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Liebert
Air Conditioner
CHALLENGER 3000
Liebert CHALLENGER 3000 User Manual
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Precision Cooling
For Bu
siness-Critical Con
tinuit
y
Li
eber
t C
ha
l
leng
er
™
3000
Operati
on & Mainte
nanc
e Manu
al - 3 & 5 T
on, 50 & 60Hz
2
Table of Contents
Default Chapter
3
Table of Contents
3
1 Introduction
9
System Descriptions
9
Compressorized Systems
9
GLYCOOL™ (Chilled Glycol Cooling) Systems
9
Chilled Water Systems
9
Start-Up Procedure
10
2 Operation with Advanced Microprocessor Controls
11
Basics
11
Figure 1 Advanced Microprocessor Control Panel
11
Figure 2 Advanced Microprocessor (A) Control for Challenger 3000
12
Status Display
13
Main Menu <MENU/ESC
13
Status/Alarm Data
13
Active Alarms
13
Operating Status
13
Alarm History Log
13
Run Hours Log
14
Analog Sensors
14
Setpoints/Setup
14
View Setpoints
14
Table 1 Default Setpoints and Ranges
14
Setup System
15
Table 2 Setup Functions, Default Values and Ranges
16
Table 3 Unit Options
16
Table 4 DIP Switch Settings
16
Table 5 Alarm Default Time Delays
17
Table 7 Alarm Default Time Delays
17
Run Diagnostics
20
Change Passwords
21
Date and Time
21
Status Display
21
Control Circuit Board
21
LCD Display Contrast
21
Non-Volatile Memory
22
DIP Switches
22
Control Outputs
22
Table 6 Control Output Leds
22
3 Operation with Advanced Microprocessor with Graphics Control
23
Basics
23
Figure 3 Advanced Microprocessor with Graphics (G) Control Panel
23
Figure 4 Advanced Microprocessor with Graphics Control Menu
24
Status Display
25
Main Menu <MENU/ESC
25
View/Set Alarms
25
Active Alarms
25
Alarm History Log
25
Setup Alarms
26
Setup Custom Alarms
27
View Water Detect Floor Plan (for Optional LTM1000/LT750)
27
Setup Water Detect Floor Plan
27
Operating Status
28
View/Set Control Setpoints
28
System Setup
28
Setup Operation
28
Table 8 Default Setpoints and Ranges
28
Table 9 Setup Functions, Default Values and Ranges
29
Select Options
30
Calibrate Sensors
30
Calibrate Valve Actuator
30
Select Control Algorithm (Chilled Water and SCR Reheats Only)
30
Table 10 Unit Options
30
Select Humidity Sensing Mode
31
Set Status Display
31
Change Passwords
31
Run Diagnostics
31
Show Inputs
32
Test Outputs
32
Test Control Board
32
DIP Switches
33
Date and Time
33
Plot Graphs
33
Modify Plot Scales
33
Table 11 Setting Options
33
Analog/Digital Inputs
34
Read Analog Inputs
34
Setup Analog Inputs
34
Read Digital Inputs
34
Setup Digital Inputs
34
View Run Hours Log
34
3.12.1 View 24 Hour Run Time History
35
3.12.2 View Total Run Hours
35
Control Circuit Board
35
3.13.1 LCD Contrast
35
3.13.2 Nonvolatile Memory
36
3.13.3 DIP Switches
36
3.13.4 Control Outputs
36
Table 12 Control Output Leds
36
4 System Performance with Advanced Microprocessor Controls
37
Temperature Control
37
Cooling/Heating Required, in Percent (%)
37
Response to Control Types
37
Cooling Operation
38
Table 13 Cooling/Dehumidification Load Status Response
38
Heating Operation
39
Humidity Control
39
Dehumidification/Humidification Required, in Percent
39
Response to Control Types
39
Dehumidification Operation
39
Humidification Operation
40
Control Types
40
Proportional Control
40
PID Control (Chilled Water or SCR Reheats Only)
40
Intelligent Control (Chilled Water Only)
41
Load Control Features
42
Short Cycle Control
42
Sequential Load Activation Control
42
Additional Features
42
Connecting the Analog Sensors
42
Table 14 Analog Input Terminals
42
Table 15 Table
42
Table 24 Table
42
Table 15 Additional Connections Available after Unit Delivery
42
Water Detection Display
43
Figure 5 Analog Input Jumpers
43
Figure 6 Connecting the LT750
43
Communications
45
5 Alarm Descriptions
46
Standard Alarms
46
Change Filter
46
Compressor Overload
47
Custom Alarms
47
High Head Pressure
47
High Humidity
47
High Humidity and Low Humidity (Simultaneously)
47
High Temperature
47
High Temperature and Low Temperature (Simultaneously)
48
Humidifier Problem
48
Loss of Air Flow
48
Loss of Power
48
Low Humidity
48
Low Suction Pressure
48
Low Temperature
48
Main Fan Overload
48
Short Cycle
49
Optional/Custom Alarms
49
Loss of Water Flow
49
Smoke Detected
49
Standby GC Pump on
49
Standby Unit on
49
Water under Floor
49
6 Component Operation and Maintenance
50
System Testing
50
Environmental Control Functions
50
Figure 7 Liebert Leak Detection Units
51
Figure 8 Recommended Liquid Sensor Locations
51
Filters
52
Table 26 Table
52
Table 16 Zone Leak Detection Kit Installation Scenarios
52
Blower Package
53
Fan Impellers and Bearings
53
Belt
53
Air Distribution
53
Table 17 Recommended Free Area Ft 2 (M 2 ) for Grilles or Perforated Panels at Output Velocities
53
Refrigeration System
54
Suction Pressure
54
Discharge Pressure
54
Superheat
54
Table 18 Suction Pressures
54
Table 19 Discharge Pressures
54
Thermostatic Expansion Valve
55
Hot Gas Bypass Valve
55
Air Cooled Condenser
56
Figure 9 Outdoor Fan/Condenser Configuration
56
Water/Glycol Cooled Condensers
57
Figure 10 Johnson Controls Valve Adjustment
57
Figure 11 Metrex Valve Adjustment
58
Compressor Functional Check
59
Compressor Replacement
59
Humidifier
61
Infrared Humidifier
61
Figure 12 Infrared Humidifier Lamps
61
Steam Generating Humidifier
62
Figure 13 Steam Generating Humidifier
62
Table 20 Humidifier Canister Part Numbers
64
Replacing the Canister
64
Figure 14 Canister Replacement
65
7 Troubleshooting
66
Table 21 Blower Troubleshooting
66
Table 22 Chilled Water Troubleshooting
66
Table 23 Compressor and Refrigeration System Troubleshooting
67
Table 24 Dehumidification Troubleshooting
69
Table 25 Glycol Pump Troubleshooting
69
Table 26 Infrared Humidifier Troubleshooting
69
Table 27 Steam Generating Humidifier Troubleshooting
70
Table 28 Reheat Troubleshooting
71
8 Monthly Maintenance Inspection Checklist
72
9 Semiannual Maintenance Inspection Checklist
73
5
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Liebert CHALLENGER 3000 Specifications
General
Brand
Liebert
Model
CHALLENGER 3000
Category
Air Conditioner
Language
English
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