9 1 2 minutes of humidifier operation This adds enough water to the pan to cause about a third of the total water used to be flushed out the overflow standpipe located in the humidifier pan This flushing action helps remove solids from the pan The flush rate is adjustable from 110 to 500 If the water quality is poor it may be desirable to increase the water flushing action above the normal
127. ws precision tuning but requires an experienced operator and seasonal adjustments Note that if PID is selected it is used for temperature control while humidity will continue to use Proportional control Refer to 4 0 System Performance with Advanced Microprocessor Controls for more detail on types of controls Setup Alarms Selecting SETUP ALARMS will step to the following menu SET TIME DELAYS ENABLE ALARMS ENABLE COMMON ALARM SET CUSTOM ALARMS Each individual alarm can be programmed with a time delay from 0 to 255 seconds Each individual alarm can be ENABLED or DISABLED and each individual alarm can be programmed to energize or not to energize the Common Alarm Relay Set Time Delays By programming a time delay for an alarm the system will delay the specified amount of time before recognizing the alarm The alarm condition must be present for the amount of time programmed for that alarm before it will be annunciated If the alarm condition goes away before the time delay has timed out the alarm will not be recognized and the time delay timer will be reset For software alarms such as Loss of Power Short Cycle and Low Suction Pressure a time delay will only delay the annunciation of that alarm The condition of the alarm is not applicable because the condition has already occurred For these alarms the time delay should be left at the fac tory default of 0 Table 5 below shows the default time delays for each alarm Tabl
128. y adjust the integral and derivative settings to 0 degree min and 0 degree min 2 Starting with 20 degree adjust the proportional setting in small increments 10 steps until the control sustains a constant hunting action the temperature swings are approximately the same amplitude from one peak to the next 3 Note the time in minutes between peaks of adjacent temperature swings and the amplitude of the temperature swing degrees above the setpoint 4 Adjust the proportional control setting to about 1 2 the value obtained in Step 2 5 Adjust the integral setting to a value calculated by the following equation Approximate room load in full load Time between peaks x peak amplitude x 4 NOTE If this calculation results in a value of less than 1 then set the integral to 1 Adjust the derivative to a value calculated by the following eguation time between peaks x 5 The above tuning procedure is only an approximation for an initial set of adjustments and are based on the average room characteristics Your particular settings may need to be further adjusted for optimum PID control performance Some suggestions for additional tuning are as follows If cooling output overshoot is occurring on load changes decrease the proportional setting or the derivative setting If system hunting occurs with constant room load decrease the integral setting If the control responds too slowly resulting in large temp
129. y others B Hot gas line frame at all points shown using Secure each leg to condenser i hardware provided LEE TEMP CONDENSER Lee Temp heater pad connection box Hot gas line oa _ _ _ _ Electric service supplied by others 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 48 Component Operation and Maintenance 6 4 7 Water Glycol Cooled Condensers Coaxial Condenser Each water or glycol cooled module has a coaxial condenser which consists of a steel outside tube and a copper inside tube Coaxial condensers do not normally require maintenance or replacement if the water supply is clean If your system operates at high head pressure with reduced capacity and all other causes have been eliminated the coaxial condenser may be obstructed and needs to be replaced 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 Standard Valve 150 psig 1034 kPa system for 3 amp 5 ton units John
130. ymbols relating to humidification and dehumidification If the control is calling for humidification a growing water drop is shown next to the word Humidification If the control is call ing for dehumidification a shrinking water drop is shown next to the word Dehumidification Main Menu lt MENU ESC gt Press the MENU ESC key to display the Main Menu The Menu selections include VIEW SET ALARMS OPERATING STATUS VIEW SET CONTROL SETPOINTS SYSTEM SETUP RUN DIAGNOSTICS DATE AND TIME PLOT GRAPHS ANALOG DIGITAL INPUTS VIEW RUN HOURS LOG Pressing the MENU ESC key while the Main Menu is displayed will return the screen to the Status Display View Set Alarms Selecting VIEW SET ALARMS will step to the following menu e ACTIVE ALARMS ALARM HISTORY LOG SETUP ALARMS SETUP CUSTOM ALARMS VIEW WATER DETECT FLOOR PLAN SETUP WATER DETECT FLOOR PLAN Active Alarms This screen displays any active alarm The alarms are numbered 1 being the most recent The type of alarm Urgent or Warning is also displayed If there are no active alarms then NO ALARMS PRESENT will be displayed Alarm History Log A history of the 60 most recent alarms is kept in nonvolatile memory complete with the type of alarm the alarm name and the date and time it occurred The first alarm in the history is the most recent and the last up to 60 is the oldest If the Alarm History is full 60 alarms and a ne

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