EasyManua.ls Logo

Liebert CHALLENGER 3000 User Manual

Liebert CHALLENGER 3000
76 pages
To Next Page IconTo Next Page
To Next Page IconTo Next Page
Page #1 background imageLoading...
Page #1 background image
Precision Cooling
For Business-Critical Continuity
Liebert Challenger
â„¢
3000
Operation & Maintenance Manual - 3 & 5 Ton, 50 & 60Hz

Table of Contents

Question and Answer IconNeed help?

Do you have a question about the Liebert CHALLENGER 3000 and is the answer not in the manual?

Liebert CHALLENGER 3000 Specifications

General IconGeneral
BrandLiebert
ModelCHALLENGER 3000
CategoryAir Conditioner
LanguageEnglish

Summary

Introduction

System Descriptions

Describes different system configurations like Compressorized, GLYCOOL, and Chilled Water Systems.

Compressorized Systems

Details configurations of compressorized systems, including cooling, heating, humidification, and dehumidification.

GLYCOOLâ„¢ (Chilled Glycol Cooling) Systems

Explains GLYCOOL systems, their features, and cooling/heating/humidification/dehumidification methods.

Chilled Water Systems

Describes Chilled Water Systems, including cooling, heating, humidification, and dehumidification.

Operation with Advanced Microprocessor Controls

Basics

Introduces control keys (ON/OFF, Menu/ESC, Enter, Arrows) and basic operation.

Status Display

Explains the normal status screen display showing temp, humidity, status functions, and alarms.

Main Menu <MENU/ESC>

Lists the main menu options available via the MENU/ESC key.

Status/Alarm Data

Details selections for viewing status and alarm data, including active alarms, status, history, and sensors.

Setpoints and Setup

View Setpoints

Lists default setpoints and their allowable ranges for temperature, humidity, and alarms.

Setup System

Details menu options for unit configuration, including setup operation, options, and calibration.

Select Options

Lists unit options like Heating, Humidifier, Dehumidifier that match installed features.

Calibrate Sensors

Describes how to calibrate temperature and humidity sensors for accuracy.

Advanced Microprocessor Configuration

Select Control Type

Discusses Intelligent, Proportional, and PID control responses.

Setup Alarms

Details programming time delays, enabling alarms, and setting custom alarms.

Set Time Delays

Explains programming time delays for alarms to control annunciation.

Enable Alarms

Describes enabling or disabling individual alarms and common alarm relay.

System Setup and Configuration

Analog Setup

Details setting up analog sensors, including slope and intercept values.

Set Status Display

Explains configuring the Status Display to show sensor readings or setpoints.

Calibrate Actuator

Describes calibrating valve actuators for chilled water or GLYCOOL cooling.

Run Diagnostics

Show Inputs

Explains how to check system input states for various devices.

Test Outputs

Details testing system outputs like fans, compressors, and valves.

Test Control Board

Describes performing a self-test of the microcontroller circuit board.

Control Circuit Board Details

Change Passwords

Covers changing passwords for setpoints and system setup for security.

Date and Time

Explains how to read or change the system's date and time for alarm history.

Status Display

Re-explains accessing the Status Display from the Main Menu.

Control Circuit Board

Locates and describes the control circuit board and its jumpers.

Advanced Microprocessor with Graphics Control

Basics

Introduces control keys and basic operation for the graphics control panel.

Status Display

Describes the status screen with temperature, humidity, and graphic symbols.

Main Menu <MENU/ESC>

Lists main menu selections for the graphics control panel.

View/Set Alarms

Details accessing and configuring alarms via the graphics interface.

Alarm Management and Configuration

Active Alarms

Explains viewing active alarms, including urgent/warning status.

Alarm History Log

Describes the storage of 60 recent alarms in nonvolatile memory.

Setup Alarms

Details alarm parameters like time delay, type, and trip points.

Setup Custom Alarms

Explains setting up custom alarm messages from standard or user-defined text.

System Monitoring and Features

View Water Detect Floor Plan

Describes viewing the floor plan to locate detected water for optional systems.

Setup Water Detect Floor Plan

Details defining the floor plan layout for water detection systems.

Operating Status

Explains the Operating Status screen for system operational feedback.

View/Set Control Setpoints

Covers reviewing and changing temperature and humidity setpoints.

System Setup Procedures

Setup Operation

Details unit configuration adjustments like Cold Start Delay and Restart Delay.

Select Options

Lists unit options like Reheat, Humidity, Dehumidify that match installation.

Calibrate Sensors

Explains calibrating temperature and humidity sensors.

Calibrate Valve Actuator

Describes calibrating valve actuators for cooling systems.

Control Algorithms and Modes

Select Control Algorithm

Discusses selecting Intelligent, Proportional, or PID control algorithms.

Select Humidity Sensing Mode

Explains choosing between relative and absolute humidity sensing modes.

Set Status Display

Details setting the Status Display to show sensor readings or setpoints.

Change Passwords

Covers changing setpoint and setup passwords for security.

System Diagnostics and Inputs

Run Diagnostics

Explains how to check system input states for various devices.

Show Inputs

Explains how to check system input states for various devices.

Test Outputs

Details testing system outputs like fans, compressors, and valves.

Test Control Board

Describes performing a self-test of the microcontroller circuit board.

System Inputs and Data Logging

DIP Switches

Explains reviewing and setting DIP switch configurations.

Date and Time

Explains setting the system date and time for logging.

Plot Graphs

Details adjusting graph layout, time scale, and resolution.

Analog/Digital Inputs

Explains monitoring four analog sensor inputs.

Analog Input Configuration and Run Hours

Read Analog Inputs

Explains monitoring four analog sensor inputs.

Setup Analog Inputs

Details configuring analog sensor inputs with slope and intercept.

Read Digital Inputs

Explains reading custom alarm inputs configured as digital inputs.

Setup Digital Inputs

Details configuring custom alarms as digital inputs for status monitoring.

Run Hours Log and Control Board

View 24 Hour Run Time History

Explains viewing hourly load history over the past 24 hours.

View Total Run Hours

Details monitoring total operating hours for major components.

Control Circuit board

Locates and describes the control circuit board and its jumpers.

LCD Display Contrast

Explains adjusting the LCD display contrast.

System Performance Overview

Temperature Control

Details how the microprocessor controls temperature based on user inputs.

Cooling/Heating Required, in Percent (%)

Explains the calculated percentage requirement for cooling/heating.

Response to Control Types

Discusses Proportional, PID, and Intelligent control responses.

Cooling Operation

Explains cooling operation for 1-Step, 2-Step DX, GLYCOOL, and Chilled Water systems.

Humidity Control and Operation

Heating Operation

Details heating operation for Electric Reheat, Hot Water Reheat, and SCR Reheats.

Dehumidification/Humidification Required, in Percent

Explains the calculated percentage requirement for dehumidification/humidification.

Response to Control Types

Discusses Proportional, PID, and Intelligent control responses for humidity.

Dehumidification Operation

Explains dehumidification operation for DX systems with part coil.

Control Type Details

Humidification Operation

Details system activation for humidification.

Proportional Control

Describes the standard proportional control method.

PID Control (Chilled Water or SCR Reheats only)

Explains PID control terms (P, I, D) for temperature control.

Intelligent Control (Chilled Water only)

Describes intelligent control rules simulating operator actions.

Load Control and Additional Features

Short Cycle Control

Explains the control preventing short cycling of the compressor.

Sequential Load Activation Control

Details energizing loads sequentially after power restoration.

Connecting the Analog Sensors

Explains connecting analog sensors and configuring inputs.

Water Detection Display

Describes the graphical display for water detection systems.

Water Detection System Setup

Physical Connections

Details physical connections for LT750 water detection systems.

Setup

Explains configuring custom alarms for water detection.

Calibration

Describes calibrating the water detection display accuracy.

Communications and Monitoring

Communications

Explains communication via RS-422 for remote monitoring systems.

Liebert Monitoring Devices and Software

Lists various Liebert monitoring devices and software.

Alarm Descriptions

Standard Alarms

Provides definitions for standard alarms like Change Filter.

Change Filter

Explains the Change Filter alarm triggered by excessive pressure drop.

Compressor Overload

Details the compressor overload alarm, manual or automatic reset.

Custom Alarms

Explains programming custom alarm messages via the LCD display.

Standard Alarm Details

High Head Pressure

Describes the high head pressure alarm and its operational logic.

High Humidity

Explains the high humidity alarm and related checks.

High Humidity and Low Humidity (Simultaneously)

Describes the alarm for lost humidity input signal.

High Temperature

Explains the high temperature alarm and related checks.

Additional Alarm Conditions

High Temperature and Low Temperature (Simultaneously)

Describes the alarm for lost temperature input signal.

Humidifier Problem

Details alarms for Infrared and Steam Generating Humidifiers.

Loss of Air Flow

Explains the loss of air flow alarm triggered by a differential pressure switch.

Loss of Power

Describes the loss of power alarm when power is restored.

System Alarms and Maintenance

Low Humidity

Explains the low humidity alarm and related checks.

Low Suction Pressure

Details the low suction pressure alarm and causes like refrigerant loss.

Low Temperature

Explains the low temperature alarm and related checks.

Main Fan Overload

Details the main fan overload alarm.

Optional Alarms and System Checks

Short Cycle

Explains the short cycle alarm for compressor protection.

Loss of Water Flow

Describes the loss of water flow alarm, requiring an optional flow switch.

Smoke Detected

Explains the smoke detection alarm via an optional smoke detector.

Standby Unit On

Details the standby unit activation when the primary has an alarm.

Component Operation and Maintenance

System Testing

Explains testing environmental control functions by changing setpoints.

Environmental Control Functions

Details testing cooling, heating, humidification, and dehumidification.

Proportional Heating/Cooling/ Dehumidification

Explains how systems with 2/3-way valves respond to room conditions.

Electric Panel

Advises inspection of the electric panel for loose connections.

Component Checks and Safety

Control Transformer and Fuses

Describes control circuits, fuses, and transformer protection.

Fan Safety Switch

Explains the function of the fan safety switch for airflow interruption alarms.

Firestat

Describes the optional firestat for unit shutdown based on air temperature.

Smoke Detector

Explains the optional smoke detector function.

Filter Maintenance and Refrigeration System

Water Detection Sensor

Discusses optional water detection sensors and their types.

Filters

Emphasizes filter maintenance and the filter clog switch.

Refrigeration System

Advises monthly inspection of refrigeration components for wear and function.

Suction Pressure

Explains suction pressure variations and low/high pressure switch functions.

Refrigeration Component Adjustments

Discharge Pressure

Discusses discharge pressure and the high pressure switch.

Superheat

Details how to determine and adjust superheat using the TEV.

Thermostatic Expansion Valve

Explains the function and adjustment of the thermostatic expansion valve.

Hot Gas Bypass Valve

Details the operation and adjustment of the hot gas bypass valve.

Condenser Maintenance and Compressor Checks

Air Cooled Condenser

Advises cleaning the condenser coil and checking refrigerant charge.

Checking Refrigerant Charge (Lee-Temp/Flood Back Head Pressure Control)

Explains how to check refrigerant level visibility through sight glasses.

Water/Glycol Cooled Condensers

Discusses coaxial condensers and their maintenance.

Regulating Valve

Explains the function and adjustment of the water regulating valve.

Compressor Troubleshooting and Replacement

Compressor Functional Check

Provides a diagnostic procedure for checking compressor operation.

Compressor Replacement

Details procedures for compressor replacement due to mechanical failure.

Electrical Failure

Describes electrical failures and system cleaning procedures after burnout.

Compressor Replacement Procedure

Outlines steps for replacing a compressor, including return procedures.

Humidifier Maintenance

Humidifier

Details cleaning the humidifier pan and changing humidifier lamps.

Infrared Humidifier

Details cleaning the humidifier pan and changing humidifier lamps.

Autoflush Infrared Humidifier Cleaning System

Explains the autoflush system for cleaning the humidifier pan.

Autoflush Operation

Details the four steps of the autoflush operation.

Steam Generating Humidifier and Controls

Autoflush Controls

Guides on programming autoflush controls via the LCD.

Steam Generating Humidifier

Describes steam generating humidifiers, their operation, and controls.

Operation

Explains the operational steps of steam generating humidifiers.

Controls

Details the humidifier RUN/DRAIN switch and control board.

Humidifier Canister Replacement

Replacing the Canister

Provides steps for replacing the humidifier canister.

Troubleshooting Guides

Blower troubleshooting

Lists symptoms, causes, and remedies for blower issues.

Chilled water troubleshooting

Lists symptoms, causes, and remedies for chilled water valve issues.

Compressor and refrigeration system troubleshooting

Lists symptoms, causes, and remedies for compressor and refrigeration system problems.

Dehumidification troubleshooting

Lists symptoms, causes, and remedies for dehumidification issues.

Component Troubleshooting

Glycol pump troubleshooting

Lists symptoms, causes, and remedies for glycol pump problems.

Infrared humidifier troubleshooting

Lists symptoms, causes, and remedies for infrared humidifier issues.

Steam generating humidifier troubleshooting

Lists symptoms, causes, and remedies for steam generating humidifier issues.

Reheat troubleshooting

Lists symptoms, causes, and remedies for reheat issues.

Maintenance Checklists

MONTHLY MAINTENANCE INSPECTION CHECKLIST

Provides a checklist for monthly maintenance tasks.

Filters

Monthly checks for filters: airflow, switch, and cleaning.

Blower Section

Monthly checks for blower: impellers, belt, bearings.

Compressor

Monthly checks for compressor: oil leaks, general leaks.

Semiannual Maintenance

Air Cooled Condenser (if applicable)

Monthly checks for air cooled condenser: coil, motor, bearings, lines.

Reheat

Monthly checks for reheat element operation and cleanliness.

Steam Generating Humidifier

Monthly checks for steam humidifier: canister, hoses, water valve.

Infrared Humidifier

Monthly checks for infrared humidifier: pan, lamps, deposits.

Semiannual Maintenance Inspections

Refrigeration Cycle/Section

Monthly checks for refrigeration: lines, moisture, pressures, valves.

Air Distribution Section

Monthly check for air distribution: grille restriction.

Refrigerant Charge

Monthly check for refrigerant level.

Filters

Semiannual checks for filters: airflow, switch, cleaning, electrical connections.

Detailed Semiannual Maintenance

Blower Section

Semiannual checks for blower: impellers, belt, bearings, electrical connections.

Compressor

Semiannual checks for compressor: oil leaks, general leaks, electrical connections.

Air Cooled Condenser (if applicable)

Semiannual checks for air cooled condenser: coil, motor, bearings, lines, electrical connections.

Water/Glycol Condenser (if applicable)

Semiannual checks for water/glycol condenser: tubes, valves, solution, leaks.

Comprehensive Semiannual Checks

Glycol Pump

Semiannual checks for glycol pump: leaks, operation, electrical connections.

Steam Generating Humidifier

Semiannual checks for steam humidifier: canister, hoses, water valve, electrical connections.

Infrared Humidifier

Semiannual checks for infrared humidifier: pan, lamps, deposits, electrical connections.

Refrigeration Cycle/Section

Semiannual checks for refrigeration: lines, moisture, pressures, valves.

Final Semiannual Maintenance

Air Distribution Section

Semiannual check for air distribution: grille restriction.

Refrigerant Charge

Semiannual check for refrigerant level.

Electrical Panel

Semiannual checks for electrical panel: fuses, connections, sequence, contactors.

Reheat

Semiannual checks for reheat element operation, cleanliness, electrical connections.

Related product manuals