Emerson 3000/ITR manual

Precision Cooling For Business -Critic al C ontinuity™ Li eber t ® Ch al l enger ™ 3000/Li e ber t Chall e ng er ITR ™ wi t h Lieb er t i C OM ® Co nt r o l Operat ion & M aintenance Manua l - 50 & 60 Hz[...]

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i T ABLE OF CONTENTS I MPORT ANT S AFETY I NSTRUCTION S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 SA VE THE SE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.0 I NTRODUCTI ON . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

ii 6.1 Standard Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 6.1.1 Change Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 6.1.2 Compressor Overload . . . . . . . . . . . . . . . .[...]

iii 7.6 Facility Fluid and Piping Maintenance for Water and Glycol Systems . . . . . . . . . . . . . . . . 49 7.7 Humidifier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 7.7.1 Infrared Humi difier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

iv TA B L E S Table 1 Keyboard icons and functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Table 2 Sample Liebert iCOM network configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Table 3 Set alarms—User Menus . . . . . . . . . . .[...]

1 I MPORT A NT S AFETY I NSTRUCTIONS SA VE THESE INSTRUCTIONS This manual co ntains important safe ty instructions that sh ould be followe d during the installa tion and maintenance of the Liebert Ch allenger 3000/Liebert Ch allenger ITR with Liebert iCOM. Read this manual thoroughly be fore attempting to inst all or operate this unit. Only qualif [...]

2 NOTICE Risk of leaking water. Can cause equi pment and building damage. This unit requires a water drain connection. It may also require an external water supply to operate. Improper installati on, application and serv ice practice can result in water leaking from the unit. Water leaks can cause severe property damage and loss of critical data ce[...]

Introd uction 3 1.0 I NTRODUCTION 1.1 System Descriptions The Liebert Challenger 3000 ™ and Liebert Challenger ITR ™ Precision Cooling sy stems are available in several configurations. 1.1.1 Compressorized Systems These systems may be air, water, or g lycol cooled , depending on the he at re jection method selected. Cooling— One stage standar[...]

Sta rt up 4 2.0 S TA R T U P Before beginning startup, make ce rtain that unit was installed accord ing to th e instructions in the installation manual , SL-11962. Verify that the fan shipping bolt has been removed, the check va lve has been installed (on air cooled units), and that th e scroll compressor is rota ting in the proper direc- tion. All[...]

Sta rt up 5 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 startup form to: Liebert Co rporation Warranty Registration 1050 Dearborn [...]

Operation with iC OM Control 6 3.0 O PERATION WITH I COM C ONTROL The Liebert iCOM ™ control offers the highest capabilities in unit control, co mmun ication and moni- toring of Liebert missio n-critical cooling units. Liebert iCOM may be used to comb ine mult iple cooling units into a team that operates as a single entity, enhancing the already-[...]

Liebert iCOM Displ ay Component s and Functions 7 4.0 L IEBERT I COM D ISPLAY C OMPONENT S AND F UNCTIONS The small an d the large displa y have a common k ey layout, as show n in Figure 2 . Figure 2 Liebert iCOM dis play component s NOTE The Help key may be pressed at any time for a brief explanation of what is being viewed. ESC ? Liquid Crys t a [...]

Liebert iCOM Displ ay Component s and Functions 8 T able 1 Keyboard icons and fun ctions Icon Key Name Function On/Off Key Controls the operational state of the cooling unit. Alarm Key Silences an alarm. Help Key Accesses integrated help menus. ESCape Key Returns to the previous display view. Enter Key Confirms all selections and selects icons or t[...]

Liebert iCOM Displ ay Component s and Functions 9 Figure 3 Liebert iCOM de fault screen s ymbols 4.1 Navigating Through th e Liebert iCOM Display Liebert iCOM displays icons and text for monitori ng and controlling your Liebert cooling unit. The number of icons and amount of text shown depends on the display size. The Liebert iCOM offers two differ[...]

Liebert iCOM Displ ay Component s and Functions 10 Figure 5 Liebert iCOM default home screen—Simple vie w 4.1.1 Control Interface—Three Main Menus The Liebert iCOM control has three main m enus: User, Service and Advanced. The User menu contains the most frequently used features, settings and status information. The Ser- vice menu contains sett[...]

Liebert iCOM Displ ay Component s and Functions 11 4.1.2 Accessing Menus and Settings Vie wi ng Da ta No password is required to view data or settings. To view data: 1. From the home screen, pres s the Enter key to view the User Menu (see Figure 8 ). 2. Press Enter again to highlight the first icon. 3. Use the keyboard’s arrow keys to move to the[...]

Liebert iCOM Displ ay Component s and Functions 12 4.1.4 Accessing Submenus To access the User, Service or Advanced menu, pr ess the Enter or down arro w key while viewing the Status menu of the unit you wish to access. The User menu will b e displayed fi rst. To view the Service or Advanced menus, press the right arrow key. Accessing Submenus on S[...]

Liebert iCOM Displ ay Component s and Functions 13 Figure 7 Menu tree—Large an d small di splays, st and-alone o r networked Stat us M en u – Sys t em Vi ew ( Large D i spl ay O n l y ) St at us M enu U ni t 1 V i ew U ser M enu U n it 1 Passw ord Setpoint s Spare Par t Li st (Lar ge Dis pla y O n ly ) Event Log G raphics View N et wor k (Lar g[...]

Liebert iCOM Displ ay Component s and Functions 14 4.2 Changing Operational Settings Changes to the Liebert Challenger 3000/Liebert Challenger ITR’ s oper ation settings in the Set Alarms and Setpoints menus require a password. 1. From the home screen, pres s the Enter key to view the User Menu (see Figure 8 ). 2. Press Enter again to highlight t[...]

Liebert iCOM Displ ay Component s and Functions 15 4.3 Changing Liebert iCOM’ s Display Settings No password is required to change the way Lieber t iCO M displays data. The Display Setup controls how the unit shows data, such as temperature, date and time. To change the display settings: 1. From the home screen, pres s the Enter key to view the U[...]

Liebert iCOM Displ ay Component s and Functions 16 4.4 Graphical Dat a Record The Graphical Data Record charts the average temperature from th e return air te mperature sensor (see Figure 10 ). The temperature scales can be changed to expand or compress the data. The time scale also can be altered to any of several selecta b le values. Changing the[...]

Liebert iCOM Displ ay Component s and Functions 17 4.6 Wiring for Unit-to- Unit Communications—U2U The Liebert Challenger 300 0/Liebert Challenger ITR with Liebert iCOM comes from the factory wired for stand-alone operati on. Multiple units can be set up in a network for efficiency, ease of operation and easier control. 4.6.1 Liebert iCOM U2U Eth[...]

Liebert iCOM Displ ay Component s and Functions 18 Large Displays A network switch is required to enable Ethernet communication on one or more cooling units with large displays. Ea ch cooling unit with a l arge displa y requires two straight-t hrough Ethernet cables from a network switch. One cable connects to port P64 on the Liebert iCOM input/out[...]

Liebert iCOM Displ ay Component s and Functions 19 Figure 12 U2U network setup diagram Net w o r k Swit ch Li eber t Chal l enger w it h S m all Li eb er t iC OM D is p la y Li eb er t Ch al l enger w it h S mal l Lieber t iC OM D is p la y Li eb er t Ch al l enger w it h L ar g e Li eb er t iC OM D is p la y Dis p la y S e r v ic e / Ne t w o rk L[...]

Liebert iCOM Displ ay Component s and Functions 20 Notes on Wiring for a U2U Network—Refer to Figures 13 and 15 1. See unit electrical sche matic. 2. Cable ‘A’ and ‘B’ are provided with each unit. One only is used as follows: • Liebert In telliSlot based comm unications - Cabl e ‘A’ is preconnected to P6 5 on I/O board an d P65 on t[...]

Liebert iCOM Displ ay Component s and Functions 21 Figure 13 Liebert iCOM wir ing—Unit as shipped Liebert I nt elliSlot Power Supply Liebert I nt elliSlo t 1 Liebert I nt elliSlo t 2 P64 A Connec t ion Locat ed Near I / O Boar d Cable ' A ' Cable†‘D ’ Cable ' C' Ribbon Cables Cable ' B ' Liebert i C OM Mi c rop[...]

Liebert iCOM Displ ay Component s and Functions 22 Figure 14 Wiring a small display for U2U network operation Standard Small Graphics Display (Rear V iew) Liebert iCOM I/O Board Straight-Through Ethernet Cable T o / From Other Networked Units CAN Cable U2U Networking Switch (Field-Supplied) Not Used Cable 'C' P64A Connection Located Near [...]

Liebert iCOM Displ ay Component s and Functions 23 Figure 15 Wiring a large display for U2U network oper ation Crossover Coupler (See Note 6) Red Crossover Ethernet Cable Liebert iCOM I/O Board Straight-Through Ethernet Cables CAN Cable See Note 4 Optional Large Graphics Displ ay (Rear View) To / F r o m O t h e r Networked Units U2U Networking Swi[...]

Liebert iCOM Displ ay Component s and Functions 24 Figure 16 Liebert iCOM inpu t-output control b oard P65 P64 (RJ-45 Jack) P66 P63 P61 P67[...]

Liebert iCOM Displ ay Component s and Functions 25 4.7 Entering Network Setup Information Setting up a U2U network requires setting a unique IP add resses for each unit, choosi ng a U2U address and designating the U2 U group. Refer to Figure 17 for the setup screen for t he control board (installed inside the Liebert Challeng er 3000/Liebert Challe[...]

Liebert iCOM Displ ay Component s and Functions 26 4.8 Viewing Multiple Unit s wi th a Networked Large Display When you first wake up the control, press the ESC key to return to the System view Status menu. This view shows an average of all the units on the network and any alarms present. To view a specifi c unit on the network, press either the en[...]

Operation 27 5.0 O PERATION The Liebert iCOM display for yo ur Liebert cooling unit features an easy-to-use , menu -driven liquid crystal display (LCD). All unit settings and parame ters can be viewed and adjusted through three menus: User, Service and Adva nced. All active alar ms are displayed on the LCD and annunciated. The control is shipped fr[...]

Operation 28 Autorest art When there is a loss of power to the cooling unit an d power comes back, the u nit will return to its pre- vious operating status—On if it was On befo re the power fail ed, Off if it was Off. When power returns, the autorestart time—time-sele ctable: Single Unit Auto Restart (Service Menu, Options Setup)—controls the[...]

Operation 29 Pump Down—Air Cooled with Condenser Only Unit s The Pump Down operation is performed to protect the compressor oil from being diluted with l iquid refrigerant, which helps ensure that the compressor is properly lubr icated for the next startup. The Pump Down op eration ope rates in the following manner: Pump down is always performed [...]

Operation 30 Evaluate the start op eration of the unit (with pump down). 1. Close LLSV 2. Wait for L PS to make or ignore for WSK time If LPS is made before WSK has expired, allow the comp ressor to continue running, if not then stop compressor and alarm low pressure alarm. 3. Once LPS makes start compressor. 4. Verify the alarm phrase for the WSK [...]

Operation 31 5.2.3 Intelligent Control (Chilled W ater Only) The intellig ent control operates from a set of general rules that define h ow the control output should be adjusted for different system conditions. Th e rules are designed to dupli cate the actions that an experienced human operator would take if manually controll ing the system. Just a[...]

Alarm Descriptions 32 6.0 A LARM D ESCRIPTIONS The Liebert iCOM will audibly and visual ly annunciate all enabl ed alarms. Alarms are wired from Terminal 24 through a normally open contact to loca tions 50 , 51, 55 and 56, r espectively, for alarms 1 through 4. The alarms can be delayed from 0 to 255 seconds. The alarms can be designated as WARNING[...]

Alarm Descriptions 33 6.1.3 High Head Pressure Compressor high he ad is monitored with a pressure switch. One SPDT pressure switch is used for the compressor in the unit. If head pressure exceeds 36 0 PSIG, the switch op ens the compressor contactor and sends an input signal to the control . On a self -contained system, the head pressure switch loc[...]

Alarm Descriptions 34 6.1.9 Loss of Air Flow A differential air pressure swi tch is used to indi cate loss of air flow in Liebert Challenger 3000/Lie- bert Challeng er ITR units. Check for blockage of unit air outlet or inlet. C h eck blower motor fuses and over load reset. Check for broken belts. Make sure blower wheel s are tight to shaft. Run di[...]

Alarm Descriptions 35 6.2 Optional Alarms 6.2.1 Loss of W ater Flow Available onl y with 3-way valves an d occurs when no water flow is detected in the chilled water or condenser water supply line. An op tional flow sw itch is required for this al arm. Check for service valves closed, pumps not working, etc. 6.2.2 Smoke Detected Smoke is detected i[...]

Componen t Operatio n and Maintenance 36 7.0 C OMPONENT O PERATION AND M AINTENANCE 7.1 System T esting 7.1.1 Environment al Control Functions The performance of all control circuit s can be tested by actuating each of the main functions. This is done by temporarily ch anging the setpoints. Cooling To test the cooling functi on, set the set point f[...]

Componen t Operatio n and Maintenance 37 Control T ransformer and Fuses The control system is divided into four separate ci rcuits. The control voltage circuits are individually protected by fuses located o n the transforme r/fuse bo ard. If any of the fuses are blown, first eliminate shorts, then use spare fuses supplied with unit. Use only type a[...]

Componen t Operatio n and Maintenance 38 Figure 22 Recommended liquid sensor lo cations The zone leak detection kit provides leak detection for a defined zon e. This kit is ideal for perimeter sensing or serpentine coverage of small areas. A simple, two-wire co nnection signals the alarms at a Liebert envi ronmental unit or at a monitoring p ane l.[...]

Componen t Operatio n and Maintenance 39 7.2 Filters Filters are usually the most neglected item in an environmental control system . To maintain efficient operation, they should be checked monthly and ch anged as required. Becaus e replacement intervals vary with en vironmental cond ition and filter typ e, each unit is equipp ed with a filter clog[...]

Componen t Operatio n and Maintenance 40 7.3.3 Air Distribution All unit models are designed f or constant volume air delivery. Therefore an y unusual restrictions within the air circuit must be avoided. For downflow models operating on a raised floor, refer to the following table for recomme nded free area for proper air flow. Grilles used in rais[...]

Componen t Operatio n and Maintenance 41 7.4.2 Discharge Pressure Discharge Pressure can be increased or decreased by load conditions or condenser effi ciency. The high pressure switch will shut the compressor down at it s cut-out setting. Refer to Table 7 , below. 7.4.3 Superheat Superheat can be adjusted by the Thermostatic Expansion Value (TEV).[...]

Componen t Operatio n and Maintenance 42 7.4.5 Hot Gas Byp ass V alve—Not A vailable on Digit al Scroll Unit s Operation—Self-Cont ained Units The hot gas bypass is inserted between the compressor discharge li ne and the leaving side of the expansion valve through the side outlet distributo r. The system, with norm al operation when the evapora[...]

Componen t Operatio n and Maintenance 43 Checking Refrigerant Charge (Lee–T emp / Flood Back Head Pressure Control) The system refrigerant level must be che cked periodically. To do so: 1. Adjust temperature setpoint in the unit so that the compressor wi ll run continuously. 2. Th e refrigerant level is visible through two si gh t glasses on the [...]

Componen t Operatio n and Maintenance 44 7.4.8 Motorized Ball V alve—Digit al Scroll Compressor On water-coo led and glycol-cooled digital scroll unit s, the dis charge pressure is controlled by a motor- ized ball valve. During unloaded operation, the pressure changes du ring each di gital cycle could result in excessive repositions with a pressu[...]

Componen t Operatio n and Maintenance 45 To raise the head pressure setting, turn the adju sting screw counterclockwise until the desired set- ting is obtained. Figure 24 Johnson Controls valve adjustment Manual Flushing —The valve may be fl ushed by insertin g a screwdriver or similar tool under the two sides of the main spring and lifti ng. Thi[...]

Componen t Operatio n and Maintenance 46 Manual Flushing —The valve may be fl ushed by rotating the socket head screw clockwise. This screw must be in the OUT position (counterclockwise) for norm al valve opera tion. Valve Disass embly 1. Shut off the water supply by using isolatin g valves. 2. Rel ieve the tension on the main spring by turning t[...]

Componen t Operatio n and Maintenance 47 7.4.1 1 Compressor Oil NOTICE Risk of improper compressor lubrication. Can cause compressor and refrigerant system damage. Failure to use oil types, viscosities an d quantities recommended by the compressor manufacturer may reduce comp ressor life and void the comp ressor warranty. See oil types specified in[...]

Componen t Operatio n and Maintenance 48 7.5.2 St andard Scroll Compressor Replacement Infrequently a fault in the motor insulation may resu lt in a motor burn, but bu rnouts rarely occur in a properly installe d system. Of those that do, most are the effects of mechanical or lubrication fa il- ures, resulting in the burnou t as a secondary consequ[...]

Componen t Operatio n and Maintenance 49 Three-phase power must be connected to the unit line voltage term inals in the proper sequence so that the scroll comp ressor rotates in the proper di rection. Rotation in the wrong direction will result in poor performance and compressor damage. Record compressor motor conn ections when removing a failed co[...]

Componen t Operatio n and Maintenance 50 7.7 Humidifier 7.7.1 Infrared Humidifier During normal humid ifier operation, deposits of mineral solid s will collect in the humidifier pan. This should be cleaned out periodica lly to ensure efficient operation. Each water supply has different char- acteristics, so the time interval between cleanings must [...]

Componen t Operatio n and Maintenance 51 Changing Humidifier Lamp s 1. Open disconne ct switch. 2. Open front panel. 3. Remove screws securing li ne voltage compartment cove r, then remove the cover. 4. In li ne voltage compartment, disc onnect one end of the purple jump ers, then locate the burned out bulb with a continuity meter. 5. Remove humidi[...]

Componen t Operatio n and Maintenance 52 Autoflush Controls Use the LCD display, menu, and ke ys on the front control panel to program the autoflush controls. 7.7.2 Steam Ge nerating Humidifier Steam generati ng humidifiers ar e designed to operate in voltage ranges f rom 200 to 575 volts and generate 11 p ounds (5 kg) of steam per hour. These humi[...]

Componen t Operatio n and Maintenance 53 Operation 1. During startup, when the humidi ty control calls for hu midification, the fill valve opens and allows water to enter the canister. When the water level reaches the el ectrodes, current flows and the water begins to warm. The canister fills until the amperage rea ches the setp oint and the fill v[...]

Componen t Operatio n and Maintenance 54 Replacing the Canister Over a period of operation, the humidifier electrodes become coated with mineral solids. This co ating insulates the electrodes and decre ases the current flow. To mainta in humidifier capacity , the water level slowly rises to expose fresh electrode. Even tually, the entire electrod e[...]

Componen t Operatio n and Maintenance 55 Circuit Board Adjustment s Humidifier operation is governed by the humidi fier control board. Th is board is locat ed on the right side of the hu midifier compartment. There are three potentiome ters mounted on the board. These pots can be used to adjust for extreme water conductivity conditions and capacity[...]

Trou bleshoot ing 56 8.0 T ROUBLESHOOTING Use this section to a ssist in troubleshooting yo ur unit. Also refer to 6.0 - Alarm Descriptions . Sug- gestions are grouped by product function for convenience. NOTICE Risk of improper control connec tion. Can cause equip ment damage. When using jumpers for troubleshooting, al ways remove jumpers when mai[...]

Trou bleshoot ing 57 T able 14 Compressor and refrige ration system trouble shooting Symptom Possible Cause Check or Remedy Compressor will not start Power Off 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 connec[...]

Trou bleshoot ing 58 Flooding Defective or i mproperly set expansion valve Increase superheat or replace valve Evaporator fan motor or belt Correct problem or replace fan mo tor and/ or belts. Low condensing pressure Check head pressure control device Slipping belts Inspect and adjust Low compressor capacity or inability to pu ll down system Compre[...]

Trou bleshoot ing 59 T able 15 Dehumidification tro ubleshooting Symptom Possible Cause Check or Remedy No dehumidification Control not ca lling for dehumi dific ation Check monitor status. Compressor contactor n ot pulling in See 7.5.1 - Compressor Functional Check and Ta ble 14 . Compressor w on't run; fuse blo wn or CB tripped See 7.5.1 - C[...]

Trou bleshoot ing 60 T able 18 Steam gen erating humidifier troubleshooting Symptom Possible Cause Check or Remedy False canister full indicatio n Foaming Check drain valve to ensure that it drain s freely. Check and replace if defective. Check water supply. If commercially softened, reconnect to raw water supply. If connected to hot water reconnec[...]

Trou bleshoot ing 61 Excessive arcing in the canister Drain valve clogged or defective 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 commercially softened, reconnect humidifier to raw water sup[...]

Monthly Maintenance Inspection Checklist 62 9.0 M ONTHLY M AINTENANCE I NSPECTION C HECKLIST Date:___________ _____________________ _______ Prepared by:__ ________________________ _______ Model #:_____________ ________________________ Serial #:_____ _________________________ ______ Filters ___ 1. Restricted air flow ___ 2. Check filter switch ___ 3[...]

Semiannual Maintenance In spection Checklist 63 10.0 S EMIANNUAL M AINTENANCE I NSPECTION C HECKLIST Date:___________ _____________________ ________ Pre pared by:____________ _____________________ Model #:_____________ ________________________ Serial #:_____ _________________________ _______ Filters ___ 1. Restricted air flow ___ 2. Check filter sw[...]

Semiannual Maintenance In spection Checklist 64[...]

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Ensuring The Hi gh A vai lab ilit y Of Mission-Critic al Dat a And App lic ations. Emerson Net work P ower , 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 sy[...]