Liebert ITR manual

Precision Cooling For Business -Critic al C ontinuity™ Li eber t ® Ch al l enger ™ ITR Install ation M anual - No minal Ca pac ities 23 or 33 kW , 50 & 60Hz[...]

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i T ABLE OF CONTENTS 1.0 I NTRODUCTI ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.1 System Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.1.1 Self Contained Systems . . . . . . . . . . .[...]

ii 5.2 Drycooler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 5.3 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 5.3.1 Line Voltage . . . . . . . . . . . . . . . . . . . . . . . . [...]

iii FIGURES Figure 1 Removing Liebert Challenger ITR from skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Figure 2 Cabinet dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Figure 3 Optional floor stand dimensions . . [...]

iv TA B L E S Table 1 Unit shipping weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Table 2 Piping connection size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Table 3 Air-cooled condense[...]

Introd uction 1 1.0 I NTRODUCTION 1.1 System Descriptions Liebert Cha llenger ITR ™ environmental contro l systems are available in th ree main system configu- rations: • self contained system with a scro ll compressor in the room unit • self contained chilled water system • split system with an evaporator section a nd a remote condensing u[...]

Installation 2 2.0 I NST ALLATION 2.1 Room Prep aration The room should be well insulate d and must have a sealed v apor barrier. The vapor barrier in the ceiling can be a polyethylene fi lm type. Use a rubber or plastic base paint on concrete walls and floors. Doors should not be undercut or have gri lles in them. Outside (or fresh) air should be [...]

Installation 3 2.4.1 Handling With Skid • Always keep the Liebert Challenger ITR up right, indoors and protected from damage. • Do not use the exte nded rear door frame to lift the unit. • If possible, transport the unit us ing a fork lift; otherw ise, use a crane with belts or cables, av oid- ing pressing on the top edges of the packaging. ?[...]

Installation 4 Figure 2 Cabinet dimensions DPN001523 Pg. 2, Rev . 1 Filter Access by Opening Door UNIT TOP V IEW 32-1/2" (826mm) 5/8" (16mm) 9-5/8" (244mm) 8-1/2" (216mm) 31-1/2" (800mm) 1-7/8" (48mm) 12-1/2" (318mm) 30-1/2" (775mm) 30-1/2" (775mm) 32-1/2" (826mm) 32-1/2" (826mm) 1-5/8" (4[...]

Installation 5 Figure 3 Optional floor st and dimensio ns 30-1/ 2" (775m m ) 30-1/ 2" (77 5mm) 1" (25. 4m m) See S peci fic at ion S heet f or heigh t of f loo r st a nd order ed. SL- 1 1897 Pg. 7[...]

Installation 6 2.5 Piping Considerations Consideration should be given b efore installing re frigerant and liq uid lines next to, under or above electronic equipment. 2.5.1 Drain Line A 3/4" (19.1 mm) female pipe thread (FPT) connection is provided for the evaporator coil condensate drain. This d rain line also drains the humi difier, if appli[...]

Installation 7 Figure 4 Piping connections for air-coole d unit s Pi ping o utlet loc ations through the plenum are the same as t he unit . See be low for descri pti ons and connection sizes. Hot W ater Return 5/8" OD CU (opti onal) Hot W ater Supply 5/8" OD CU (opti onal) Liqui d Ref rigerant Line 1/2" OD CU on Model s B R06 7A/ BR [...]

Installation 8 Figure 5 Piping connections for split s ystem fan coil unit s Piping outlet locations throu gh the plenum a re the same as the uni t. See below for descr iptions and connec tion s ize s. Hot W a ter Su pply 5/8" OD C U (opti onal) Condensate Pump Line 1/2" OD CU PIPI NG O UTL ET LO CA T ION S (See Cabinet and Floor P lannin[...]

Installation 9 Figure 6 Piping connections for wa ter/glycol and GL YCOOL units Pi ping out let l ocati ons th rough the plenum are the same as t he unit. See below for descriptions and connection sizes. Hot W ater Supply 5/8" OD C U (opti onal ) Cond ensate P ump Li ne 1/2" OD CU PIPI NG O UTL ET LO CA T IO NS (See Cabi net and Flo or Pl[...]

Installation 10 Figure 7 Piping connections for chilled wa ter self-cont ained unit s Pi ping outl et lo cati ons through the plenum ar e the same as the unit. See be low for desc ripti ons and conn ecti on siz es. Hot W ater Return 5/8" OD CU (opti onal) Chille d W ater Retur n Lin e 1-1/8" OD CU Hot W a ter Su pply 5/8" OD CU (opti[...]

Installation 11 2.6 Electrical Connections Three-phase electrical servi ce is required for all mode ls in either 208, 230, 460, or 575 V, 60 Hz; or 200, 230, or 380/415 V, 50 Hz. Electrical service sh all conform to national and local electrical codes. Refer to equipment nameplate regard ing wire size and circuit protecti on requirements. Refer to [...]

Installation 12 9. Special alarm connecti ons . Field-suppli ed 24V Class 1 wiring for special al arm. Connection made by adding normally op en contacts between terminals 24 + 50. Opti onal additional connections available with Advanced or Advanc ed with Graphics controls and appropriate optional accessories (connections 51, 55 , and 56). 10. Liebe[...]

Installation 13 2.8 Checklist for Completed Inst allation ___ 1. Unpack and check received material. ___ 2. Proper clearance for service acces s has been maintained around the equipment. ___ 3. Equipment is level and mounting fasteners are tight. ___ 4. Piping completed to refrigerant or coolan t loop (if requi red). Piping has bee n leak checked, [...]

Air-Cooled Models 14 3.0 A IR -C OOLED M ODELS 3.1 Condenser Location The air-cooled condenser should be located for maximum security and maintenance accessibility. Avoid ground level sites with public access or area s that contribute to heav y snow or ice accumula- tions. Utilize centrifugal condense rs whenever interior building lo cations must b[...]

Air-Cooled Models 15 Figure 9 Air-cooled condenser s T able 3 Air-cooled condenser st at istics Model Number of Fans Connection Sizes (OD Copper) Net Weight lb (kg) “A” Dimension in (mm) Hot Gas (in.) Liquid (in.) 083 1 7/8 5/8 295 (133.8) 42 (1067) 104 1 1-1/8 5/8 315 (142.8) 42 (1067) Secure each leg to c ondenser frame at all point s shown u[...]

Air-Cooled Models 16 3.3 Refrigerant Piping All refrigeration pip ing should be installed with high temperature brazed joi nts. Prevailing good refrigeration pr actices should be employed for piping supports, le ak testing, dehydra tion and charg- ing of the refrigeration circuits. Unit refrigeration components and piping are shippe d from the fact[...]

Air-Cooled Models 17 3.4 Fan Speed Control Systems Fan Speed Co ntrol provid es an infini te number of speed variations on spec ially desi gned, permanent split-capacitor motors. The control module varies the air quantity pa ssing over the condenser coil by monitoring refrigerant pressure. 3.4.1 Materials Supplied 1. Built-in pre-wired condenser co[...]

Air-Cooled Models 18 3.4.2 Dehydration/Leak T est and Charging Procedures for R22 (st and ard) or R407C (Optional) Fan S peed Control T ype Condenser Dehydration/Leak T est 1. Make sure unit is OFF. Open all disconnects an d remov e all fuses except control fuses. On units supplied with circuit brea kers, open all breakers except for the transforme[...]

Air-Cooled Models 19 Figure 10 Air-cooled fan speed control general arra ngement SL -11 89 7 P G 5 Con de nser Co il Sc hra d e r Va lv e Fu si bl e Pl ug In v e rted Trap s* on disch ar ge an d retu rn li ne s to ex te nd ab ov e ba se of co il by a mi ni mu m of 7 1 /2" (1 90 mm ) Tr ap s* e v er y 25 ft. (7.6 m) of ris e Ev ap o r at o r Co[...]

Air-Cooled Models 20 3.4.3 Charging 1. Make sure unit is OFF. Open all disconnect swit ches and, on units su pplied with circuit breakers, open all breakers. Replace all fuses for th e Fan and Compressors or close breakers. 2. Remove jumper on the Fan Safety Switch and reconnect the system wire connections. Ensure that all operational components ar[...]

Air-Cooled Models 21 3.5.2 Materials Supplied 1. Built-in pre-wired condenser control box 2. Air-cooled condenser 3. Piping access cover to be rein stal led when pipi ng is complete 4. Bolts (four per leg) 3/8" x 5/8" 5. Terminal block for two-wire 24 V interlock connection between the unit and the condenser 6. Condenser leg s: four on on[...]

Air-Cooled Models 22 Dehydration/Leak T est 1. Make sure unit is OFF. Op en all disconne ct swit ches and pull all fuses except control fuses. On units supplied with circuit breakers, open all breakers except for the transformer. 2. Add a jumper to the Fan Safety S witch betw een Common and Normal Open and disconnect the wire connected to the Norma[...]

Air-Cooled Models 23 Figure 1 1 Air-cooled, Lee-T emp general arrangement FA C TO R Y PI PI NG FIEL D PI PI NG SING L E CI RC UIT S H OW N SL -10061 PG 4 SL -10071 PG 4 Piping Assembly * * Co ndenser Coil Rotalock Valve ** 1/4" ( 6.4m m) Pr essure Relief Valve * * Sight Glass Lee-Te mp Rec eiver He ad P ressure Co ntrol with Integral Ch eck Va[...]

Water-Cooled Models 24 4.0 W ATER -C OOLED M ODELS 4.1 Piping Considerations Manual shut-off valves should be install ed at the supply and return lines of each unit. This will pro- vide for routine maintenance or emergency isolation of the unit. When the water source for the condenser is of poor quality, it is g ood practice to provide cleanable fi[...]

Water-Cooled Models 25 Figure 12 W ater-cooled ge neral arrangement SL -11 89 8 P G 5 E vap or ato r Co il E xpa ns io n Va lv e Se ns in g Bu lb Ex te rn al Eq ua lizers Hot Ga s Bypas s Va lv e Scro ll Compressor Se rvi ce Va lves Hot Ga s Byp as s So le no id Va lv e Si ght Glas s Filt er Dr ier Hot Gas Bypass Tube in Tube Co n denser Byp as s V[...]

Water-Cooled Models 26 4.3 W ater Regulating V alve The water regulating valve automati cally regulates the a mount of flui d necessary to remove the heat from the refrigeration system, permitting more flui d to flow when load conditions are high and less fluid to flow when load conditions are low. The va lve consists of a brass body, balance sprin[...]

Glycol/GLYCOOL-Cooled Mo dels 27 5.0 G LYCOL /GL YC OOL-C OOLED M ODELS 5.1 Drycooler Location The drycooler shou ld be located for maximum secu rity and maintenance acce ssibility. A void groun d- level sites with public access or areas which contribute to heavy snow or ice accu mulations. To assure adequate air supply, it is recommend ed that dry[...]

Glycol/GLYCOOL-Cooled Mo dels 28 5.4 Glycol Piping NOTICE Galvanized pipe mu st not be used in or wi th systems or units that contain glycol. The phosphates in the inhi bitor can react with the zinc in the galvan ized pipe, precipitating an insoluble m aterial that can eventually foul the system. To help prevent piping failures, supply and return l[...]

Glycol/GLYCOOL-Cooled Mo dels 29 5.5 Filling Instructions 5.5.1 Prep aring the System for Filling It is important to remove any dirt, oil or metal fi lings that may contamin ate the cooling system piping in order to prevent contamination of th e fresh glycol so lution and foul ing of the drycool er piping. The system should be flushed thoro ughly u[...]

Glycol/GLYCOOL-Cooled Mo dels 30 5.5.2 Glycol Solutions When considering the use of any glycol products in a particular application, you should rev iew the lat- est Material Safety Data Sheets an d ensure that the use you intend can be accomplished safely. For Material Safety Data Shee ts and other product saf ety informatio n, contact the supplier[...]

Glycol/GLYCOOL-Cooled Mo dels 31 5.5.3 Filling the System Installation of hose bibs at th e lowest point of the system is recommended. When filling a glyco l sys- tem keep air to a minimum. Air in glycol turns to foam and is di ffic ult and time-consuming to remove. (Anti-foam additives are ava ilable and may be cons idered.) Open all operat ing sy[...]

Glycol/GLYCOOL-Cooled Mo dels 32 Figure 14 Drycoolers and pump pa ckages Notes 1. Single pump packages are 17-1/4 " (438 mm) wide. Dual pu mp packages are 32-1/4" (819 mm) wide . 2. Mounting holes are 15-1/4" (387 mm) apart on single pump packages and 30- 1/4" (768 mm) apart on dual pu mp packages. 3. Connection sizes apply to p[...]

Glycol/GLYCOOL-Cooled Mo dels 33 Figure 15 Pump p ackages—exp ansion t ank T able 15 Mounting hole dimensional dat a PUMP PACKAGE A in (mm) B in (mm) C in (mm) SINGLE (0.75 - 7.5 hp) 15-1/4 (3 87.4) 2-1/2 (63.5) 22-1/2 (571.5) DUAL (0.75 - 5 hp) 30-1/4 (768. 4) 2-1/2 (63.5) 22-1/2 (571.5) DUAL (7.5 hp) 39-5/16 (998.5) 1-3/4 (44.5) 26-7/8 (682.6) [...]

Glycol/GLYCOOL-Cooled Mo dels 34 Figure 16 Glycol general arrangement SL-1 1898 P G 6 Glyco l Pum p Pump Hou sing Uni ons* Isol ati on Val v es* Expa nsi on Valv e Dr yc o o l e r Ele ct ric Box Dr yc o o l er Coi l Flui d Ret urn to Pum p Fluid Supp ly from Pum p Uni ons* Fill * Expa nsio n Ta nk Fi e l d In stal led at High est Po int i n Sys tem[...]

Glycol/GLYCOOL-Cooled Mo dels 35 Figure 17 GL YCOOL general arrangement SL -1190 1 P G 5 Pump Hou sing Glyco l Pump Uni ons* Isolati on Valv e s* Expa nsion Val ve Ev apor at or Coi l Dr yc o o l e r Coil Dr yco ol er El e c t r ic Box Uni ons * Pr essur e Po rt * Hose Bi b* Fill * Fluid Retur n to Pump Fluid Sup ply from Pump Air Vent s * at Top o[...]

Glycol/GLYCOOL-Cooled Mo dels 36 5.6 Condenser The condenser is designed to operate in conjuncti on with a dry cooler. The maximum coolant pressure is 350 psig (2413 kPa) . 5.7 Glycol Regulating V alve The glycol regula ting valve automa tically regulates the amount of coolant necessary to remove the heat from the refrigeration system, permitting m[...]

Chilled Water Models 37 6.0 C HILLED W ATER M ODELS 6.1 Piping Considerations Manual shut-off valves should be install ed at the supply and return lines to each unit. This will pro- vide for routin e service and emergen cy isolation of the unit. Consideration of the minimu m water temperature to be supplied fr om the chiller will determine if the n[...]

Split System Models 38 7.0 S PLIT S YSTEM M ODELS Three (3) condensing unit styles are available: two (2) air-cooled and one (1 ) water/glycol-coo led con- densing un it. 7.1 Location Considerations 7.1.1 Air-Cooled Condensing Unit s To assure an adequate air supply, it is recommende d that al l condensing un its be located in a clean air area, awa[...]

Split System Models 39 7.3 Piping Considerations 7.3.1 Refrigerant Loop All split systems require two refrigerant lines ( an insulated copper suction line and a copper liquid line) between the evaporato r and the condensing unit. Two possible methods exist for installi ng the copper suction and liquid lines. 1. Using an optional Sweat Adapter Kit a[...]

Split System Models 40 Once all piping is comp lete, check for leaks and dehydrate the field pi ping as follows: 1. Pressurize the field piping to 150 PSIG (1034 kPa) usi ng dry nitrogen with a trace of refrigerant. Check system for leaks with a suitable leak detector. 2. After completion of leak testing, release the test pressure (per local code) [...]

Split System Models 41 Figure 19 Refrigerant p iping diagram T able 23 Equivalent lengths (feet) for various pipe fittings Copper Pipe OD in. 90 Degree Elbow Copper 90 Degree Elbow Cast 45 Degree Elbow Tee Gate Valve Globe Valve Angle Valve 1/2 0.8 1.3 0.4 2.5 0.26 7.0 4.0 5/8 0.9 1.4 0.5 2.5 0.28 9.5 5.0 3/4 1.0 1.5 0.6 2.5 0.3 12.0 6.5 7/8 1.45 1[...]

Split System Models 42 7.3.2 Quick Connect Fittings Be especially careful wh en connecting the quick connect fitting s. Read through the following steps before making the connectio ns. 1. Remove prote ctor caps and plugs. 2. Carefully w ipe coupling seats and th readed surfaces with a clean cloth. 3. Lubricate the male di aphragm and synthetic rubb[...]

Split System Models 43 7.4 Out door Air-Cool ed Condensing Unit s Figure 20 Out door air-cooled condensing unit—hor izont al air discharge models A B C INDICATES A MINIMUM CLEARA NCE OF 18" (4 57m m) FOR PR O PER AI R FL OW . SHAD ED ARE A INDI CATES A MINI MUM CLEARA NCE OF 18" (457 mm ) FOR PR OPER AI R F LOW SHADED ARE A INDICAT ES A[...]

Split System Models 44 T able 24 Horizonta l air discharge cabi net and floor planning dimensional dat a Model Numbers D imensional Data in. (mm) Module Weight lb (kg) net 60 Hz 50 Hz A B C PFC067A-_L P FC066A-_L 53 (1343) 36-1/4 (918) 18 (457) 351 (159) PFH067A-_L T able 25 Horizonta l air discharge pi ping and electrical conn ection dat a Model N[...]

Split System Models 45 Figure 21 Out door air-cooled conde nsing unit—top air disch arge models SL -11081 PG 5 C A 2" B LEFT AIR INTAKE (5 1mm) D GUARD HEIGH T TOP AIR DISCHA RGE RIGH T AIR INTA K E SH ADED AR EA INDI C ATE S A RE COMME NDED CLE ARANCE OF 18" (4 57 mm) FOR P ROPER AI R F L O W SHAD ED AREA INDI C A TE S A R ECOM M EN DE[...]

Split System Models 46 T able 26 Cabinet and floor planning dimension al dat a - prop fan condens ing modules, top air discha rge Model Numbers Dimensional Data, in. (mm) Module Weight lb (kg) net 60 Hz 50 Hz A B C D PFC067A-_H PFC066A-_H 53 (1343) 36-1/4 (918) 38-1/2 (978) 5-1/2 (140) 488 (222) PFH067A-_H PFCZ67A-_L PFCZ66A-_L T able 27 Piping and[...]

Split System Models 47 Figure 22 Electrical field connect ions, prop fan condensing module NOTE: Refer to specification sheet for full load amp and wire size amp ratings. SL-1 1081 P G 8 Factor y-wire d to components on electric panel. Heat rejection connection. Field- supplied 24V NE C class 2 w iring. Wire connections from evaporator module: 1. 2[...]

Split System Models 48 7.5 Centrifugal Air-Cool ed Condensing Unit s 7.5.1 Inst alling the Indoor Cond ensing Unit Refer to drawings for unit dime nsions and component locations. The indoor condensing unit is usual ly mounted abov e the ceiling and must be securely mounted to t he roof structure. The ceiling and ce iling sup ports of existing buil [...]

Split System Models 49 Figure 23 Det ail of ceiling hanging bracket 7.5.2 Ducting The total external static pressure for the inlet an d outlet ducts, including grille, must not exceed 0.5 inches of H 2 O. Hood intake dimensions should be the same as t he condensing unit d uct dimen- sions. If the condensing unit is lo cated close to the outside of [...]

Split System Models 50 Figure 24 Centrifugal air-cooled condensing un it dimensional dat a SL -11087 PG 4 51 13/ 16 " 1 3 /4 " 21 1/4 " 1 5 /8 " 48 " 33 5/8 " 54 " 32 " 8 1 5/1 6 " 15 3/4 " 3 3 /8 " 14 1/2 " 24 " (812. 8mm ) (13 71. 6m m ) (41. 1m m ) (12 19. 2m m ) (40 0m m) (227m m)[...]

Split System Models 51 Figure 25 Centrifugal air-cooled conde nsing un it dimensional dat a (con' t.) DPN 000226 Rev . 0 Field-suppli ed unit disconnect switc h when factory unit disconnect s witch is not suppl ied. Electr ic ser vice not by Emerson Optional factory-ins talled disconnect sw itch Line volt age electric pow er supply condui t vo[...]

Split System Models 52 Figure 26 Split sys tems general arrang ement SL-1 1900 PG 5 Co n denser Co il 1/2" (12. 7m m) NP T Press ure Reli ef Valve Si ght Glas s Check Val ve Lee -Tem p Re cei ve r High P res sure Sw itc h Scroll Co mpre ss or Hea d P res sure Con trol wi th Int eg ral Ch eck Va lve Li quid Lin e So le no id V al ve Su ct ion L[...]

Split System Models 53 7.6 W ater and Glycol-Cooled Condensing Unit s For installation gu idelines, refer to Installing the Indoor Condensing Unit on page 48. 7.6.1 Piping Considerations It is recommended that manual serv ice shut-off va lves be installed at the supply and return line to each unit. This will provide for routine service or emergency[...]

Split System Models 54 Figure 27 W ater/glycol-cooled c ondensing unit dimensions SL -11087 PG 6 32 " 32 " 29 13/ 16 " 33 5/ 8 " 24 " (812 .8mm) (610mm ) (854.1m m) (7 5 7 .2 mm ) CABIN E T DI ME N S ION THREA DED ROD CEN TE RS (812. 8mm) CABI N ET DI M E NS ION CAB IN ET DI M E NSION TH READ ED R O D CENTE RS Han ger Brack[...]

Split System Models 55 Figure 28 W ater/glycol-cool ed condensing unit (con't.) DPN00 0228_Rev0 Heat reject ion connect ion. Field-supplied 24V NEC Class 2 wiring. Wir e connections f rom evaporat or mod: 1. 24V gr ound 2. 24V s upply 3. High press ure alarm (opt ional) 4. Hot gas bypass connect ion (only on units with hot gas bypass ) Remote [...]

R407C Refrigera nt 56 8.0 R407C R EFRIGERANT T able 32 R407C pressure/temp erature chart for oper ation and superheat (discharge/hot gas and suction gas) Temperature Gauge Pressure Temperature Gauge Pressure Temperature Gauge Pressure °F °C Psi g kPa °F °C Psig kPa °F °C Psig kPa 0.0 -17.8 18.9 130 3 5.0 1.7 54.8 378 70.0 21.1 114.9 792 1.0 -[...]

R407C Refrigera nt 57 8.1 Calculating Subcooling Example Measure the liquid pressure (e.g., 200 psig). Find the liquid saturation temperature at that pressure on Table 33 (e.g., 93°F). Measure the temperature of the li quid line (e.g., 90°F). Subtract the actual temperature from the liquid saturati on temperatur e to obtain the subc ooling (e.g.,[...]

Ensuring The Hi gh A vai lab ilit y Of Mission-Critic al Da t a And App lic a tions. Emerson Net work P ow er , the global leader in enabling business-critical continuity , ensures network re siliency and adaptabilit y through a family of technologies—inc luding Liebert power and cooling technologies—that prot ect and suppor t business-critical[...]